Senior Design Project

Final Report

Device for Measuring Misalignment in

Sand Cast Parts for X-ray Inspection

Group Number: 2

Jonathan Chu
Dylan Magee
Leonardo Rubio
Tony Chen

Faculty Advisor: Professor Jon Longtin

Professor Robert Kukta

Department of Mechanical Engineering

May 9, 2016
Revision Date Written by: Description of Change in the Latest
Letter Revision
A 10/26/16 J. Chu Initial Release
B 11/10/16 T. Chen Updated Patent and Market Research
C 11/16/16 L. Rubio Added Conceptual Design
D 12/07/16 D. Magee Added Detail Design
E 3/08/17 J. Chu Finished Detail Design
F 5/08/17 T. Chen Added Results

ii
 Project Summary
X-ray imaging is a tool used for the inspection of cast, forged, and machined parts. The
orientation of these parts is critical in evaluating the integrity from an image. Cast parts often have
surface imperfections that cause the part to be rotated out of the normal plane. VJ Technologies,
an X-ray manufacturer, has mounted the X-ray imaging device on a 5-axis robotic arm. This allows
the image to be captured at any angle. However, the operator must manually readjust the position
of this arm to obtain consistent images. The problem VJ Technologies is facing is how to automate
sensing of the orientation of a part with respect to the surface of the table.
The design goal is to sense the orientation and report position to within one degree. This
measurement data would then be sent to a controller that repositions the robot arm. As many of
these machines are used to inspect cast parts for the automotive industry it is important that the
sensing element performs at a fast pace. This machine should have a throughput of no more than
30 seconds which will allow manufacturers to keep their standard workflow. The fixture is required
to hold up to 50 pounds and a footprint of 1200mm long by 500mm wide. The fixture material in
contact with the cast aluminum will need to withstand a maximum temperature of 200oF.
Our initial approach will be to implement pressure sensors on the fixture table which will
send data to a microcontroller. The microcontroller will then calculate the orientation of the part
based on the weight distribution of the part. The student engineering team will also explore the
feasibility of implementing non-contact type sensors such as ultrasonic or laser sensors, which do
not need to be mounted directly to the fixture table.

iii
 Table of Contents

Introduction ............................................................................................................... 11
1.1 Preface .................................................................................................................................11
1.2 Background ..........................................................................................................................11
1.3 Objective ..............................................................................................................................11
1.4 Technical Expertise..............................................................................................................12
1.5 Timetable .............................................................................................................................13
1.6 Resource Chart .....................................................................................................................13
Background Research ............................................................................................... 14
2.1 Market Research ..................................................................................................................14
2.2 Existing Models ...................................................................................................................15
VJT RIX160/225 .......................................................................................................... 15
VJT Inline Robotic X-ray Inspection System .............................................................. 16
Nelson Air A-121 PIglide AT1 Compact Linear Air Bearing Stage Series ................ 17
CNC Indexing Compact Tilt Rotary Table (TR-250S)................................................ 18
2.3 Existing Model Comparison ................................................................................................19
2.4 Patent Research .................................................................... Error! Bookmark not defined.
Patent #: US20080031421 ............................................Error! Bookmark not defined.
Patent #: US20080226028 ............................................Error! Bookmark not defined.
Patent #: US20150168316 ............................................Error! Bookmark not defined.
Patent #: US005715167 ................................................Error! Bookmark not defined.
2.5 User Needs Research ........................................................... Error! Bookmark not defined.
Product Design Specifications .......................................Error! Bookmark not defined.
3.1 Scope .................................................................................... Error! Bookmark not defined.
3.2 Assumptions......................................................................... Error! Bookmark not defined.
3.3 Performance ......................................................................... Error! Bookmark not defined.
The system shall measure out of plane misalignment of any part of a single
geometry to within 1 degree of the XY-plane........................Error! Bookmark not defined.
Inspection zone must be able to fit castings of sizes up to 1200mm x 500mm x
400mm. ..................................................................................Error! Bookmark not defined.
Vertical static design load is 3.5G, where the maximum weight is
approximated to be 50 lb. This value accounts for shock loading as well. . Error! Bookmark
not defined.
Lateral static design load is 0.6G. .................................Error! Bookmark not defined.
3.4 Constraints ........................................................................... Error! Bookmark not defined.
The fixture must be constructed from X-ray compatible materials. .. Error! Bookmark
not defined.
Fixture surfaces must be able to tolerate temperatures ranging from 60-200oF
for a service life of 10 years. ..................................................Error! Bookmark not defined.
System must have access to 120 V 60 Hz AC power ...Error! Bookmark not defined.
Motors, motor-control apparatus, and motor branch-circuit conductors shall be
protected against overheating due to motor overloads or failure to start, and against
short-circuits or ground faults. ...............................................Error! Bookmark not defined.

