Electrostatic Penetrant Application Process and Attributes


Operators will advance a part contained in a fixture onto the turntable with a 500lbs lift capacity. The operator will then select a recipe that will include the number of passes that the part should rotate in the encompassing electrostatically charged penetrant spray. The turntable is capable indexes in a full 360 degrees. The operator then presses process ‘start’. The turntable then elevates the fixture and rotates it through the penetrant spray after the end doors are closed. Before finishing the penetrant application process, the station control allows for the operator to open the front door to interact with the part to ensure complete penetrant coverage. Upon receiving the input that the operator is satisfied the station will rotate to a home position and the end doors will open signifying that the part is ready to move on to the next processing step.

Station Attributes

Integrated safety components ensure safe operator interaction during the penetrant application process. Integrated roller locks engage the rollers inside the booth during turntable rotation to ensure part doesn’t roll off during rotation. This station depends on the operator placing the part fixture on the turntable in the proper orientation.

Separate guns are used for top and bottom enveloping electrostatic penetrant spray application to maximize efficient penetrant usage. There is a handheld electrostatic spray gun for operator use in touching-up areas on the parts, should the operator deem it necessary before giving the system the input that the process is complete. A mist collector with HEPA filtration is mounted on the top of the station, this filters the internal air of the penetrant booth to minimize penetrant escape to the surroundings, and to provide airflow past the operator to meet ASHRAE standards during manual intervention. This is controlled by the PLC to remove the spray mist from the enclosure.

Utilizing electrostatic spray application method, penetrant savings of at least 80% can be expected when compared to a dip process. Additionally, less penetrant usage leads to longer intervals between the changing out of emulsifier fluid. Also a drop in the concentration of penetrant in wastewater leads to lower costs in wastewater treatment. These direct chemical savings are based off real data gathered by REL’s existing customers who upgraded to the electrostatic spray for penetrant application.

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