COMET X-RAY insight

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FOOD INSPECTIONS

Searching for foreign bodies in food products

MINING

a modern-day treasure hunt

the Magazine of industrial X-ray

coMet SPirit

An interview with the R&D department: “We demonstrate the physical possibilities to our customers.” 04

coMet inSiDe

Food inspections: Searching for foreign bodies in food products 10

Nondestructive material testing: High power for maximum safety in the aviation industry 16

Mining: A modernday treasure hunt 19

Security inspections: Takeoff for efficient cargo inspection 22

coMet eXPertiSe

The ASTM E1165 focal spot standard ensures clarity 14

coMet ProDuctS & neWS

MXR225HP/11: unipolar xray tube assembly 25

coMet coMMitMent

Band of partners 26

imprintissuer: COMET AG, Flamatt (Switzerland). Project management: Flavia Nicolai, VP Business & Marketing Communications Industrial XRay. Production and editing: Denon Publizistik AG, RapperswilJona (Switzerland), Guido Lichtensteiger, Fabrizio Milano.Photos: Nick Veasey (cover), Gaëtan Bally (pages 2, 4–13, 20, 26–28), Klaus Bavendiek (pages 14 and 15), Airbus S.A.S 2013 e*m company/H. Goussé (page 17), zvg YXLON (page 18), zvg De Beers Group (pages 19 and 21), istockphoto (pages 20 and 22).translation and proofreading: Apostroph AG, Lucerne (Switzerland). Lithography: Küenzi & Partner/mediacheck, Langnau a. A. (Switzerland).Printed by: Rub Media AG, Wabern (Switzerland).Print run: 700 copies (ger), 700 copies (eng).

02 X-RAY insight 2 | 2013

Contents

Stephan Haferl, General Manager, industrial X-ray

technologies (iXt)

Dear reader,

Technical requirements and expectations imposed upon xray components are becoming increasingly challenging. This is best exemplified by the increasing demand for highpower, highresolution xray modules for cycled, fullyautomated inspection systems. Simultaneously, the range of applications based on xray technology has broadened continuously. Not long ago, a good understanding of physics, experience and trial and error were all that was needed. Nowadays, much more thorough approaches are required to understand existing phenomena as well as to design modern xray equipment. Our business world demands increased efficiency, applications are becoming more complex and the limits of physics are being further explored. Therefore, simulation and analyses based on computational modeling – taking into account all areas of physics – are becoming increasingly important.

Whereas the last issue of “XRay insight” emphasized the need for close collaboration with our customers – this issue sheds light on how COMET’s R&D and Technology groups employ computational modeling to rapidly create prototypes and initial products that can be verified and validated in field tests. Your inputs are critically important here so that we can understand and recreate exactly how you use our equipment.

The largest part of this magazine is dedicated to you – our customers. True to its motto, “XRay insight” should be a sounding board for the industrial xray community, featuring contributions from all areas. This includes the nondestructive testing of turbine blades with highenergy xray sources, applications in diamond mines and modern packaging facilities and the testing of welding seams on gas and oil pipelines. We wouldn’t be anywhere close to our present position if it weren’t for our reliable network of suppliers. We decided to cover a very special partner on page 26 of this issue – the Band Association.

I wish you an inspiring read of “XRay insight”.

Stephan Haferl

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FOOD INSPECTIONS


MININg

A modern-day treasure hunt

The Magazine of Industrial X-Ray

cover The cover shows an image created by xray artist Nick Veasey. www.nickveasey.com

coMet connected Our magazine is available online: www.cometxray.com (PDF and Issuu).

Questions, feedback, suggestions?Drop us a line:magazine@cometxray.com

“X-ray insight” 1/2014The next issue will be available in March 2014.

03X-RAY insight 2 | 2013

editorial

industrial X-ray offers ‘customized design’ to its customers. How

exactly would you define this?iris Schmid: This means that we customize the technical and physical properties of the xray tubes according to the precise requirements and wishes of the customer.

What is the most significant advantage for customers?The xray tube – or the light itself – is at the heart of every xray system. If the customer finds a light source that fits their needs exactly, then the client can build everything around that more effectively, on a smaller scale and at lower cost. The

vP r&D Manager iris Schmid discusses the results of a simulation with Lothar Schultheis (Manager technology).

COMET Industrial XRay generates the highest possible added value for customers thanks to individually tailored xray products. vP r&D Manager coMet iXt iris Schmid highlights two key components of successful ‘customized design’ – detailed knowledge of customer requirements and wishes, and a sound knowledge of validated simulation.

An interview with the R&D department

“We demonstrate the physical possibilities to our customers”


Comet spirit

customer therefore receives a customized solution for optimizing their xray system, which gives them performance and cost advantages in their business area. This is achieved by combining their expertise and technology with our knowhow.

Where is the room for maneuver when designing a customized tube?In principle, virtually anything is possible. Nobody stops us changing a parameter if this offers the customer added value and is technically and physically feasible. This starts with relatively simple external features such as size and shape, right up to more complex parameters such as focal spot and output.

Where do you reach the limits?Quite simply, our limits are set by physics. One of our basic principles is never giving promises that we can’t keep. We demonstrate the physical possibilities to our customers, plus the consequences of pushing the boundaries too hard or even crossing them. On the other hand, a new development not only has to be technically feasible – it also has to make economic sense. In other words, product costs must remain within clearly defined boundaries, otherwise there will be no added value for the customer!

