Accuscan

User Manual

AUT Solutions, LLC

29382 McKinnon Rd, Ste. C
Fulshear, TX 77441
www.autsolutions.net
 Table of Contents

SPECIFICATIONS ----------------------------------------------------------------------------------------------------------------------------- 4
Design Intent ---------------------------------------------------------------------------------------------------------------------------- 4
Dimensions and Weight -------------------------------------------------------------------------------------------------------------- 4
Scanning Speed ------------------------------------------------------------------------------------------------------------------------- 4
Encoder Ticks per Inch values ------------------------------------------------------------------------------------------------------- 4
FEATURES-------------------------------------------------------------------------------------------------------------------------------------- 5
LIST OF COMPONENTS --------------------------------------------------------------------------------------------------------------------- 7
SET-UP ------------------------------------------------------------------------------------------------------------------------------------------ 8
TRANSDUCER SETUP---------------------------------------------------------------------------------------------------------------------- 11
MOTOR CONTROLLER -------------------------------------------------------------------------------------------------------------------- 14
MAINTENANCE AND SAFETY ----------------------------------------------------------------------------------------------------------- 15
Replacing Motors --------------------------------------------------------------------------------------------------------------------- 15
Regular maintenance ---------------------------------------------------------------------------------------------------------------- 15
Greasing X-Motor Gears-------------------------------------------------------------------------------------------------------------16
Greasing Y-Motor Gears-------------------------------------------------------------------------------------------------------------16
Actuating Arm Lubrication----------------------------------------------------------------------------------------------------------17
Wheels-----------------------------------------------------------------------------------------------------------------------------------17
Safety Instructions--------------------------------------------------------------------------------------------------------------------18
SOFTWARE INSTALLATION-------------------------------------------------------------------------------------------------------------- 19
OPERATION --------------------------------------------------------------------------------------------------------------------------------- 22
File --------------------------------------------------------------------------------------------------------------------------------------- 22
Options---------------------------------------------------------------------------------------------------------------------------------- 23
Scanners -------------------------------------------------------------------------------------------------------------------------------- 24
Help -------------------------------------------------------------------------------------------------------------------------------------- 24
Exam Setup ---------------------------------------------------------------------------------------------------------------------------- 24
Virtual Joystick ------------------------------------------------------------------------------------------------------------------------ 24
Position Setup ------------------------------------------------------------------------------------------------------------------------- 24
Scan -------------------------------------------------------------------------------------------------------------------------------------- 25
Encoder calibration ------------------------------------------------------------------------------------------------------------------ 26
Temperature Monitor --------------------------------------------------------------------------------------------------------------- 27

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 KEEP THIS MANUAL – DO NOT LOSE
This manual provides important information about the AUT Solutions Accuscan system. Keep this manual for the
life of the product. Pass on to subsequent users.

Please read the Instruction Manual thoroughly as to installation, operation and maintenance. Should you
require additional assistance in servicing this equipment, please contact AUT Solutions directly. Returned
products will not be accepted at headquarters without a RETURN AUTHORIZATION number, obtainable by
contacting AUT Solutions (281) 346-8091 or email at support@autsolutions.net.

DANGER!
FALLING OBJECTS!!
Failure to comply with the instructions and the safety precautions
described in this manual could result in INJURY or DEATH.

DANGER!
STRONG MAGNETIC FIELD!!
The wheels of Accuscan produce an extremely strong magnetic field
which may damage items like watches, memory devices and other
electronics. People with pacemakers must exercise additional causing
around the strong magnetic field.

Warranty Information
AUT Solutions warrants its ACCUSCAN system to be free from defects in design, workmanship and material
under normal use and service for a period of 1 Year (365 days), after the date of shipment. AUT Solutions will
repair or replace free of charge (excluding freight/shipping charges) all defective parts in systems which are
returned to their headquarters in Fulshear, Texas, USA, within the above applicable warranty period, and
provided further that the equipment has not been altered or repaired other than with authorization from AUT
Solutions and by its approved procedures, not been subject to misuse, abuse, improper maintenance,
negligence or accident, damage by excessive current or otherwise had its serial number or any part thereof
altered, defaced or removed and warranty stickers are in place. All defective items released hereunder shall
become the property of the seller.

NO OTHER WARRANTIES ARE EXPRESSED OR IMPLIED INCLUDING, BUT NOT LIMITED TO, THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. AUT SOLUTIONS IS NOT
LIABLE FOR CONSEQUENTIAL DAMAGES.

AUT Solutions shall not be liable for improper use of this equipment or data loss and user/owner shall carry full
responsibility of its use. AUT Solutions shall not be responsible for any bodily injury or property damage that
could occur with use of this equipment.

