Thermal imaging improves QA in ultrasonic welding

Share this on social media:

Thermal imaging specialist Thermascan has developed a novel system for inspecting ultrasonic welds for a company that was losing nearly £1m in wasted product due to faulty welding.

The welding process joins a top lip to a plastic container, which is then filled. The lid is subsequently applied and a vacuum lift takes the finished product off the production line. Weld failure results in the bottom of the container separating from the top, spilling the contents and resulting in waste and costly production downtime.

A Flir A320G thermal imaging camera is mounted to monitor the thermal performance of each of the probes and therefore the integrity of the weld.

'The I/O ports on the Flir camera allow it to perform not just a monitoring but also a control function,' explained Thermascan's Dave Blain. 'It works in conjunction with a pneumatic arm that is activated when the weld temperature is not adequate. It simply pushes the reject off the line so there is no danger of it being filled and causing damage.'

The Flir A320G thermal camera is GigE Vision and GenICam compatible, a feature that cuts down integration time significantly. This model can also be fully controlled from a PC and comes with a choice of software to suit the application.

Flir's own software allows the camera to produce high-speed, real-time radiometric images but another benefit of the Flir A-Series camera for Thermascan is that it is also compatible with LabView. 'This allows us to integrate a solution such as this into the customer's management and maintenance system,' Blain explained.

The flexibility of the Flir A-Series means its operation can be tailored to suit the precise need of the application. For example its output can trigger alarms or activate other control devices such as oven thermostats or cooling sprinkler systems. The technology can also be used to monitor can or container fill levels.

Recent News

12 February 2021

Video recorded at 2,800 frames per second has been used to test high-speed trains travelling through the newly opened Ceneri Base Tunnel in Switzerland

29 July 2020

The Perseverance rover contains 19 cameras, including seven scientific instruments. It will analyse the climate and geology of Mars, looking for signs of past life, as well as monitoring the Martian atmosphere

02 July 2020

Norwegian seafood firm, Lerøy, has installed hyperspectral cameras on processing lines to sort fish. The system is able to measure the amount of blood in white fish, which gives a grade of quality

09 June 2020

Hyperspectral imaging is being used in a research programme at hospitals in Maryland and New York to investigate the prognostic value of skin findings associated with Covid-19 infection