So you have to think holistically? Exactly. The physics behind xray technology is extremely complex. There are many parameters at work that sometimes conflict with one another. For example, it is simply impossible to achieve an eversmaller focal spot and higher outputs at the same time. We demonstrate the technical possibilities and their effects on finances and time scales, then customer can choose.

So it’s always a case of either/or?Whenever we change something, this will affect other parameters. There is always a physical compromise – the customer gains on one side but has to deal with the consequences on the other. Our job is to find the ideal balance for the customer according to their application.

“With the light source that fits their needs exactly, the client can build everything around that more effectively.”

iris Schmid, vP r&D Manager, coMet iXt

iris Schmid: “in principle, virtually anything is possible.”

From individual require-ment to customized design in six steps.1. Clarify and determine

the customer’s needs, wishes and requirements.

2. Check the technical feasibility of the customized design.

3. Finalize the specifications and obtain approval from the customer.

4. Develop the product through simulation and construct a prototype.

5. Carry out test phase and any revisions of the prototype.

6. Start production.


Comet spirit

What does this mean for you in research & Development?The customer comes to us with a certain idea for a specification. Direct contact with the customer is a key aspect here. It is important that they tell us their exact

wishes and requirements right from the outset. First and foremost, it is our job to comprehend the customer’s problem precisely. We can only create the best possible solution when we understand the exact application and its characteristics. For

example, is the device in constant use for 20 hours a day, or does it switch on and off in a matter of microseconds? We are delight ed when we can surprise the customer or provide them with unexpected options.

What is the key to coMet’s ‘customized design’ skills?There are many different aspects. It is very important that the xray tubes are produced at our headquarters in Flamatt right from the start. We can feed data into the process quickly and react swiftly to problems. After all, the production facilities are next door to the development team. However the most important aspect is our expertise in validated simulation.

What does simulation achieve?We used to have to build new proto type xray tubes throughout the development process until we achieved the right specifications. With simulation, we can dramatically shorten this process. We understand fundamental aspects such as electron emissions and focusing, plus design rules relating to highvoltage stabi lity, target aging and filament aging. This means we can achieve validated simu lation of almost the entire tube with virtually all characteristics. We have comprehensive statistics and we are almost certain that we can take a pipe design that has been created exclusively through simulation and implement this exactly in production. We can therefore offer customers quick and effective solutions. Thanks to simulation, we can work on several projects simultaneously, which would have been unthinkable five or ten years ago (see also the text on page 7).

“With simulation, we can dramatically shorten the development process.”

iris Schmid

iris Schmid: “We can feed data into the process quickly. after all, the pro-duction facilities are next door to the develop-ment team.”


Comet spirit

Physical, computercontrolled simulations are par-ticularly important to research and development at coMet. What are the advantages of simulations and what makes the work of the Technology group at Industrial XRay so fascinating? Lothar Schultheis, Manager technology at coMet aG, has the answers.

“at coMet, physicists can draw on ample resources”

First and foremost, those working with simulations need to have a de

gree of curiosity and a passion for discovery. Of course, this has to be backed up by specialist knowledge and training as an engineer or physicist. Of far greater importance is the ability to follow your de sire for knowledge, and then to be re warded by those moments of understanding or enlightenment.

It is only natural to encounter occasional disappointments and setbacks. The ability to deal with frustration and difficulties is all part of life. I am just the

same: I have clear expectations about how something should work, but in reality this is often very different. To tolerate this, you need a great deal of curiosity. Ultimately, I have to be satisfied with new discoveries, regardless of how small and insignificant they may appear at first glance.

The joy of discovery is the rewarding part of my work, otherwise I would become tired of it quite quickly. After all, my work is not all about creating beautiful images – that part is relatively easy. What counts is that the images reflect reality. At Indus

Lothar Schultheis: “i have clear expectations about how something should work, but in reality this is often very different.”

07X-raY insight 2 | 2013

Comet spirit

trial XRay from COMET, this is extremely complex – many physical disciplines and subjects come together here, and this is unique.

The interdependence of the many problems and phenomena that I am able to analyze at COMET is what makes my work so interesting. From thermodyna mics to electrodynamics, structural mechanics to fluid mechanics and xray physics to solidstate physics, there is a little of everything involved. The challenges facing our company touch on all of these areas, which are also connected to one another. I have worked in a sensor systems division, for example, but the range of topics I dealt with there was extremely limited by comparison. At COMET, physicists can draw on ample resources. The Technology group does

not sit and work in an ivory tower, though: we evaluate simulation results firsthand through testing in the laboratory and seek contact with our colleagues in the R&D team. We all work closely together, and that motivates us all.

But what exactly do we mean by simulation? In our opinion, simulations are much more than simply buying a program and feeding it finished geometries and physical parameters. Firstly, we offer simu lations inhouse as a service for the design team and specify design rules. When needed, we scrutinize the material parameters and thus seek to optimize the design.