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Specifications
Design Intent

The AccuScan is an automated, 2-axis scanning system. It is modular, robust, accurate and easy to use. It can
scan on items ranging from 2” pipe to flat surfaces at the rate of 30”/sec. The complete system including the
motor controller and the umbilical fit in one case, making travel simple.

• Fast - scans up to 30 inches per second

• Lightweight - scanner weighs less than 14 pounds
• Portable - entire system fits in one travel case
• Battery powered- can run on the optional battery pack for up to 8 hours per charge
• Modular - arms and motors can be switched in only a few minutes.
• Versatile - works on 2 inch pipe and on items that are 300°F or higher.
• Magnetic wheels - enable the scanner to scan up a vertical surface
• Compatible - works with ProScan, Omniscan, TD Scan Systems, Pocket UT, VEO, and more

Dimensions and Weight

The scanner by itself weighs just 14 lbs. The shipping case containing the components weighs about 75 lbs.

Scanning Speeds

Max scanning speeds:

• Wheel: 7"/sec.
• Arm: 30"/sec.

Recommended scanning speeds:

• Wheel motor: 4"/sec.
• Arm motor: 20"/sec.

Encoder Ticks per Inch Values:

• X-axis (Wheel): 36200
• Y-axis(arm): 6666.67

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Features

• The air supply manifold is indicated by the arrow in the picture below for elevated temperature
operations, see page 18 for temperature and scan time ratings.
• Pressurized air enters the manifold and is expelled out small diameter ports on the scanner truck. The
Scanner truck blows compressed air onto the magnets and wheels and also diverts heat away from
scanner body.
• Pressure not to exceed 50psi.

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 • The pictures below show different configurations in which the scanner can be used.

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List of Components
The complete list of components may vary on an order to order basis. Below is a list of components for a typical
order:

• Scanner
• Umbilical
• Motor controller
• Controller Power supply
• Controller USB cable
• Controller encoder whip
• UT Cable
• Transducers
• BSP skid with tools
• Spare parts kit

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Set-Up
• Remove scanner and components from the shipping case.

• Plug scanner umbilical connector (db15 pin connector) into the motor controller. Make sure to screw the
connector screws into the controller receptacle.

• Plug power supply into AC wall socket.

• Plug the power supply’s LEMO connector into the motor controller “Power” receptacle.

• Plug the USB cable into the “USB” receptacle on the motor controller.

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• Plug the other end of the USB cable into the computer.

• Plug the Encoder whip cable into the “Encoder” receptacle on the motor controller.

• Plug the other end of the Encoder whip into your UT instrument (below are pictures of the AUT Solutions
ProScan Flaw Detector). Follow this step if you are plugging into an Omniscan, TD Scan, VEO or other
encoded based UT system.

• It is important to make sure the connection screws are screwed tightly into the receptacle.

• Plug the other end of the umbilical into the scanner and tighten the connection.

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• Power up the motor controller. The light will come on and the fan will begin to run.

• On the computer, double click on the AUT Controller software to launch. Your scanner is now ready to be
operated. Please see the scanner’s user manual for software functions and operations.

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Transducer Setup
• Using a dual microdot-to-BNC cable (4-6’ long), connect the microdot connectors to the AUT transducer’s
microdot receptacles. Make sure the connection is tight!

• Plug in the irrigation tubing into barbed fitting (Irrigation tubing size: 1/4” OD / 1/8” ID).

• Loosen one of the fork’s cap screws using a hex key set and slide the fork outward to allow the AUT probe to
be fitted in between both forks. Line up the forks cone screw tips with the drill holes on the probe, then
push the loose fork inwards to allow the forks to firmly hold the probe into place. Tighten fork cap screw.

• Along the length of the UT cable, tie the irrigation tubing every three inches with a zip tie.

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• Zip tie the cable assembly to the tie back holder located on the arm’s slide bar. Make sure there is enough
slack for the probe to move freely on the gimble or this could cause signal loss problems during scanning.

• Move the gimble/probe assembly to the end of the arm. Adjust the cable assembly as shown in the picture
below to ensure there is enough cable for a full stroke of the arm before scanning.

• Zip tie the cable assembly to the tie back holder located on the center of the scanner’s junction box as
shown below. Please ensure there is some slack on the cable assembly before tightening the zip tie.

• Move the gimble/probe assembly from one end of the scanner to the other to insure the UT cable assembly
does not get tangled or caught on any part of the scanner.

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• Attach the irrigation tube end into the water value unit located at the end of the umbilical. Insert the tube
into the value end, pushing hard to insure the fitting has a firm grasp of the tube.
(Note: To release the tube from the value during disassembly, push in the grasp fitting and then pull the tube
out.)

• Connect the UT cables to the umbilical UT cables as shown below.

• Zip tie the UT cables and irrigation tubing to the umbilical exactly as shown in the picture below. It is very
important these cables/tubes are neatly tied to the umbilical so that there are no snags while scanning in
the field. Always do your best to protect these cables while in the field!!

