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Mining Heavy Equipment Lug or Bore Inspections


excavator mining

Surface mining often entails the use of large trucks and shovels including massive Dragline excavators in large scale operations to remove overburden to access coal and other deposits of desired resources. Due to the size of this equipment many of the components are very thick resulting in challenging applications for ultrasound. In addition the preferred test methods are with the components in place and in operation which can mean limited access to the areas that need inspected. Phased Array can offer many benefits to these inspections. There are many lug and bore type components utilized to hold various shafts and pins that allow equipment operation.

Lug and Bore Inspections

Lug and bore inspections typically can be very thick wall (7-12” +). A typical high stress area prone to cracking is the inner bore. It is preferred to inspect these components with the pin or shaft in place to allow continued operation of the piece of equipment. For conventional shear wave ultrasonics this poses a limited access issue and often multiple wedges must be changed to inspect as much of the inner bore as possible.


Typical Lug
Typical Lug in Place in Dragline Excavator


  Typical UT and PA coverage
Typical Coverage from Conventional Ultrasonics and Phased Array. Red line shows possible limited access

Phased Array Benefits

  • Multiple angles allow for single probe and large coverage area in lug bore
  • Better detection of "winding crack"
  • Better coverage when in position with limited access
  • Imaging and data recording for crack monitoring

Typical inspection
Typical Lug for Bore inspection utilizing OmniScan SX. This component has the boom of a dragline excavator.

PA readout
Phased Array allows simultaneous viewing of bore geometry and cracks propagating from the inner surface.

Equipment Used

OmniScan SX or MX2

  • Portable for easy access inside cramped area of excavator
  • Conventional, Phased Array and TOFD capable
  • Manual or encoded data

Phased Array Probes and Wedges

  • Vary on application
  • 2.25 MHz common frequency
  • Shear and 0 degree wedges
  • Contact wear faces for long 0 degree metal paths

Optional Software and Accessories

Olympus IMS

Productos para la aplicación
Este software es una opción eficiente y económica para los análisis de datos adquiridos con el OmniScan. Otorga las mismas herramientas analíticas del software integrado en el equipo OmniScan más la flexibilidad de una ejecución en una computadora/un ordenador personal.
El codificador miniatura Mini-Wheel es usado para ubicar y dimensionar defectos en el eje de escaneo. Puede sincronizar la adquisición de datos con el movimiento de la sonda. Es hermético y compatible con las suelas (zapatas) estándar de Olympus.
Este equipo ligero de un solo canal proporciona una pantalla táctil fácil de leer de 8,4" (21,3 cm) y soluciones bastante rentables en el plano precio-rendimiento. Viene en dos modelos: SX PA y SX UT. El modelo SX PA es una unidad 16:64PR que, al igual que el modelo SX UT [con un solo canal UT], también está equipado con una canal UT para inspecciones de pulso-eco (pulse-echo), emisión-recepción (pitch-catch) y TOFD.
El OmniScan MX2 ahora proporciona un módulo Phased Array (PA2) con un canal UT y un módulo de ultrasonido convencional de dos canales (UT2), que puede ser usado con la técnica TOFD (difracción de tiempo de vuelo). Asimismo, proporciona opciones informáticas que amplifican las capacidades de esta plataforma.
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