However, our work really becomes interesting when we encounter problems. We set up various physical models and vali

How long does a specific development project take?COMET divides development projects into three groups:Group 1: Existing components are slightly modified and integrated back into the

system. Development takes between six and twelve months. Group 2: Mediumsized customer projects where significant component

adjustments or new developments are required, including feasibility analyses and clarifications. Duration: up to two years.

Group 3: Mainly inhouse developments, such as the launch of a new product range. Additional clarifications, market studies and analyses are performed. Duration: three to four years.

08 X-raY insight 2 | 2013

Comet spirit

date them, meaning we compare them with measurements. In doing so, we rely on our expertise and our own physical expectations to determine how, for instance, thermoelastoplastic damage or a highvoltage flashover on the insulating ceramics will occur. To make improvements, hypotheses for the cause of the problem must be formulated before using the simulation to check whether they adequately describe the problem. Improvement measures are then derived from the results.

In other words, simulation is a diagnostic tool for us. In contrast to sensor systems,

we are confronted with the challenge that we can no longer see into the product when the xray tube is produced and in action. The tubes are operated under high voltage in an isolated lead booth and are hermetically sealed.

As a producer of xray modules, simulation is extremely important to us. We both need and want to test boundaries – for the customers and for ourselves. Thanks to simulation, customers receive a competent answer to their queries very early on in the project – and all without needing to produce a single prototype. We can show them exactly where physical laws and technological limitations lead to a conflict of objectives. We can

describe this exactly and make it easily understandable. This means we have to build fewer prototypes in the development phase and can reach conclusions quicker, which saves both time and costs for the customer.

“We save time and costs for the customer.”

Lothar Schultheis, Manager technology, coMet iXt

Lothar Schultheis: “We both need and want to test boundaries – for the customers and for ourselves.”


Comet spirit

Lorem ipsum dolor sit amet, sadipscing elitr, sed diam nonumy eirmod tempor invidunt ut labore et est Lorem ipsum dolor sit amet.

As the saying goes, appetite comes with eating. The same could be said of developments for customers of Wipotec GmbH, where demand for foreign body detection in foodstuffs based on xray technology is increasing. “As a manufacturer of weighing instruments, we have always found ourselves right at the end of the packag

ing process. Our systems are the last monitoring mechanisms before the goods are packaged together,” comments Wipotec founder and managing director Theo Düppre. For this reason, it has often been asked whether this equipment could do more than simply weighing, such as inspecting goods for small metal particles at

Whether detecting foreign bodies in yoghurts or measuring the holes in Emmentaler cheese, the use of xray technology is rapidly growing at Wipotec GmbH. In this area, the company relies on MXR100 xray tubes from COMET Industrial XRay. For Wipotec managing director theo Düppre, what counts is the quality of the products, the flexibility offered by COMET and their cooperative partnership.

Food Inspection


at the Wipotec headquarters in Kaiserslautern, systems for foreign body detection in foodstuffs are assembled and tested with the help of pre-prepared instant soups, for example.


Comet inside

the same time. “As we are always on the lookout for new challenges, we started to market metal detectors,” recalls Düppre. “Soon afterwards, the questions started again. Can you also detect glass? What about stones or shells? Can you help us filter out plastic or rubber parts?” Soon the metal detection technology was no longer sufficient. Wipotec began looking for alternatives, and quickly found the solution in xray technology.

Today, some of the world’s leading food corporations such as Nestlé, Unilever and Procter & Gamble use Wipotec technology to test their yoghurts, muesli and ready meals (such as instant soups and vegetable/pasta microwave meals) for foreign bodies, or to check filling levels. Leading Swiss cheese producers also measure the holes in their cheese, which enables them to find the optimum cutting position to the nearest millimeter and thereby reach their intended product weight. “In this way, the producers of Emmentaler cheese were able to increase their yield by around 70 to 98 percent, and all with reduced giveaway,” explains Düppre.

Wipotec relies on a core skill that has made the company unique in the weighing instrument field – namely measurement within a dynamic production process at high speeds. “The handling of the product is of key importance, along with the question of how the product is transported,” says Düppre. The greatest challenges in food inspection at Wipotec include accuracy, the level of contamination (foreign bodies), the need to minimize the rate of rejected goods and hygiene as the machines are also used to handle unpacked foodstuffs such as cheese, meat and fish.

One of the core values at Wipotec is to manufacture all parts of the system inhouse where possible, which allows for a high net output ratio. This means the Kaiserslauternbased company can offer high levels of flexibility when addressing the

“the chemistry has been right from the very start”

theo Düppre, Wipotec founder and managing director

Wipotec managing director theo Düppre explains the interaction between the linear camera, MXr-100 x-ray tube and image recognition software.


Comet inside

individual needs of customers. As Düppre comments, “This is often the difference between European companies and our competitors in Asia.” When setting up xray technology, the decision was made to manufacture as many of the components as possible inhouse, including the linear camera and cooling equipment. When it came to the xray tubes, however, a solidly reliable partner was needed. “We looked at what the market had to offer and it didn’t take long to see that COMET was the right partner for us,” explains Düppre. “Nothing has changed since, the chemistry was right from the very start. We speak the same language and share the same philosophy. This is reflected in our communications – COMET always calls us back when we have a query, and all questions are answered professionally. You can’t always take that for granted elsewhere.”