iv
 Wire and cables should not be placed in the paths of moving parts. . Error! Bookmark
not defined.
A product cost lower than $5000 is desired ..................Error! Bookmark not defined.
3.5 User Interface ....................................................................... Error! Bookmark not defined.
Reference Mode ............................................................Error! Bookmark not defined.
Measuring Mode ...........................................................Error! Bookmark not defined.
3.6 Maintenance ......................................................................... Error! Bookmark not defined.
Sensors should be accessible within five minutes for replacement in the event
of defect that cannot be resolved through simple recalibration. .......... Error! Bookmark not
defined.
Ball screws or any other mechanism used to achieve motion should be
accessible within one minute when light lubrication is required. ........ Error! Bookmark not
defined.
3.7 Deleted or Changed Requirements ...................................... Error! Bookmark not defined.
3.8 Standards Compliance ......................................................... Error! Bookmark not defined.
ISO 3057:1998 Non-destructive testing – Metallographic replica techniques of
surface examination ...............................................................Error! Bookmark not defined.
ISO 3059:2012 Non-destructive testing – Viewing conditions .. Error! Bookmark not
defined.
CFR Title 21 Sec. 1020.40 Cabinet X-ray systems ......Error! Bookmark not defined.
OSHA 1910.305 Wiring methods, components, and equipment for general use . Error!
Bookmark not defined.
OSHA 1910.219 Mechanical power-transmission apparatus – Machinery and
Machine Guarding .................................................................Error! Bookmark not defined.
S20080031421 Method for Displacing a Superimposed Measuring Surface on
a Sensor Surface of an X-ray Detector and X-ray System for Implementing Said
Method ...................................................................................Error! Bookmark not defined.
US20080226028 Method and Apparatus for Automated, Digital, Radiographic
Inspection of Aerospace Parts ................................................Error! Bookmark not defined.
US20150168316 Adjustable Fixture Structure for 3-Dimensional X-ray
Computed Tomography .........................................................Error! Bookmark not defined.
US005715167 Fixture for Calibrated Positioning of an Object .. Error! Bookmark not
defined.
Concept Design ...............................................................Error! Bookmark not defined.
4.1 Overview .............................................................................. Error! Bookmark not defined.
4.2 Concept Generation ............................................................. Error! Bookmark not defined.
Critical Product Design Specifications .........................Error! Bookmark not defined.
Concept 1: Kinect Image Processor on Vertical MountError! Bookmark not defined.
Concept 2: Ultrasonic Sensor on XY Table ..................Error! Bookmark not defined.
Concept 3: Pressure Sensors on Four Corners of Bed ..Error! Bookmark not defined.
Concept 4: Laser Sensor Mounted to Sweeping Servo .Error! Bookmark not defined.
Concept 5: Laser Sensor on XY Table .........................Error! Bookmark not defined.
Concept 7: Laser Shadow Technique ...........................Error! Bookmark not defined.
Concept 8: Image Processing Using MATLAB ...........Error! Bookmark not defined.
4.3 Concept Evaluation .............................................................. Error! Bookmark not defined.
Justification of Pros and Cons.......................................Error! Bookmark not defined.

