Measurement eZ-NDT User Manual
IOtech
www.iotech.com
eZ-NDT version 6.0.9
USER’S MANUAL
Software for Non-Destructive Testing
25971 Cannon Road
Cleveland, OH 44146-1833
(440) 439-4091
*372163C-01*
372163C-01 1086-0924 rev 9.2
productsupport@iotech.com
Fax: (440) 439-4093
sales@iotech.com
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Contents
1 - Introduction
2 - Investigative Mode Testing
3 - Inspection Mode Testing
4 - Windows and Menus
Main Window …… 4-1
Graphical Display …… 4-6
File Menu …… 4-8
Edit Menu, Configuration …… 4-10
Acquisition Tab …… 4-10
Input Channels Tab …… 4-11
Automation Tab …… 4-14
Edit Menu, Limits …… 4-17
Edit Menu – Display and General Options …… 4-18
Display Preferences ……4-18
Copy Window …… 4-18
Load Picture ……4-18
Remove Picture …… 4-18
Erase History File ……4-18
Erase Template File …… 4-18
Menus with Associated Window Panels ….. 4-19
Project …… 4-19
Control …… 4-19
Display …… 4-19
View …… 4-19
Report Menu …… 4-20
User Menu …… 4-25
Notes for Efficient use of eZ-NDT …… 4-26
5 - Setting Limits
eZ-NDT 938895 iii
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Introduction 1
Reference Note:
System Requirements
Minimum re quirement s include:
• Monitor: SVGA, 1024 x 768 screen resolution
• Requires 32-bit version of Windows: Windows 2000 SP4, Windows XP, or Windows Vista (x86)
Windows 2000 SP4 and Windows XP Users:
PC with Intel
Windows Vista (x86) users:
PC must be Windows Vista Premium Ready
What is eZ-NDT?
eZ-NDT is a non-dest ructive QA /QC inspecti on system based on the ZonicBook FFT. High frequency
vibration data is collected and compared against user-defined amplitude and frequency limits. A passed
(good) part will have the maximum spectral peak(s) within the defined limit band(s). A failed (bad) part
will have one or more spectral peaks outside the defined limit band(s).
™
Pentium 4 or equivalent; 1 GB memory; 10 GB disk space
If necessary, refer to your system’s associated hardware
manual for information regarding the following:
Software Installation
System Requirements
Hardware Setup
Driver Installation
eZ-NDT systems typically include a computer running a Microsoft Windows 2000 SP4 or Windows XP,
an analyzer such as a ZonicBook FFT Analyzer, or an IOtech 640 or 650, one modal hammer, and one
response instrument, such as a microphone or an accelerometer.
Note: The term “ZonicBook” refers to a ZonicBook-Medallion and/or a ZonicBook/618E device unless
otherwise specified.
eZ-NDT has two modes: Investigation and Inspection.
The Investigation Mode is used to define the spectral acceptance regions. It is an iterative process that
compares the spectral frequency and amplitude differences between known Good and Bad parts.
Limit bands are defined based on vibration peaks that occur in the tests of “good” parts, but not in the tests
for “bad” parts. Aft er the limits are defined all the parts are tested to ensure t hat:
• all the “good” parts pass and
• all the “bad” parts fail
Some fine-tuning ma y be required.
When test results are consistent, you are ready to start testing pro duction parts in the Inspection Mode.
Typically, good parts should have a consistent spectral response, in other words, a good repeatable pattern.
A shift or change in spectral pattern indicates a change in the part’s Mass, Stiffness, or Damping. These
changes often indicate a problem with the part.
To ensure repeatable results make certain that setup conditions are consistent;
for example: the Impact Location and Force of hammer strike.
When an automated system is used, there are additional process considerations.
These are typically addressed and configured at the factory prior to shipment.
eZ-NDT 988390 Introduction 1-1
Multiple user levels exist for project protection. Level 3 is for the manager and allows complete access to
the System. Level 2 is for the technician and Level 1 is for the inspector. Levels 1 and 2 do not permit
configuration modifications, among other limitations.
The first time eZ-NDT is executed it will automatically load the default configuration parameters into the
“Project Template”. The template is located in the Windows directory in which eZ-NDT was installed .
You should consider an “eZ-NDT Project” equal to a unique Part that you wish to test. For example, if you
manufacture Widgets and Gizmos, you would have 2 separate eZ-NDT projects, one for Widgets and one
for Gizmos.
Each eZ-NDT project is saved in one project file with the extension “.ndt.” Thus the widget project could
be named “widget.ndt” and the gizmo project could be named “gizmo.ndt”.
Each eZ-NDT project is saved in one project file with the extension “.ndt.”
eZ-NDT, Operation Sequence
1-2 Introduction 958194 eZ-NDT
Investigation Mode Testing 2
To ensure repeatable results make certain that setup conditions are consistent;
for example: the Impact Location and Force of hammer strike.
When an automated system is used, there are additional process considerations.
These are typically addressed and configured at the factory prior to shipment.