With compact MXr-100 x-ray tubes from coMetWipotec particularly appreciates the fact that COMET Industrial XRay offers customized solutions that are tailored to customer requirements, and that they react quickly if needed. “On the one hand, it is important that we have a supplier manufacturing products of perfect quality and the highest precision for our everyday work. After all, our systems are in operation around the clock on the production lines. On the other hand, we need a partner we

can rely on in any situation, one who pulls in the same direction,” says Theo Düppre. He adds, “In many cases, enhancements are only possible through discussion. COMET takes our input and wishes on board in the best way possible, which we greatly appreciate. This allows us in turn to address the needs of our customers.” For example, Wipotec has subsequently been able to react to increased competition on the market as the company can now rely on specially developed, compact MXR100 xray tubes from COMET. This further development of the MXR75 xray tube, which fits in perfectly with the Wipotec systems, “opens up interesting new perspectives for us” according to Düppre.

valued uL certification supportAnother COMET service valued by Theo Düppre is UL certification support when using the systems in the USA, where Wipotec is the current market leader in Mail & Logistics thanks to its weighing instruments. The company now intends to gain a foothold with xray systems for food inspections. “We have to go along with this, as do our suppliers,” explains Düppre. “Although we can prove that our products conform to the standards to a certain extent, our options are limited when it comes to other equipment such as the tubes. Without COMET’s support, we would not be awarded the certificate and would be unable to succeed on the US market.”

Wipotec GmbHWipotec GmbH is a global innovation leader in the field of intelligent, dynamic weighing technology. The company has made highprecision weighing technology for integration in packing machines viable for industrial use. Under the brand name OCS Checkweighers GmbH, Wipotec develops, produces and markets highspeed precision weighing cells and hightech weighing systems for dynamic weighing processes in industrial applications. Checkweighers and continuous scales are core products in the ‘Food & Pharmaceuticals’ and ‘Mail & Logistics’ segments. Xray scanners for detecting foreign bodies complete the product range. Wipotec employs approximately 400 staff, with its headquarters in Kaiserslautern, Germany.

Learn more: www.wipotec.com and www.ocscw.com

theo Düppre: “We looked at what the market had to offer and it didn‘t take long to see that coMet was the right partner for us.”

Michael Schmid (coMet Sales Manager) with the MXr x-ray tube that meets Wipotec’s needs perfectly.


Comet inside

With its letter scales, kitchen scales and bathroom scales, visitors to Wipotec GmbH in Kaiserslautern can immerse themselves in a fine museum dedicated to weighing technology. Managing director and founder Theo Düppre has spent decades collecting over 1,000 vintage exhibits of all shapes and sizes, lovingly restoring most of them to their former glory by himself. Dotted throughout the company premises, the exhibits have little in common with the fast hightech weighing systems produced nowadays in the region. “It has become a cherished hobby of mine,” admits Düppre.

Where did this fascination for weighing technology and instruments come from? “Well, it’s nothing to do with my star sign,” says the electrical engineer with a laugh, nipping any speculation in the bud. “It wasn’t something I grew up with either.” In fact, Düppre’s fascination with scales began 35 years ago at university, where he was heavily involved in weighing technology. “Right from the start, I

was fascinated by the movement of the scales. This is a special physical challenge, where many different aspects have to be considered – and it’s great fun to boot.”

It is 25 years since Theo Düppre founded Wipotec GmbH with Udo Wagner, his former assistant at the university. The company was followed some years later by the subsidiary OCS Checkweighers

GmbH. “We have always produced systems for dynamic weighing, never static scales,” he explains. The approach has paid off: “Among other things, we now hold the world record for weighing speeds, with letters being weighed at a speed of four meters per second.”

The company is Theo Düppre’s life work and also his ‘family’. The company is seen as a symbol of

Kaiserslautern’s transformation into a hightech city. Its success is reflected in constant growth. Significant investments are currently being made at company headquarters, where production space is being increased from 17,000 to 25,000 square meters, with an additional 10,000 square meters to follow by the end of 2014. This will create more space for the core business of weighing technology as well as xray technology, which is expected to grow further. Aside from core applications in the foodstuffs industry (see the main article), Düppre recognizes the potential for xray technology in several other sectors where Wipotec weighing systems are already in use. These include the pharmaceuticals industry (including filling level checks for capsules, syringes and pill jars along with breakage checks on packed tablets and crack detection on vials), mail and logistics (automatic security checks on letters or private post) and the toy industry (nondestructive testing of packaged toys for completeness and damages).

a fascination with weighing technology

these vintage scales from a railway station are just one of over a thousand pieces in theo Düppre’s collection.


Comet insideComet inside

– Fact 1: Part of the unsharpness found in xray images in nondestructive testing (NDT) is a result of the finite focal spot size of the xray tubes used.

– Fact 2: The permissible level of unsharpness in xray images is restricted by standards. In the USA, the focal spot size is measured according to the ASTM E1165 standard; the equivalent standard in Europe is EN 12543.

– Fact 3: The old EN 12543 standard was split into five sections and sometimes delivered results that were impractical and varied. The old ASTM E1165 stan

dard, which was based on one of the five methods, produced markedly smaller results due to the different evaluations applied. Given the impractical values and conflicting results, both old standards tended to be dismissed by many users.

– Fact 4: The ASTM E1165 standard was revised in the USA and came into force in 2013.