v
 Summary of Strengths and Weaknesses .......................Error! Bookmark not defined.
4.4 Concept iteration .................................................................. Error! Bookmark not defined.
4.5 Conclusion ........................................................................... Error! Bookmark not defined.
Detail Design ...................................................................Error! Bookmark not defined.
5.1 Subunit PDS......................................................................... Error! Bookmark not defined.
5.2 Subunit A: MATLAB .......................................................... Error! Bookmark not defined.
Part Placement ..............................................................Error! Bookmark not defined.
Camera Image Manipulation.........................................Error! Bookmark not defined.
CAD Model size and rotation .......................................Error! Bookmark not defined.
Image Properties ...........................................................Error! Bookmark not defined.
Programming Flow Chart .............................................Error! Bookmark not defined.
5.3 Subunit B: Camera ............................................................... Error! Bookmark not defined.
The camera must have a minimum resolution of 12 Megapixels. ..... Error! Bookmark
not defined.
The camera must be able to save images at a minimum size of 1024 x 768
pixels. .....................................................................................Error! Bookmark not defined.
The camera must be able to zoom out from its mounted position to capture the
1200mm x 500mm x 400mm inspection zone of the fixture bed. ....... Error! Bookmark not
defined.
Pixels within camera images that are part of the inspected part geometry must
not exceed the black color threshold of the MATLAB algorithm. ...... Error! Bookmark not
defined.
5.4 Subunit C: Camera Mount ................................................... Error! Bookmark not defined.
The mount must provide a stable location for the camera and not allow for any
misalignment during operation. .............................................Error! Bookmark not defined.
The mount must allow the camera to be in a position such that the view of the
camera covers the full fixture bed (1200mm x 500mm x 400mm). .... Error! Bookmark not
defined.
The mount must be positioned outside of the path of the X-ray c-arm so it will
not interfere with X-ray operation. ........................................Error! Bookmark not defined.
The mount must include a screw of size ¼”-20 in order to securely couple to
the camera tripod end. ............................................................Error! Bookmark not defined.
5.5 Subunit D: Tilt Table ........................................................... Error! Bookmark not defined.
The tilt table must operate in the range specified by the customer (max 3° of
tilt). .........................................................................................Error! Bookmark not defined.
The angle setting must be known to the nearest degree. ............. Error! Bookmark not
defined.
5.6 SolidWorks Model of Assembled System ........................... Error! Bookmark not defined.
5.7 Physical Prototype ............................................................... Error! Bookmark not defined.
5.8 Bill of Materials with Cost Analysis.................................... Error! Bookmark not defined.
5.9 Results .................................................................................. Error! Bookmark not defined.
5.10 Discussion .......................................................................... Error! Bookmark not defined.
5.11 Conclusion ......................................................................... Error! Bookmark not defined.
Self-Evaluation of Team Work ...................................Error! Bookmark not defined.
Jonathan Chu’s Contribution ......................................Error! Bookmark not defined.
Dylan Magee’s Contribution.......................................Error! Bookmark not defined.

vi
 Tony Chen’s Contribution ..........................................Error! Bookmark not defined.
Leonardo Rubio’s Contribution ..................................Error! Bookmark not defined.
References .........................................................................................Error! Bookmark not defined.
Appendix A. VJT Engineering Manager Email ............................Error! Bookmark not defined.
Appendix B. US Patents ..................................................................Error! Bookmark not defined.
Appendix C. MATLAB code ...........................................................Error! Bookmark not defined.

vii
Nomenclature or List of Symbols
VJT – VJ Technologies
DOF – Degrees of Freedom
CFR – Code of Federal Regulations
OSHA – Occupational Safety and Health Administration
ISO – International Organization for Standardization

viii
 List of Figures

Figure 2.1: VJT RIX160/225 [1] .................................................................................................. 15

