karma innovations & solutions pvt ltd, coimbatore, radiographic inspection system

Karma Innovations & Solutions Pvt. Ltd. #46, Arasamara Street, Avarampalayam, Coimbatore – 641006,

Mobile: +91-98942-57406, Land line: +91-422-2560609 E-mail ID: [email protected]

Inspection of HRC Fuses Using Digital X-ray Inspection System

HRC Fuse or High Rupturing Capacity Fuse

HRC Fuses are able to withstand and interrupt high current during short circuit. The fuse wire or

element can carry short circuit heavy current for a known time period. During this time if the fault

is removed, then it does not blow off otherwise it blows off or melts. The enclosure of HRC

Fuse is either of glass, ceramic or some other chemical compound. This enclosure is fully air tight

to avoid the effect of atmosphere on the fuse materials. The ceramic enclosure has metal end

caps on both heads, to which fusible silver wire is welded. The space within the enclosure,

surrounding the fuse wire or fuse element is completely packed with a filling powder. So, the

defect if any of the fuse element is invisible once manufactured.

Karma Innovations has the solution to find the Internal Defects of HRC Fuses using

Digital X-ray Inspection System with Quality, Convenience and Minimum Cost.

Digital X-Ray Today

The film based x-rays were in vogue for over 100 years. It required separate dark rooms,

chemicals & consumables, etc. and we can get result through hard copies (film). It consumes

much time to inspect the component.

But the Digital x-rays passing through the object are then collected and displayed in a computer

using advanced digital x-ray sensors. This is a great advancement when compared with the

film based x-ray systems.

Our Solution

Going strength for strength we have launched our Digital X-ray Inspection System Upgrade

Services. Our first customer to use this service is a multinational manufacturer of high end

industrial grade electrical fuses.

They were finding it difficult to operate their machine which they purchased earlier, as the images

were not sufficient for quick and easy decision making. The time taken for the operators to detect

the defective components and back tracking for the components removal was very straining and

hence consuming a lot of time. The sample image from the old machine is shown in Picture 1.1.



Picture 1.1

The Advantages of the Karma Digital X-Ray System

Compared to old x-ray machine Karma’s Digital x-ray system has the following advantages:

1. We have provided with a cutting edge technology sensor that has 5 megapixels of resolution.

2. Also by adding a time saving automated loading table, up to 64 fuses per loading can be

inspected. This ensures that there is 100% Inspection of all the fuses made in a day and adds

to the operator convenience.

3. High clarity images ensure that the operator be an unskilled person. (see picture 1.2)

4. We have provided additional protective lead shielding adding to the operators’ safety.



Picture 1.2

Image Comparison

1. The hexagonal fuse element & thin gauge filament inside the ceramic holder in Karma’s

Image (picture 1.2) has the Better Clarity. But this is not visible in the competitor’ image

(picture 1.1).

2. Pseudo coloring image (picture 1.3) shows the fuse with multicolor which helps the operator

to identify the internal defect of the fuse without any extra effort.



Picture 1.3

Karma Innovations & Solutions Pvt Ltd’s Specialization

Karma specializes in offering custom made Digital X-Ray Inspection Systems. We have

capability to customize the following as per the customer’s needs:

1. X-Ray Source

2. X-Ray Sensor

3. Radiation Protection Safety System

4. Software for easy decision making

5. Automation to different levels based on customer needs



Our expertise in providing automation solutions was a major strength to offer the optimum

solution to our customer. Customers Achieving Higher Effectiveness and Higher Efficiency go

with Karma’s Policy of Working Empathetically with Our Customers to Deliver the Maximum

Value.

The system also used for checking for defects such as pores, blow holes and shrinkage in

components made of different materials [aluminium, plastics, rubber and steel in automobile

industry] and detecting foreign bodies in industries such as food processing and cosmetics.

In case any need related to Digital X-Ray Inspection Systems, please feel free to mail/call us.

Karthikeyan Jawahar Director

Karma Innovations & Solutions Pvt Ltd Mobile: +91 98942-57406 E-Mail ID: [email protected]

mailto:[email protected]


Mobile: +91-98942-57406, Landline: +91-422-2560609 E-mail ID: [email protected]

Inspection of Aluminium Components Using Digital X-ray Inspection System

Digital X-Ray Inspection Systems are used for checking for defects such as pores, blow holes

and shrinkage in components made of different materials [aluminium, plastics, rubber and

steel in automobile industry]. The system can also be used for detecting foreign bodies in

industries such as food processing and cosmetics.

Principle of Working

This inspection method utilizes the penetration capability of x-rays to sense for internal

defects in any component.

Most of the aluminium automobile components require a maximum material thickness of

about 50mm only. Such thickness can easily be penetrated by X-Ray generators that generate

X-Rays as and when required.

Digital X-Ray Today

The film based x-rays were in vogue for over 100 years. It required separate dark rooms,

chemicals & consumables, etc. and we can get result through hard copies (film). It consumes

much time to inspect the component.

But the Digital x-rays passing through the object are then collected and displayed in a

computer using advanced digital x-ray sensors. This is a great advancement when compared

with the film based x-ray systems.

The Advantages of Digital X-Ray System

Compare to film based X-ray system Digital X-ray system has following advantages:

1) 100% Inspection Possible. Because the time taken for the capturing the image is very

less.

2) One exposure of the image on the computer takes 0.5 seconds in Digital X-ray

Inspection. But film based x-rays takes dozens of minutes cycle time.

3) X-ray viewing in the form of Video while monitoring the component is moving with

5 degrees of freedom (X, Y, Z axes; Tilting; Rotation).

4) Being digital, the image can be modified in different ways for identifying defects.

Zooming, measuring length of defects, writing comments and analyzing number

of defects in a given region can all be done by any operator with minimal training.

5) Special software is available for advanced image processing to enhance the defects

to ensure only the best quality components reach the customer.

6) No Consumables. Does not require films, chemicals, dark rooms, etc.

These advantages lead to the most important benefit to our customers Improved Quality of Manufactured Products.



The Digital X-ray Image below shows the defects in an aluminum component.

Picture 1.1

Picture 1.2



Karma Innovations & Solutions Pvt Ltd’s Specialization

Karma specializes in offering custom made Digital X-Ray Inspection Systems. We have

capability to customize the following as per the customer’s needs:

1. X-Ray Source

2. X-Ray Sensor

3. Radiation Protection Safety System

4. Software for easy decision making

5. Automation to different levels based on customer needs

In case any need related to Digital X-Ray Inspection Systems, please feel free to mail/call us. Karthikeyan Jawahar Director Karma Innovations & Solutions Pvt Ltd Mobile: +91 98942-57406

E-Mail ID: [email protected]

www.karmainnovations.com

mailto:[email protected]

http://www.karmainnovations.com/

karma innovations & solutions pvt ltd, coimbatore, radiographic inspection system

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