➢– Fact 5: In Europe, the 2008 revision of the

old EN 12543 standard from 1999 still applies. The five sections of the standard deliver unrealistic and differing values, and a revision is currently envisaged.

The revised aStM e1165 focal spot standard has been in force in the USA since 2013. While bringing about numerous practical improvements in nondestructive testing (NDT), it also establishes the basis for revision of the european en 12543 standard.

Expert opinion

the aStM e1165 focal spot standard ensures clarity

aStM e1165: What is the issue?


Comet expertise

– advantage 1: The new test method has a standard deviation of <1% and is objective, meaning it is based on mathematical calculations and is not a visual evaluation.

– advantage 2: The new E1165 standard also contains a user test with a simple pinhole penetrometer. With suitable software, just three clicks of the mouse can generate a result with a standard deviation of <3%.

– advantage 3: The new test method cancels out both the conflicting results in the old EN 12543 standard and the discrepancies of the old ASTM E1165 standard.

– advantage 4: Together with the new ASTM E2903 micro focus standard, the E1165 standard also allows for a seamless transition from mini focus tubes to micro focus tubes – the same focal spot sizes are recorded in the overlapping areas.

➢– advantage 5: The new E1165 and E2903 standards have established the foundation on which the current revision process of the old EN 12543 standard is based. In future, all test methods in the various standards will deliver the same results, offering clarity to the user.

Klaus Bavendiek“The new test process in the ASTM E1165 standard delivers practical focal spot sizes that allow users realistically to calculate unsharpness resulting from the focal spot in line with standards. This means that the design of the xray testing system can be stripped back to the bare essentials. With an optimal design, up to 50% of testing time is saved while maintaining the same testing quality.”

Klaus Bavendiek, Director Development Imaging, YXLON International GmbH, Technical Contact for Revision of ASTM

adrian riedo“We know exactly how to design the focal spot to achieve the best compromise between detail recognition and the radiation level. The customer can then select the tube quicker and more easily, and save time.”

Adrian Riedo, R&D Technologies, COMET Industrial XRay

uwe Zscherpel“With the new standard, it is now finally possible to work with digital detectors instead of film. This revision makes sense and is actually long overdue. After all, digital detection is becoming ever more dominant in practice – it is easier and more precise. Users can also replicate the results of the manufacturer, which improves comparability. Now is the time for Europe to tackle the revision of the EN 12543 standard and resolve the unsatisfactory situation by unifying the different testing guidelines.”

Uwe Zscherpel, Senior Scientist at the German Federal Institute for Materials Research and Testing (BAM)

Which improvements will the new aStM e1165 focal spot standard bring with it?

images are recorded in the coMet testing laboratory. they show the lit focal spot, with the dose increasing from top to bottom.


Comet expertise

The aviation industry has a zero error margin, so the demands on testing quality are correspondingly high. High-tech systems from YXLon have proven themselves in this area for years and emerged as leading systems in the field of nondestructive material testing – using the 600 kV highenergy xray source from COMET, among others.

Nondestructive testing (NDT)

High power for maximum safety

The blades on highpressure turbines represent one of the greatest challenges in nondestructive material testing. Manufactured from nickel superalloys, they are able to withstand extreme pressures and temperatures. The trend in the aviation industry towards saving weight has made turbine blades increasingly fine, thin and complex while good cooling properties guarantee their durability. “With conventional xray tubes of up to 450 kV, it was not possible to xray certain areas of the tested material,” explains Malte Kurfiß, Director Product Marketing at YXLON International. “We were forced to use linear accelerators or isotopes, which was not without problems due to the radiation protection and resolution involved.” It came as no surprise, then, that the development of a 600 kV xray source with highpower technology by COMET Industrial XRay was met with great enthusiasm at YXLON. “It addresses the current trend in the aviation industry perfectly,” says Kurfiß. Materials with a higher density can be xrayed thanks to the higher voltage, while the highpower technology allows for high resolution. Ac

cording to Kurfiß, “With the 600 kV xray source, we can strike a balance between xraying parts with a higher density inside

a turbine blade while achieving the necessary resolution to recognize fine material structures and identify the smallest possible faults.”

Clear results are critically important in the aviation industry. Zero error margins

“the development of the 600 kv x-ray source with high-power technology by coMet addresses the cur-rent trend in the aviation industry perfectly.”

Malte Kurfiß, Director Product Marketing,

YXLon international

Comet inside

16 X-raY insight 2 | 2013

the particularly lightweight construction of the airbus a350 shows the direction in which the aviation industry is headedin terms of materials. 17X-raY insight 2 | 2013

Comet inside

are the norm and the demands on testing quality are extreme. When developing new technologies or materials, the question of verifiability always arises. “Sooner or later, xrays are involved,” comments Kurfiß. This may be at the stage of basic research, in the testing laboratories when moving from research to production, or in final quality control. As Malte Kurfiß emphasizes, “As a hightech company, we always want to be the frontrunners. Thanks to our knowhow and experience, we can also offer the best possible support to the aviation industry in this area.” He also underlines the advantages of xray technology as an imaging procedure. “Computer tomography in particular makes it completely clear whether there is actually a fault or simply an anomaly,” explains Malte Kurfiß. “We can therefore reduce the rate of false alarms and waste.”

new production method is resulting in new fields of application für nDtThe Dreamliner from Boeing and the Airbus A350 show the direction in which the aviation industry is headed. The two latest flagship airliners from the leading aircraft manufacturers have one particular thing in common: they are built predominantly from composite materials reinforced with carbon fiber. This design leads to a significant weight reduction and thus lower kerosene consumption – one of the main goals of the industry given that kerosene is one of the largest cost drivers for airlines.