Figure 2.2: VJT Inline Robotic X-ray Inspection System [2] ....................................................... 16
Figure 2.3: Image of the XY table. [3].......................................................................................... 17
Figure 2.4: Image of tilt rotary table. [4] ...................................................................................... 18
Figure 2.5: Method for displacing a superimposed measuring surface ....... Error! Bookmark not
defined.
Figure 2.6: Method and apparatus for automated, digital, radiographic inspection of
aerospace parts ...................................................................Error! Bookmark not defined.
Figure 2.7: Adjustable fixture structure for 3-dimensional X-ray computed tomography .... Error!
Bookmark not defined.
Figure 2.8: Fixture for calibrated positioning of an object ............Error! Bookmark not defined.
Figure 4.1: Hand sketch of the Kinect system mounted above X-ray compatible table
holding fixed part. ..............................................................Error! Bookmark not defined.
Figure 4.2: Hand sketch of the ultrasonic sensor housings on an XY table above X-ray
compatible table holding fixed part. ..................................Error! Bookmark not defined.
Figure 4.3: Hand sketch of the X-ray compatible bed with pressure sensors at each
corner. ................................................................................Error! Bookmark not defined.
Figure 4.4: Hand sketch of laser sensor mounted to servo motor above X-ray compatible
table holding fixed part. .....................................................Error! Bookmark not defined.
Figure 4.5: CAD model of the laser sensor mounted to an XY table above X-ray
compatible table holding fixed part. ..................................Error! Bookmark not defined.
Figure 4.6: Laser Shadow Technique ............................................Error! Bookmark not defined.
Figure 4.7: Basic image processing of Real image and CAD image ........... Error! Bookmark not
defined.
Figure 4.8: Components of the integrated imaging system ...........Error! Bookmark not defined.
Figure 5.1: Results of Image Processing........................................Error! Bookmark not defined.
Figure 5.2: Layered comparison of the Real image and a CAD image ....... Error! Bookmark not
defined.
Figure 5.3: Programming flowchart ...............................................Error! Bookmark not defined.
Figure 5.4: Canon EOS Rebel T3i Camera with EF-S 18-135mm IS Lens [5] .. Error! Bookmark
not defined.
Figure 5.5: Preliminary Setup with Stand-Alone Camera .............Error! Bookmark not defined.
Figure 5.6: Photograph Taken using Stand-Alone Camera Setup .Error! Bookmark not defined.
Figure 5.7: Post-Processed Image from Stand-Alone Camera Setup .......... Error! Bookmark not
defined.
Figure 5.8: Bolt VM-160 LED Macro Ring Light [6] ...................Error! Bookmark not defined.
Figure 5.9: Drawing for square tube component [7]......................Error! Bookmark not defined.
Figure 5.10: Drawing for Floor-Mounting Base component [7] ...Error! Bookmark not defined.

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Figure 5.11: Drawing for L-Bracket component [7] ......................Error! Bookmark not defined.
Figure 5.12: Drawing for Camera Mount Attachment component Error! Bookmark not defined.
Figure 5.13: Drawing for Leg Base component .............................Error! Bookmark not defined.
Figure 5.14: Oben BD-0 Mini Ball Head [8] .................................Error! Bookmark not defined.
Figure 5.15: CAD Models of Tilt Table Gauge Blocks. ................Error! Bookmark not defined.
Figure 5.16: CAD Models of Camera Mount. ...............................Error! Bookmark not defined.
Figure 5.17: Image of prototype to highlight the fasteners used for L-Bracket. Error! Bookmark
not defined.
Figure 5.18: Image of the floor mounting base with which the prototype stands. ................ Error!
Bookmark not defined.
Figure 5.19: Image of the prototype with the completed camera mount, ball head, and
plywood foundation ...........................................................Error! Bookmark not defined.
Figure 5.20: Image of the tilt table and gauge blocks set ..............Error! Bookmark not defined.
Figure 5.21: Image of the complete prototype with fixed camera and tilted part under
inspection ...........................................................................Error! Bookmark not defined.
Figure 5.22: Plot of Pixel Error vs Tilt - Real Casting Resting on Flat Plane .... Error! Bookmark
not defined.
Figure 5.23: Plot of Pixel Error vs. Tilt – Real Casting Resting on 0o, +1o Tilted Plane ...... Error!
Bookmark not defined.
Figure 5.24: Plot of Pixel Error vs. Tilt – Real Casting Resting on 0o, +2o Tilted Plane ...... Error!
Bookmark not defined.