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Motor Controller
IMPORTANT: NEVER DISCONNECT CONNECTORS FROM MOTOR CONTROLLER WHILE
POWERED UP! THIS CAN DAMAGE THE MOTOR CONTROLLERS!!

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Maintenance and Safety
Replacing Motors

X-Motor Replacement: The X-motor can be removed by removing the screws as shown below:

Remove these cap

screws

Y-Motor Replacement: The Y-motor can be removed by removing the screws as shown below:

Regular Maintenance

• Keep both X and Y gears lubricated at all times.

• Always inspect these gears for loss of lubrication on a regular basis.
• Make sure the motor shaft area near the motor housing is full of grease as this will help prevent water from
getting into the motor.
• Standard lithium or bearing grease will be sufficient and can be found at any local hardware store.

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Greasing X-Motor Gears

• Remove the X-motor as shown on page 15.

• The X-gears should be visible as shown below.
• Apply grease to the exposed gear, rotate the scanner wheels and continue applying grease until the whole
gear is covered.

Greasing Y-Motor Gears

• Unscrew the screws shown below to remove the Y-motor gear cap.
• Pack 50% of the volume of the gear box with bearing grease.

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Actuating Arm Lubrication

• Keep debris, dirt, grim, etc. out of the lead screw, lead nut and linear bearings.
• Clean and lubricate the arm assembly, i.e. linear rail, bearing and lead screw with WD40, this will wash out
the grime and will also provide lubrication to the components.

Wheels

Keep debris, dirt, grime, rust, etc. from building up on or inside of the wheels and magnets. This could cause the
scanner to fall off a vessel, tank, etc. Furthermore, make sure set screws inside the wheels are tight at all times.

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Safety Instructions

• When scanning from elevated heights, use a life line at all times to prevent accidental falls.

• The scanner can be removed in two ways. It is recommended to drive the scanner off to a non-ferrous
material to break the bond. Do not attempt to turn off the motors and push or pull the scanner onto a non-
ferrous material; this could damage the drive gears. The scanner can also be removed by pulling from the
end of the scanner arm.

• Keep scanner/motor controller out of rain and damp areas. It is advised the scanner be stored indoors in
temperatures ranging from 60-85°F.

• Never ship the scanner with the umbilical attached, always disconnect from the scanner while transporting.

• Keep fingers away from pinch points such as the magnet wheels or the actuating arm while running.

• Temperature limitations:

• -20F to 200F: Continuous

• 201F to 300F: 10 minutes with 10 minute cool down
• 301F to 400F: 5 minutes with 10 minute cool down*
• 401F to 500F: 3 minutes with 10 minute cool down*

*Air cooling needed for scanner truck (See page-5) to help cool the magnets and X-motor, using 1/4” OD – 1/8” ID
hose and supplied air. Y-motor will also require the motor to be wrapped with an insulation wrap which can be
found at most hardware stores. The wrap we commonly use is for home AC insulation, it is rubber foam type
insulation with adhesive on one side and a foil coating on the other with insulation thickness being 1/8” to 1/4”
thick (this will help slow down the heating of the Y-motor)

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Software Installation
• Insert the USB flash drive provided by AUT Solutions into the USB port of your computer. Double click on the
file “AUT Controller Installer.EXE” to run the installer.
• Click “Install”.

• A prompt appears checking for internet connection. Click “Yes” (even if an internet connection is not
available at the moment).

• If an internet connection is not available, manual installation of the run time engines from the USB flash
drive is required. This step is not required for updating the controller to a newer version.
• For the first segment of installation (Drivers)- click “Next” thrice, then click “Install” and then “Finish”

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• For the second segment of installation (Controller Software)- click “Next” twice and then “Finish”.

• The third segment (LabVIEW Runtime) requires internet connection. If internet connection is not available,
it can be manually installed from the USB flash drive found under the run time folder.

• For the LabVIEW installation, click “Next” six times and then click “Finish”.

• DO NOT CHANGE THE FILE SAVE PATHS!!

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• When finished you will be prompted to Restart, DO NOT RESTART, click “Restart later”!

• Install the fourth and the final segment of the installation (VISA runtime) the same way as the previous
runtime installment.
• Restart the computer.
• After the restart, run the AUT Controller software by double clicking on the Icon on the desktop, or for
ProScan users, click on the “Motion” button as specified in the ProScan User’s Manual.

• On launching the program, the following window appears, make a note of the “PRODUCT ID” and contact
AUT Solutions to obtain the “PASSCODE KEY” to unlock the software.

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Operation
To start the program, double click the icon located on the Desktop. Program will not start unless the USB cable
to the motor control is plugged in.

Program has opened and is ready for use.

File

Load: Loads scanner configuration file.