The new production method is resulting in new fields of application for nondestructive material testing, as the aviation industry has comparatively little experience in handling carbonfiber composites. Moreover, any defects are harder to see from the outside and the reproducibility of all faults is more difficult as the production process is predominantly manual rather than automated. This is where YXLON and their systems for nondestructive material test ing come in. “We are constantly pushing the boundaries of what is technologically possible,” reveals Malte Kurfiß. “To do this we need strong partners and suppliers, such as COMET. Only with their support can we continue to break new technological ground and master new challenges that arise.”

The Director Product Marketing at YXLON International also notes just how difficult it is to explore new technological possibilities in the aviation industry. According to him, everything is regulated down to the finest detail, guidelines are strict and the certification process is incredibly demanding and protracted. Furthermore, there are no standard processes between customers. “We have to be flexible and develop individual solutions for the market that adapt to sophisticated production processes and customer tests. Built to print is the key word here. It’s also very difficult to achieve this without partners and suppliers who share the same philosophy.”

YXLon internationalYXLON International is the leading supplier of industrial xray systems and computer tomography (CT) systems for nondestructive material testing using xrays. YXLON has a wide range of portable, mobile and stationary systems that can be operated manually, semiautomatically and automatically. YXLON thus covers a wide range of applications in the automotive, aerospace, shipbuilding, boiler construction and electronics industries, among others. YXLON International has been part of COMET Holding AG since January 2007.

Learn more: www.yxlon.de

Y.Mu56 tB for fully automated testing of tur-bine blades. robots and temporary storage reduce loading times.


Comet inside

As Marilyn Monroe famously sang in the 1950s, “Diamonds are a girl’s best friend”. In the 21st century, the song title remains as relevant as ever. Morethan ever, yields as close as possible to 100% and high levels of process efficiency matter in today’s mining industry.

Mining

a modern-day treasure hunt

Precious stones are still highly coveted. While particularly large and pure stones continue to command record prices at auctions, smaller examples can still make people’s eyes light up with joy.

There is only one problem – diamonds are not exactly a dime a dozen. Even profitable mines only yield an average of one gram of diamonds per 15 tons of mined ore. This highlights the challenge facing

mine owners every day: they have to ensure that even the smallest stones are procured in the forbidding mine environment and that yields are as close to 100% as possible, all the while ensuring their own resources are deployed with maximum efficiency. To achieve this, mining companies use a variety of technologies, with xray technology becoming increasingly popular. “In mining, xrays are

impressive: the victor Mine, located in the James Bay Lowlands in ontario (canada).

Comet inside

19X-raY insight 2 | 2013

very effective and efficient,” says Don Brennan, Vice President Business Development & Sales at COMET Industrial XRay. “While xrays are an expensive method, they have an aboveaverage price/performance ratio. Our customers can significantly increase their process efficiency using xrays, especially when mining rare minerals that are only found in small quantities – and are thus more valuable. This applies in particular to gold nuggets and diamonds.”

customized coMet productsThanks to its years of experience in xray technology and its wide range of products, COMET is also an ideal partner to

industrial X-ray – four approaches The most common method used in mines is X-ray transmission, a highly efficient approach used to detect precious stones and ore on the basis of their differing densities. It is mainly used to analyze large quantities of material and highly valuable ores. XRay Transmission can also be combined with X-ray Luminescence, which increases yields at diamond mines even further. XRay Luminescence exploits the fact that even the smallest impurities cause diamonds to glow when exposed to xrays. Until now, X-ray Fluorescence and X-ray Diffraction have generally been used for smaller quantities of material and in laboratory work only. XRay Fluorescence enables ore to be differentiated through its spectrography. XRay Diffraction, meanwhile, completely analyzes the material – which poses enormous challenges where quantities are large.

Don Brennan: “our customers use x-rays to increase their proc ess efficiency when mining rare, valuable miner-als. this applies in particular to gold and rough diamonds.”

Screening of rocks often takes place in huge processing build-ings close to mines like the orapa mine in Botswana.


Comet inside

X-rays in the mining industryThe use of xrays in the mining industry has a long tradition. For many years, miners were xrayed as they left the mine as owners wanted to prevent their workers from smuggling diamonds out by swallowing them. Nowadays, such fears are mostly unfounded. Current mining systems are designed so that most workers no longer come into contact with the actual diamonds, thereby eliminating temptation. Xray technology is now used with increasing frequency to detect diamonds, gold and other valuable materials.

“in mining, x-rays are very effective and efficient.”