1. Gather known “good” and “bad” parts ……2-1
2. Set up the analyzer, hammer, microphone, and computer …… 2-1
3. Launch eZ-NDT …… 2-2
4. Open a New eZ-NDT Project …… 2-3
5. Select Investigation Mode …… 2-4
6. Configure the Analyzer …… 2-4
7. Select Plot Display Type …… 2-4
8. Turn on Data Acquisition ……2-4
9. Test All Good Parts …… 2-4
10. Test All Bad Parts ……2-6
11. Compare the Results of Good and Bad Tests ……2-7
12. Configure the Limits …… 2-7
13. Verifying the Limits and Ranges …… 2-9
The following process can be used to determine whether eZ-NDT testing is feasible for the part that is
being tested. Typically this is an iterative process in which the user:
establishes the resonant signature of the part
determines the distinct peaks of the signature
uses the peaks to set up eZ-NDT test criteria
1. Gather known “good” and “bad” parts.
Locate both good and bad parts. Typically 10 of each are sufficient. Make sure the Bad parts include all
possible reject (failure) modes. The good parts will be used to test for NDT feasibility.
Block Diagram of Typical NDT Setup
eZ-NDT 938691 Investigation Mode Testing 2-1
2. Set up the analyzer, hammer, microphone, and computer.
Reference Note:
If necessary, refer to your hardware user’s manual as applicable for information regarding:
Software Installation
System Requirements
Hardware Setup
Driver Installation
Connect your analog input signals to the analyzer (e.g., ZonicBook/618E, 640, or 650 device) BNC inputs.
Configure the analyzer as needed.
a. Connect the Impact Hammer to Channel 1.
b. Connect the Microphone to Channel 2.
c. Place the microphone within range of the output.
3. Launch eZ-NDT.
To run eZ-NDT, double-click the eZ-NDT icon or use your Windows desktop Start button to navigate to
the program file.
First Time Running eZ-NDT
Registration Form
Note: After you have completed the following steps, each succeeding time that you start eZ-NDT you will
be taken immediately to the main screen.
A registration form will open the first time you run eZ-NDT. You must complete the information in this
form to enable the eZ-NDT application.
The password accompanies your CD-ROM. You will not have to re-enter this information again, unless
you upgrade to a newer version, or have to re-install eZ-NDT.
2-2 Investigation Mode Testing 938691 eZ-NDT
Because multiple eZ-NDT Projects will exist on your computer we suggest you create project
folders to organize and save your files. These folders can be located anywhere on your system.
eZ-NDT will open to its main screen, as indicated below.
4. Open a New eZ-NDT Project.
Each eZ-NDT Project contains configuration and data files. You should logically equate an eZ-NDT
project with a specific part that you wish to inspect.
a. On the File menu select New Project to open the “Save As” window.
b. Select a folder for your eZ-NDT Project or create a new folder.
eZ-NDT Main Window
Save As Dialog
eZ-NDT 938691 Investigation Mode Testing 2-3
If you created a new folder...
DO NOT use NDT.ndt as a filename. NDT.ndt is the default template. A good file
name is on that identifies the part, for example, part232.ndt.
If you have tested both good and bad parts, and you do not see a difference between them,
you may need to modify one or more of the configuration values. Increasing the Trigger
Delay is the most common solution.
Spectrum/FRF Display
With “New Folder” highlighted, type a name for the Project Folder. Then, double-click on the folder to
open it. This is where you will save your new project files.
c. Type a filename for the project, including the file extension, in the File name data entry box.
i.e. part234.ndt
d. Click the Save button to create the new project. Now all the files for this project will be saved in the
folder you just used.
5. Select Investigation Mode.
On the main screen select Investigation Mode.
6. Configure the Analyzer.
To start use the default values.
7. Select “Spectrum/FRF Display” as the Plot Type.
The plot display types are selected by clicking on one of the first two buttons. The first button on the left is
“Spectrum / FRF Display.” The second button is “Time Display.”
For our “Investigation Mode” we want to use the “Spectrum/FRF Display” for the type of plot. Click on
the Spectrum icon (first button).
8. Turn on Data Acquisition.
To initialize the hardware and turn on the data acquisition, click the red toggle switch in the Acquisition
panel of the Main window. The toggle switch will flip up and change from red to green. Prior to
proceeding, wait for the status to change form “Initializing Hardware” to “Ready.”
2-4 Investigation Mode Testing 938691 eZ-NDT
9. Test all “Pass” (Good) Parts.
Use of the logarithmic scale (Log Scale Y Axis button) tends to enhance the peaks. This makes
it easier determine significant peaks.
Investigation Mode, Pass Part Template
To test all “Pass” (Good) parts:
a) Select the Pass parts in the grid (see figure, upper right). Note that you can right-click on a part
number, e.g., “1” to access its associated template.
b) Strike the parts several times at a consistent location with a consistent amount of force.
c) If you do not see anything on your plot, click on the <Autoscale> button, or the <Log Scale Y Axis>
button, to expand the y-axis.