Figure B.1: First Page of US20080031421 ....................................Error! Bookmark not defined.

Figure B.2: First Page of US20080266028 ....................................Error! Bookmark not defined.
Figure B.3: First Page of US20150168316 ....................................Error! Bookmark not defined.
Figure B.4: First Page of US005715167 ........................................Error! Bookmark not defined.

x
 List of Tables

Table 1.1: Time Table ................................................................................................................... 13

Table 1.2: Resource Chart............................................................................................................. 13
Table 2.1: Matrix Comparison of Prior Art .................................................................................. 19
Table 3.1: Changes to Requirements .............................................Error! Bookmark not defined.
Table 3.2: Design Experience Information ....................................Error! Bookmark not defined.
Table 4.1: Design Concept Evaluation Matrix ..............................Error! Bookmark not defined.
Table 5.1: Bill of Materials with Cost Analysis ............................Error! Bookmark not defined.

xi
 Introduction

1.1 Preface
This report lays out the entire design process of a device for measuring misalignment in
sand cast parts for X-ray inspection. The introduction explains the problem and its importance in
the industry. The objective, challenges, project timetable, and responsibilities are listed here as
well. Chapter 2 presents Background Research with existing product search and summarization,
patent search and summarization, quality function deployment, and matrix analysis for existing
products. Chapter 3 follows up with the design requirements and constraints in the PDS.

1.2 Background
X-ray inspection of cast parts can save time and resources of a production line by
identifying defective parts before any further machining or fabrication. This method is more
difficult when dealing with complex castings. Although X-ray technology is powerful enough to
distinguish the most miniscule impurities, the acceptability of the part can only be determined
through proper analysis of the defect. Any difference in the position with respect to the X-ray beam
of the part under inspection will deem the image useless. The most common uncertainty in the
inspection procedure arises from the manual placement of the part on the table. Similar to
machining without clamps or milling without the handwheels, the location and orientation of the
part are extremely inaccurate when arbitrarily placed. Discrepancies occur when the part is
transported via conveyor belt or rotating turntable. If the bottom surface of the part is not
manufactured exactly to specifications, it is difficult if not impossible to simply lay the part on the
workspace for proper imaging. These variances will completely change the hole or crack defect in
the X-ray image and produce misleading information. In other words, an unacceptable part may
seem acceptable, or vice versa.
Unlike the misalignment due to placement, which can be corrected using a fixture, the
offset due to casting is unavoidable. Creating a shell fitting to mount the cast part does not
accommodate for the surface finish of the sand casting manufacturing process. Even with advanced
tools, sand casting inherently has drawbacks. Usually, machining and polishing would eliminate
the poor quality of the surface of sand cast parts. Since X-ray inspection takes place before these
final steps, the parts will be imperfect. Sand casting may produce unintentional geometry when
creating the mold incorrectly, pouring the metal unevenly or allowing for uneven cooling, or
cracking the mold to recover the part.
Taking a plethora of X-ray images at numerous angles or manually recalibrating the part
with each undesirable image would also be counterproductive. The proposed work-around is to
automatically measure the misalignment of each part and electronically send the data to the robotic
C-arm to reposition for proper imaging.

1.3 Objective
The optimal system would adjust the location and orientation of the part to mimic the
reference in the minimal amount of time with minimal input from the operator. When a perfectly
machined, polished, and finished casting is placed on the workspace, the X-ray image will be taken
at an angle that clearly defines the major internal features. The objective of this project is to create

12
a system that analyzes cast parts not yet machined to the proper tolerances and evaluates the
differences in location and orientation. Our design will produce the supplemental information
required by the robotic C-arm to orient the X-ray beam desirably. The X-ray can be reconfigured
in an optimal trajectory to eliminate the discrepancies due to the casting of each part. The result
would be continuous and effortless inspection of cast parts and accurate X-ray images detailing
the true characteristics of any defects.