Don Brennan, vP Business Development & Sales, coMet iXt

the mining industry. “We offer a variety of options,” comments Don Brennan. “We can then customize the products according to the individual requirements of our customers, enabling us to build ideal xray sources. If we are involved in a new project from the outset, we can utilize the full potential to the greater benefit of our customers.”

outstanding success rates when search-ing for precious metals and oreThis is the driving principle behind COMET. The development of specific solutions is a central aspect in discussions with customers. “We develop our products at the R&D Center in Flamatt and react quickly thanks to short processing routes and the best possible infrastructure. Tailored solutions and small production runs also mean reliable, highquality systems for our customers in the mining industry.” Among other aspects, Industrial XRay achieves this thanks to very high success rates when searching for precious metals or ore. What’s more, mining companies are now checking and scanning earth and excavated material considered worthless some years ago for a second time – and discovering valuable materials that were previously overlooked.

One key aspect in enhancing process efficiency is ‘sorting in the field’, whereby screening systems are used at mines to analyze stones or mined ore, leading to a significant reduction in transport costs. Waste material is often a major problem, as this must be taken away and disposed of. With this in mind, Don Brennan notes that the machines are often used in extremely harsh environments and that the mines are usually found in the remotest corners of the world. “This means that customers have particularly stringent demands. They have to be able to count on the xray sources working reliably on a longterm basis, as replacements are not usually available at short notice.”


Comet inside

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To meet the everincreasing demands of the air cargo sector, manufacturers of detection and inspection systems use equipment that makes the inspection process as efficient as possible. One of the global market leaders in the field – Smiths Detection – relies on a specially developed 300 kV xray tube from COMET.

Security inspections

take-off for efficient cargo inspection


Comet inside

Security is always the top priority in the international transport business, and especially the air cargo sector. As legal requirements become ever more stringent, increasingly accurate inspections of consigned goods are demanded. At the same time, the flow of shipments is also growing as a result of globalization, which means there are more goods to be inspected. This places especially high demands on the manufacturers of detection and inspection systems. “Consigned goods have to be inspected as quickly as possible,” explains Joachim May, Vice President of Global Operations at Smiths Detection in Wiesbaden. This can either be achieved by maximizing the size of packaging units for scanning, or through efficient handling. “The goal is to create

processes that are as efficient as possible in order to guarantee quick and secure handling, which saves our customers time and money. The integration of xray inspection equipment is becoming increasingly popular in the process chain when it comes to meeting the rising demands on throughput and data recording.”

As one of the global market leaders in the field of detection and inspection systems,

Smiths DetectionSmiths Detection leads the global market in the production of detection and inspection systems for military applications, transportation and internal security. With the help of a wide range of technologies, dangers such as biological and chemical agents, toxic industrial chemicals, explosives, drugs, weapons and illegal objects can be quickly identified. Smith Detection is a separate operating division of Smiths Group plc, which has around 23,000 employees in 50 countries.

Learn more: www.smithsdetection.com

“consigned goods have to be inspected as quickly as possible.”

Joachim May, vP Global operations, Smiths Detection

Security is always the top priority in the international trans-port business, and especially the air cargo sector. Goods ship-ments have to be x-rayed in their entirety.


Comet inside

Smiths Detection (see box) boasts an extremely broad portfolio of security technologies that can be combined and linked as required. Air cargo is a very important segment, with a customer base that includes qualified shipping agents and freight forwarders alongside airlines and airports throughout the world. Goods shipments have to be xrayed in their entirety. Smiths Detection developed the HiScan 180180 product range specially for the high demands placed on Consolidated and Palletized Cargo (CPC). This uses 300 kV xray tubes to inspect pallets and air cargo containers. The dualview systems primarily used in air cargo make the inspection process as efficient as possible. For these

systems, Smiths Detection uses 300 kV xray tubes from COMET. “We were on the lookout for a second source. We already knew that COMET was a professional and reliable partner. The design of the tubes offers other benefits too, so our decision was an easy one,” recalls Joachim May. As the products from Smiths Detection

have to meet stringent demands in terms of functionality and availability, the reliability of purchased components and cooperation between the companies both play decisive roles. “We are also extremely satisfied on these points. Our working relationship with COMET is based on mutual trust. Any problems which arise are dealt with jointly and expertly, so they are overcome in the end. We are bound by a true partnership characterized by expertise, openness, flexibility, reliability and a passion for confronting and resolving challenges.”

One example of this is the cooperation on the CIP300 project (Car Inspection Portal). This system allows for the quick and efficient inspection of cars and delivery vehicles while delivering exceptional image quality. The radiation dose is so low that the driver (depending on local legislation) does not have to leave the scanned vehicle, and the inspection can be made in transit. For this purpose, a special 300 kV tube was developed in partnership with COMET which could be integrated into an existing 300 kV electronics system in special housing with no significant alterations. “A joint project team developed a prototype and brought it to the production stage together,” comments Joachim May. “There were many positive aspects, but we particularly valued the high level of technical expertise at COMET and the flexibility to work out solutions quickly in the event of unexpected problems.”

“our working relationship with coMet is based on mutual trust. any problems which arise are dealt with jointly and expertly.”

Joachim May

Smith Detections customer base includes qualified shipping agents and freight forwarders alongside air-lines and airports.