Autoscale Log Scale Y Axis
Linear Scale of Initial Strike
d. Click the Autoscale button to have the Y axis minimum and maximum scaled to the data
eZ-NDT 938691 Investigation Mode Testing 2-5
10. Test all “Fail” (Bad) Parts.
Autoscale of Initial Strike (Logarithmic Scale)
Investigation Mode, Fail Part Template
To test all “Fail” (Bad) parts:
a) Select the “Fail” parts in the grid (see figure, upper right). Note that you can right-click on a part
number, e.g., “1” to access its associated template.
b) Strike the parts several times at a consistent location with a consistent amount of force.
c) If you do not see anything on your plot, click on the <Autoscale> button, or the <Log Scale Y Axis>
button, to expand the y-axis.
2-6 Investigation Mode Testing 938691 eZ-NDT
Because this process detects internal, non visible defects, you may have an occasional
part fail, which you thought was a “Pass” part.
If you do not need all four of the limit bands, remove the extra ones. Instructions for removing and
adding limit bands follow.
11. Compare the Test Results of Pass and Fail Parts.
Visually locate the spectral differences between the Pass and Fail parts. You should be looking for
resonant peak(s) that shift in frequency (e.g., red lines to the left or right of the blue line) and/or amplitude
(red lines shorter or taller than the blue line). If blue and red peaks are almost identical, they are probably
not good choices. Ideally you will find significant single peaks.
Using Investigation Mode, Comparing a Good Part to a Bad Part
12. Configure the Limits.
Modify the limit bands to match the “Pass” part’s spectral peaks that you want to use. As mentioned earlier,
this is an iterative process. Quite often, some of your “Pass” parts will fail with these exact limits the first
time.
eZ-NDT will find the maximum spectral amplitude in a frequency range. If this point is in the defined limit
region, the range status is “Pass.”
The default step includes four limit bands, already placed on the plot. These limit bands are green
acceptance limits [peaks for subsequently tested parts must be within these limits to be counted as “Pass”
parts]. Working from left to right, drag the first band to the first peak you want to use. Next, drag the
second band to the second peak you want to use, etc.
eZ-NDT 938691 Investigation Mode Testing 2-7
To remove a Limit Band from the plot:
a) Right-click on the Limit Band’s associated letter. Each enabled limit band has a letter in a white box
(see figure).
A property box will appear. In the figure below Limit D is being selected.
b) Remove the checkmark from “Enabled.”
c) Click the <Apply> button.
Removing a Limit Band
Note: Limit bands can also be added or removed via the “Limits” selection within the Edit pull-down
menu. The difference in using the Edit menu’s “Limits” selection is that all properties (for all limit
bands) are displayed at the same time [instead of one at a time]. See following figure.
Limit Values Window, Partial Display
Limit Bands can be “Enabled” and “Disabled” from the first column.
To add a Limit Band to the plot:
a) Right-click on a disabled Limit Band’s associated letter. Note that disabled limit bands are designated
as letters in gray boxes
A property box will appear.
b) Add a checkmark to the “Enabled” property.
c) Click the <Apply> button. The new limit band will appear on the plot display.
2-8 Investigation Mode Testing 938691 eZ-NDT
Note: Limit bands can also be added or removed via the “Limits” selection within the Edit pull-down
menu. The difference in using the Edit menu’s “Limits” selection is that all properties (for all limit
bands) are displayed at the same time [instead of one at a time].
Note: Up to ten limit bands can exist on a plot.
13. Verify the Limits and Ranges.
a. Switch to Investigation Mode.
b. Test all the known “Pass” (Good) and “Fail” (Bad) parts. Look for consistent results.
If parts pass and fail as expected . . .
You are ready to run tests on production parts. If this is the case ensure that the “Graphical Limit
Changes are Disabled” (locked padlock) image is showing (following figure). If the padlock image is
open, click on it to lock in the limit bands at their current settings.
Graphical Limit Changes
If good parts fail and/or bad parts pass . . .
Are any peaks just a fraction out of range? If so, tweak those limits.
Are there peaks that you missed the first time? Add one or more limit bands.
Are there two peaks that are fairly close, one within the band and one just outside it?
Sometimes you will have 2 closely spaced peaks. These peaks will “fight” for dominance.
In this type of case you can either:
remove the entire range
widen the range to include both peaks, or
split the range with one peak in each range.
are Disabled
c. Re-test the known “Bad” parts. Did they all fail?
If not, consider setting amplitude limits. Sometimes, the only difference between a good and bad part
is a difference in amplitude of a significant peak.
You can change the amplitude and/or frequency limits of band by: (1) unlocking the “Graphical Limit
Changes” button, (2) placing the mouse cursor over the limit edge to be changed, (3) stretching or
shrinking the band to the desired new limit. (4) repeat steps 2 and 3 for the other limits of the band, as
desired. An example follows.
eZ-NDT 938691 Investigation Mode Testing 2-9
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