Frequently Ask Questions: Ultrasonic Technology

What is ultrasound?

What is ultrasonic technology?

How can ultrasonic technology be implemented into a regular predictive maintenance program?

If I already use vibration analysis or infrared, why would I need ultrasonic technology?

How is ultrasound used to inspect, test, and diagnose industrial systems?

What is ultrasound?
Ultrasound is sound that occurs above the normal range of human hearing. Impact, turbulence, electrical arcing, and friction produces sound all along the spectrum. The machines and equipment comprising industrial systems generate great amounts of human audible sound and ultrasound when in operation.

Mechanics have always used audible sound as part of the information gathering process to diagnose the operating condition of their machinery. They often use a screwdriver, electronic stethoscope, or even vibration analysis. The audible sounds generated by individual bearings or leaks are difficult to differentiate in a noisy environment where components operate within close proximity of one another. With ultrasound, differentiation is possible. Additionally, ultrasound waves are detectable prior to the audible waves, which helps provide early diagnosis.

What is ultrasonic technology?
Ultrasonic technology utilizes the properties of ultrasound for the benefit of maintenance diagnostics, safety, and quality control. Industrial machines and equipment emit ultrasound waves that can indicate defects or failures. CTRL's UL101 converts ultrasound into the human audible range so that these "warning signs" can be heard. At the same time, the unit ignores sounds typically heard by the human ear so that the problems detectable in the ultrasound range can be more clearly discerned. These converted sounds can be easily recognized through the UL101's headset and distinguished by the human ear and brain. For example, a bearing sounds like a bearing and an air leak sounds like an air leak. Therefore, listening for gas leaks or monitoring the condition of bearings becomes very reasonable in extremely noisy environments.

Ultrasound has many characteristics that make it even more beneficial than traditional predictive maintenance methods. Ultrasound is very directional; therefore, the source of a problem can be pinpointed more accurately. It attenuates much faster than audible sound, so it stays close to its source - also allowing for easier detection. It is nondestructive, meaning components are monitored while in normal operation. Ultrasonic testing is instantaneous, providing useful, real-time information. In the case of bearings and gears, ultrasound will occur prior to mechanical failure, thus giving the end-user of the UL101 the ability to lubricate or replace bad components before a critical breakdown occurs.

How can ultrasonic technology be implemented into a regular predictive maintenance program?
The UL101 is easy to use and provides instantaneous information. It is a compact and user-friendly tool that is also very durable. It can be stored in a toolbox or carried with a belt pouch during routine inspections of your machinery. The UL101 can be implemented for routine predictive and preventive maintenance inspections, for identification of failed components when a problem is suspected, and for confirmation of repairs.

If I already use vibration analysis or infrared, why would I need ultrasonic technology?
To be applied properly, vibration analysis is expensive and requires sophisticated equipment/procedures and experienced specialists. Results require trending and are not immediately available. With the UL101, the user can diagnose the condition of components within seconds. Use of ultrasonic technology can also be learned quite quickly, allowing for easy transition with employee turnover.

Infrared analysis can sometimes be ineffective at pinpointing problems. Some equipment is naturally hot when in operation. Also, some naturally hot components can mask other components that become heated due to malfunction. Usually, by the time the temperature or vibration is "out of line," the damage is already done.

Both vibration and infrared analysis have limited applications. Neither can detect a vacuum or pressure leak. The UL101 provides much greater utility to you and your customers for less money.

If you have already made the investment in these other types of predictive technologies, the UL101 is an inexpensive tool that can be used as a supplemental device to confirm the results of vibration analysis, infrared, or other predictive technologies.

How is ultrasound used to inspect, test, and diagnose industrial systems?
When the technician is provided the ability to hear ultrasound with the CTRL UL101, the properties of ultrasound make it a unique and powerful tool in the process of both detecting and diagnosing operating malfunctions.

The UL101 is used in contact mode to inspect, test and diagnose a diverse range of internal operating components in complex equipment assemblies. The tool provides the mechanic real time (instant) internal component condition assessment of bearings, gears, valves, solenoids, hydraulic or pneumatic pistons, cylinders, etc. Contact mode is accomplished using selectable length solid probe attachments to the receiver.

The UL101 is used in scan mode to detect and pinpoint leaks in compressed air, steam, and other gas systems and vacuum systems. It is also used in scan mode to detect and pinpoint electrical arcing or corona discharge. Scan mode is accomplished using the acoustic probe attachments.