GLoBaL X-raY eventS in 2013/14

22 – 24 october 2013aerospace testing russiaMoscow, Russia

30 october – 1 november 2013Quality control ShowShanghai, China

4 – 7 november 2013aSnt, Fall conference 2013Las Vegas, USA

13 – 15 november 20135th international Symposium on nDt in aerospaceSingapore

18 – 22 november 201314th asia Pacific conference on non- Destructive testing (aPcnDt 2013)Mumbai, India

25 – 28 February 2014 ict 2014 – 5th conference on industrial computed tomographyWels, Austria

25 – 27 March 201428th aerospace testing SeminarLos Angeles/CA, USA

6 – 9 May 201428th control – internatio-nal trade Fair for Quality assuranceStuttgart, Germany

26 – 28 May 2014DGZfP annual conferencePotsdam, Germany

Show us your images!

Key customer benefitsThe MXR225HP/11 is a unipolar watercooled xray tube assembly with inte grated radiation protection. It is characterized by a dual focal spot, highpower tungsten anode and a directional beam. The tube has been specially developed for imaging applications in nondestructive material testing.

Standard applications– Weld seam testing– Testing of cast parts in the automotive

and aviation industries

Further information on MXR225HP/11: www.cometxray.com/Products/XRayTubes

MXr-225HP/11 unipolar x-ray tube assembly

Seashells by Brad Kraai, instructor/radiology, X-r-i nDt training & consulting.

Xray images are an integral part of our everyday work and continue to fascinate us, so we are always pleased to receive your correspondence. Send us your best xray images, whether these are imaginative shots of everyday objects or items from your workplace. The best entries will be published in upcoming editions of ‘XRay insight’.

The seashellsimage by Brad Kraai, Instructor at XRI NDT Training & Consulting, was captured with COMET MXR225/22.

Send your images (300 dpi/max. 5 MB) and your personal details (name and company), also describing the subject and how it was taken, to magazine@cometxray.com.

X-raY insight 2 | 2013 25

Comet produCts & neWs

The Band Association employs 325 staff with some form of disability. It has established itself as a social business enterprise with flying colors.

Band Association

Band of partners

It soon becomes obvious to visitors that the motto adorning the flag fluttering in the wind above the Band Association headquarters – ‘Social, skilled and marketfocused’ – is not just three words. In fact, these are values embraced every day here in western Bern. “Our challenge is to achieve a balance between social responsibility and market orientation,” says Andreas von Niederhäusern, Operational Manager at the Band Association. “We can’t put our disabled employees under excess strain, but we still have to do business to the highest quality standards.”

On one hand, the private sector company achieves this balance by focusing on the people themselves: “We take the time to address the specific needs of our employees. We also constantly ask ourselves what each different disability means and how much we can expect from an employee.” On the other hand, von Niederhäusern emphasizes the importance of good planning. “We analyze orders precisely and break them down into manageable tasks. That way, each person can take on a task and contribute to the successful completion of an order.” The management team also plays a very important role. Team leaders not only have the required technical expertise and highly developed social skills, but also undergo spcial training on a regular basis. As von Niederhäusern emphasizes, however, anyone who thinks that life in the company is easy due to its social stance is very much mistaken. “We have to

provide exceptional services at all times.” One glance at the production hall confirms this, where stateoftheart machines are used for turning, milling, soldering, welding and assembly – all with the diligence, high motivation and concentration found in any other production facility. A supervisor is always nearby in case the staff mem

ber requires assistance.The success of the Band Association is reflected in its long list of high profile customers – which includes COMET AG, for whom lead casings are welded and cable harnesses and circuit boards produced in Bern. The production of lead casings in particular shows just why von Niederhäusern is fully convinced by the partnership between the two companies. “With the support of COMET, we have been able to develop the expertise required for welding lead casings,” explains von Niederhäusern. “Lead is much softer than steel, for example, meaning extra care and attention are needed in processing. The development work has paid off – we now have several employees who are experts in this area.”

Band associationAndreas von Niederhäusern (pictured) is Operational Manager at the Band Association, a private sector company located in western Bern dedicated to providing employment to people with disabilities or social issues. Since its establishment in 1946, Band has grown steadily and now employs a total of 540 staff, 325 of whom have some form of disability.

Learn more: www.band.ch

“With the support of coMet, we have been able to develop the expertise required for welding lead casings.”

andreas von niederhäusern, operational Manager, Band association


Comet Commitment

at the Band association factory, vari-ous tasks are performed for coMet with great care – and at the highest quality standards. these include (from top to bottom-right): mechani-cal processing of casing pipes for radiation protection, quality control, cable harness production, cable as-sembly and hand soldering of circuit boards.


Comet Commitment

Our aim is to also keep you happy after purchasing our products. In addition to the high standards and quality of our products you can also rely on the competence of our employees. Prompt and reliable processing of service requests are part of your success. Immediate reaction in response to your service request is a guarantee for you to get production up and running again. Please contact us.

Global Service Centers

Quick and reliable service

Service center euroPa & roW coMet SwitzerlandHerrengasse 103175 FlamattSwitzerland

T +41 31 744 9000F +41 31 744 9887 [email protected]

Service center uSacoMet technologies uSa, inc.76 Progress DriveStamford, CT 06902USA

T +1 203 504 7464F +1 203 969 [email protected]

Service centeraSiacoMet china1201 Guiquiao RoadBuilding 10, 1st floorPudong, Shanghai 201206P.R. China

T +86 21 6879 9000F +86 21 6879 [email protected]

Documents

COMET X-RAY insight