Save: Saves display values settings. Example: If you are running continuous scans from X-0 to X-100,
you can save this typed value and the software will remember this value after reboot.

Save As: Allows you to save all scanner settings to a user configuration file which will include display values and
scanner encoder counts.

Exit: Closes program down.

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Options

Administrator Mode: Used by AUT Solutions ONLY

Axis Labeling: This function switches the motor axis labeling. By default we call motor-1 (wheels) X in name but
some automated systems on the market may name their motor-1 axis "Y". When switched, motor-1 (wheels)
will be renamed to "Y" thus making motor-2(X).

NOTE: Please note the motor labels on the scanner are labeled to our default.

Single Axis Mode: Enables you to disable a motor. - Example: If you only need to perform line scans for weld
inspection, you can disconnect and disable the arm motor axis (Y) and only use the wheel motor (X) to perform
line scans.

Multi-probe: The feature opens a new tab within the controller software which enables multi-probe indexing.

To use the feature, turn the ON/OFF control to ON, then select the number of probes to use (2 or 4). Next,
specify the probe offset spacing. Once set, you can run a scan, but the scan will stroke and then index the
increment value up until the probe offset value is reached before the scanner will index the full size of the probe
array.

Example: If the X-axis index value is 0.500” and the probe offset is 0.500” then after the first scan stoke, the scan
index will be 0.500”, the next scan increment will be 2” and this will repeat to the end of the
scan.

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Scanners

Preloaded Scanner Configurations: You can load pre-existing configurations or modify them and then resave, in
which they will save into this directory for future use.

Help/About: Help: Opens the folder containing the User manual.

About: Contains the software version and AUT Solutions Information.

Exam Setup: This software works on the "World" coordinate scheme which allows the user to match up scanner
coordinates to their drawings using the same 0" reference point. Example: You can start a scan from 0 to 100,
or 100-200, or scan back from 200 to 0.

Virtual Joystick: When an arrow button is pressed, the motor associated with the button will move as per the
jog speed set on the slide bar. The motor can also be moved using the computer’s arrow keys when holding
down the "Alt" key simultaneously.

Position Setup

Current Position: Displays current position (in or mm) with an accuracy of 0.001".

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New/Jog Positions: This box is where you type in the current position to set, or a position you want to jog to.

Rel. Jog: Relative jog movements - Example: if you wanted to move the Y axis +10 from its current position, type
in 10 and then click "Rel. Jog" and the motor will move 10"

Abs. Jog: Absolute jog movements - Example: when using the world coordinate scheme, if you needed to move
the X motor from its current position of 10" to position 80", type in 80 and click "Abs. Jog" and the scanner will
move to position 80", which is a relative movement of +70".

Go to Start: This button will move the scanner to the start position as typed in the above "Position Setup" start
location. Example: If you were scanning a section of pipe circumferentially and the scan starts at top dead
center (0") and the circumference is 36", the scan coordinate will be from 0 to 36". Once the scan finished and
the scanner is stopped at 36", you can click the "Go to Start" button and the scanner will jog back to the start
position of 0 while un-wrapping the umbilical from the pipe.

Scan

Start: Starts the scan using the coordinates typed under "Exam Setup".

Stop: Stops the scan.

Pause: This button is enabled when a scan is running. This feature allows the user to pause during a scan and
will allow them to resume from the current position or even from a jogged position. Example: if you were
running a scan from 0 to 100" but you started to lose data from position 50" to your current position of 70", you
can press pause and then jog back to 50" using the virtual joystick or "ALT+Arrow keys" and then click "Resume"
and the scan will resume from position 50", thus allowing you to rewrite over the bad data.

E-Stop: Emergency stop.

Reset Motors: Resets the motor controller without turning off power to the controllers. You may have to reset
from time-to-time if problems occur with the controller.

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Power Off: Disables the motors without turning off the power to the motor controller. This feature is useful
when setting up scans, thus allowing it to be pushed into place with ease.

Abnormal End Dialog Box: When a scan ends abnormally, a dialog box will appear giving you two options:

Continue Scan: When pressed, the scan will resume from the place at which it was stopped.

Abort Scan: when pressed, the scan will abort/stop.

Encoder Calibration

Origin Axis: Sets the current encoder position to 0.

Calculate: After clicking "Origin Axis" to set the current position to zero and then drive the scanner using the
virtual joystick to a known distance, ex. 10", type in the distance (10) in the empty box and then click
"Calculate". This will give the software the "counts per inch” value used to calibrate the scanner to the specified
distance.

The default ticks per inch values are listed under section 1.4.

Note 1: This same counts per inch value can be entered into the encoder counts per inch entry located on your
UT Instrument's Encoder/Motor configurations, thus syncing both systems.

Note 2: On this tab, jog movement speeds are done by ticks per second.

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Temperature Monitor

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