1.4 Technical Expertise

The project crosses many disciplinary borders. It is recommended to find anyone with
technical expertise in X-ray imagery, X-ray design, fixture design, casting procedure, pressure
sensor technology, and precision motion control. Research in every one of these fields is necessary
to aid in the design of a working solution. As with many design processes, must-have skills include
proficiencies in 3D printing, CAD modeling, programming, communication and teamwork,
contemporary instrumentation and engineering equipment, and laboratory procedure. Competence
in these areas must be shown to be able to design a measuring system that interprets and converts
information to actuate a mechanically rotating system with less than one degree of error.
The challenging aspect of the project is that normal fixtures will not work here due to the
varying size of each individual sand cast. First, we must solve the problem with the variation in
each part by developing a method to measure the misalignment. Second, we must design a tool
and integrate it into the X-ray system. The two most tenable designs involve a robotic arm to move
the X-ray laser and detector or a free motion table that can maneuver about the desired range. The
arm solution requires ample programming; the positional difference values of the inspected part
must be inversely input into moving the arm the appropriate amount. The motion table will move
directly with the part, with the problem of stability. With this solution, the center of gravity of the
part must be taken into consideration. A clamp may be required to prevent the casting from
toppling as the table is tilted into the appropriate orientation. The clamp would be made of plastic
or another X-ray friendly material so the image is not affected and the data is not obscured.

13
1.5 Timetable

Table 1.1: Time Table

Due Date Milestone

9/14/16 Problem Statement

10/26/16 Market Research

10/29/16 Product Design Specification

11/16/16 Conceptual Design

11/23/16 CNC Model Testing

12/01/16 Calculations and Verification

12/07/16 Proposed Detail Design

1/30/17 Finalized Detail Design

2/23/17 Prototyping Layout

2/25/17 Material Preparation

2/29/17 Machining

3/05/17 Assembly

4/14/17 Testing

5/6/17 Formal Project Report

5/16/17 Final Project Presentation

1.6 Resource Chart

Table 1.2: Resource Chart

Member Responsibilities

Jonathan Chu CAD Modeling, Programming, Lab Testing

Dylan Magee CAD Modeling, Programming, Prototype Assembly

Tony Chen CAD Modeling, GDT, Drawing, Report Editing

Leonardo Rubio CAD Modeling, Research, Machining, Electronics

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 Background Research

This section discusses the current market for X-ray imaging and X-ray inspection
techniques as well as some technical background information.

2.1 Market Research

For this project, we will study the market for X-ray imaging systems that detect defects in
casted parts for industrial manufacturing processes. Other applications such as dentistry and
oncology involve using X-ray technology in methods much different from the industrial use. For
industrial use, X-ray imaging creates 2D images of 3D parts for inspection/quality purposes. By
creating these images, engineers can assess a part’s dimensional qualities. While this technique
can prove to be very useful, it has its downsides. Simple X-ray imaging creates a 2D image of the
object normal to the X-ray emitter/detector. If the part has some orientation variance, the 2D image
generated will be different from what is expected and, therefore, cannot provide valid feedback
regarding the part. There are methods to avoid this error in part orientation such as 3D computed
tomography as well as rigid fixture support of casted parts.
3D computed tomography uses multiple angles of X-ray imaging in order to produce a
more detailed, 3D view of the part as compared to that of the simple 2D image produced. While
this method can account for the orientation error for the parts, it can be costly and the technology
becomes increasingly complicated and costly. The alternative solution, which is much more cost
effective, is the use of rigid fixtures, which orient a part in such a way that the surface normal to
the X-ray emitter/detector is always uniform to eliminate orientation error. The material that the
fixture is to be made out of has to be X-ray transparent; i.e. it must permit the X-rays to pass
through without altering the image produced. This solution is broad because there are many
methods for creating fixtures to support the casts depending on the size, shape, and specific
industry that the part will serve.

15
2.2 Existing Models
This section explores current VJT X-ray system models as well as systems that offer
solutions to the variable orientation of the casted parts. Alternative machines that use armatures
that move the X-ray emitter and detector relative to the part are available as well as traditional
cabinet X-ray systems, which do not change the orientation of the part, nor the X-ray relative to
one another.
VJT RIX160/225

Figure 2.1: VJT RIX160/225 [1]

(Left) Image of the ‘C’ which houses the X-ray emitter at the top and detector at the bottom. The
parts are introduced onto a table in between them. (Right) The cabinet that houses the system.

Features

 Approximante Cabinet Dimensions: 98” x 103” x 110”

 Power: 208V single phase or 220/230 single phase
 Inspection envelope: 48” x 24”
 Sample Maximum Weight: 60 LBS
 Simultaneous load and unload
 5-axis motion of C-arm

The price of this system is lower than those that may incorporate technology to account for
variances in part orientation. This system does not feature any feedback for part orientation. It is a
less complicated system in this regard and therefore may require less maintenance and software
involvement.

16
 VJT Inline Robotic X-ray Inspection System

Figure 2.2: VJT Inline Robotic X-ray Inspection System [2]

(Left) C-arm, which holds the X-ray source and detector, attached to a robotic arm. Parts
placed on a turntable. (Right) The cabinet that houses the system. The black door prevents the
leaking of X-rays.

Features

 Approximante Cabinet Dimensions: 6000mm x 6000mm x 3225mm

 Power: 208V single phase or 220/230V single phase
 Inspection Envelope: 565mm x 728mm
 Sample Maximum Weight: 20 kg
 5 – axis Robotic Manipulator
 Robotic arm moves C-arm relative to the turntable

This price of this system is also lower than those that may incorporate technology to
account for variances in part orientation. The C-arm is fixed to a 5-axis manipulator, which allows
it to move relative to the turntable.

17
 Nelson Air A-121 PIglide AT1 Compact Linear Air Bearing Stage Series

Figure 2.3: Image of the XY table. [3]

Features:

 Table Size: 115mm x 115mm

 Travel up to 350mm
 Maximum Load: 100 N
 Velocity: 1 m/s
 Resolution: 0.001 microns
 Power: 48VDC nominal, 80VDC max

This XY table model can move the part relative to the C-arm. Cannot tilt the tabletop
relative to the plane parallel to the X-ray flat face. This table itself is not X-ray transparent. The
table would have to be controlled using feedback based on part orientation. Demonstrates high
level of accuracy in a small footprint.

18
 CNC Indexing Compact Tilt Rotary Table (TR-250S)

Figure 2.4: Image of tilt rotary table. [4]

Features

 Table Diameter: 9.84”

 Rotating/Tilting Axis
 Clamping Torque: 651 ft-lb
 MIN. Increment (degrees): .001 (Rotating and Tilting)
 Indexing Accuracy (seconds): 15” (rotating) / 30” (tilting)
 Tilting Degree (degrees): -15 ~ 115
 MAX. Work Load: 287 LBS

This tilt rotary table can have an object fixed to it, and then be oriented at the user’s
discretion. The table cannot traverse in the X or Y directions, only tilted, or rotated about its normal
axis. The table itself is not X-ray transparent. The table would have to be controlled using feedback
based on part orientation. This table demonstrates a high level of accuracy in a small footprint.

19
2.3 Existing Model Comparison
A matrix comparison below displays the advantages and disadvantages of the different
components of the final system that satisfies the problem.

Table 2.1: Matrix Comparison of Prior Art

VJT Inline Robotic

Nelson Air A-121

VJT RIX160/225

X-ray Inspection
Prior Art

TR-250S
Features

Tilt Capability   
Rotation Capability  
XY Motion   
Max Work Load >50 LBS   
X-ray Transparent  
Clamping system
Operating Temperature
 
>200 Degree F
Resolution < 1 degrees

(tilting)
Resolution <.01 microns

(XY positioning)

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21