INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY

VOLUME 3 ISSUE 1 JANUARY 2015 - ISSN: 2349 - 9303

Checking Performance Test for Fresh Sub Assembly

Inspection Facility (FSIF) Elevation Using Optical
System
T.Bhuvaneswari
National Institute of Technology, Tiruchirappalli, India
Department of Electronics and Communication Engineering
bhuvaneswariarasu@gmail.com

Dr.D.Sriram Kumar
National Institute of Technology, Tiruchirappalli, India
Department of Electronics and Communication Engineering
srk@nitt.edu

AbstractThe Checking of performance test for the system of Fresh Subassembly Inspection Facility (FSIF) at
elevation 21M in the fuel building of Prototype Fast Breeder Reactor (PFBR) with the inspection of straightness
checking of Fresh Sub Assembly (FSA) is being measured using the Optical system. A device for measuring the
profile of a Fresh Sub Assembly (FSA) uses three expanded planar laser beams, each of the planar beams relatively
disposed at angle of 45 and directed towards the FSA. Respective photocells are arranged to be illuminated by the
beams after passing through the deviated body. If the FSA is deviated from its position then the relative movement is
effected between the FSA and the laser beams.
Index Terms Planar Laser beams, Fresh Sub Assembly, Photo detector, Plurality of heights.

1 INTRODUCTION

HE Fresh Sub Assembly Inspection Facility (FSIF) is a system

used for identification and inspection of fresh SA before
loading into the reactor. Each Sub assembly is primarily
designed for particular flow zone in the reactor. FSIF consists of a
dimensional inspection set up, measuring the straightness of sub
assembly from deviation is checked up using Optical system before
loading into the reactor. The Dimensional inspection setup consists
of a bottom support structure, which holds the foot of the Sub
assembly in vertical direction in a sleeve. This support structure rests
on the floor on its flanges. Using the optical system with the source
of planar laser beam, Inspection is made by checking the straightness
of the Fresh Subassembly which is being sensed at the sensing
distance of 2.5mm from deviation.

Camera Motor Parameters:

1) Input Voltage: 238v AC, 50Hz Supply,
2) Current drawn: 130 mA.

3 FOOT PROFILE INSPECTION

Sub Assembly foot profile Upper zone identification mechanism (X)
and Lower zone identification mechanism (Z) is checked by a
diametrically opposite two sets of measuring heads on the bottom
structure. The absolute values for the foot profile LVDTS are
available in control panel. The foot profile measurement details:
X=79.96, Z=54.64.

TABLE 1

IDENTIFICATION ON SUB ASSEMBLY USING

CAMERA ROTATION

Rotation mechanism for the camera is checked by a powering

drive motor mounted on the mechanism. The motor is rotated up
to the end limits. The end limits were checked by a limit switches
mounted on the structure. It is found that motor supply is cut off
by an end limit switches actuation.
Camera Motor Name plate details:
1) Vishal_sync, Serial: 9116.
2) Synchronous speed: 60 RPM.
3) Rated Torque: 10.

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FOOT PROFILE INSPECTION OF FSA.

With SA

Without SA
Sl.
LVDT
1(Lower)

LVDT
2(Upper)

LVDT
1(Lower)

LVDT
2(Upper)

44.68

67.61

54.22

79.88

44.63

67.48

54.18

79.80

No

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INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY

VOLUME 3 ISSUE 1 JANUARY 2015 - ISSN: 2349 - 9303

4 FSA SEATING CHECKING
The Sub assembly check up limit switch is accurate when the sub
assembly rest on the bottom support structure. The Sub Assembly is
rested on the bottom structure the limit switch is adjusted to actuate.
It is found that seating check up sensing indication available in
control panel.

5 EXISTING STRAIGHTNESS CHECKING

After the lowering of Sub assembly in to the dimensional setup, a
cylindrical gauge is inserted into the head of the sub assembly from
the top of the cell manually. A proximity switch located at the bottom
of the top sleeve sensed the straightness gauge. Setting of the
proximity switch is done by adjusting the sensing the length, when
the straightness gauge is inserted into the top sleeve without Sub
Assembly.
Proximity switch parameters:
Supply voltage: 24V DC
Sensing distance: 5mm.

Referring to Fig.1 there is shown a laser 1 generating a cylindrical

beam Fl which is directed to illuminate a cylindrical lens 2. Lens 2
has a diameter which is slightly larger than that of beam F1 and a
cylindrical length substantially equal to the beam diameter. Lens 2 is
located at the focus of a thin converging lens 3 having a width
substantially equal to the length of cylindrical lens 2. Lens 2 in effect,
provides an expanded beam F2 which illuminates lens 3, which in turn
effectively converts the beam F2 into a planar parallel beam F3. The
width of lens 3 is small with respect to its height such that beam F3 is
equivalent to a planar beam.

In Fig.2. there is shown in plain view, three planar laser beam

generating means of the type just disclosed, including respective
lasers 4,5 and 6 of the continuous emission type, cylindrical
lenses 7, 8 and 9 and thin lenses 10, 11 and 12.

1.

ed, followed by a period.

5.1 Concept Flow Laser Beam

A system utilizing a plurality of laser beams relatively disposed in a
vertical plane. A relative motion in a horizontal direction is affected
between the beams and the FSA, such that the FSA passes through the
beam and effectively masks photoelectric detectors disposed to
receive the beams. The photoelectric detectors enable pulse counters
during the period they are shut off from the beam by the object. The
pulses are generated in accordance with the relative motion of the object
and light beam. The measurement by means of one or more vertically
disposed planar light beams, obtained from a laser and photoelectric
detectors which are vertically movable within the plane of the beam.
The optical systems include a cylindrical lens disposed at the focus of
a converging thin lens, the cylindrical lens having an axis at right
angles with the laser beam. The device includes three vertical planar
laser beams intersecting at a vertical segment and cooperating with a
single array of detectors.
Fig. 2. Diagrammatic view of a profile control device with
three planar laser beams.

Fig.1. Generation of a planar laser beam

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Fig. 1. Magnetization as a function of applied field. Note that Fig.
is abbreviated. There is a period after the figure number, followed
by one space. It is good practice to briefly explain the significance
of the figure in the caption.

Lasers 4, 5 and 6 and lenses 7-12 operate to produce respective

planar beams F4 F5 and F6. Planar beams F4, F5 and F6 are vertically disposed and intersect at a vertical segment P. Beams F4 and F6
are disposed at 45 with respect to beam F5. A horizontal movable
support member 13 is arranged at a right angle with beam F5 and
supports
conventional
photo detector
cells
which
Fig. 1.three
Magnetization
as a function
of applied
field.
Note are
thatarranged
Fig. is
abbreviated.
There
is a period
afterand
theF4
figure
number, and
followed
by
to be
illuminated
by beams
F6, F5
respectively
shutting
space. It is good practice to briefly explain the significance of the
out one
the
beams
from
the
associated
cells
14-16.
The
time
periods
during
figure in the caption.
which FSA blocks or shuts out light beams F4, F5 and F6 from cells 16,
15 and 14 are respectively proportional to the diameters M1 N1, M2
N2 and M3 N3 of the cross-sections of the object in the horizontal plane
containing the cells. The shut out periods are measured by counting of
periodic pulses, the accuracy in determined by the intermediate profile.

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VOLUME 3 ISSUE 1 JANUARY 2015 - ISSN: 2349 - 9303

The polygonal mirror is rotated at high speed, so that a line scan is
performed with a high frequency between 100-1000 Hz. Due to the
modulation of the laser beam in the MHz regime, each data point
provides is between 100 to 1000 pulses to be collected and
subsequently integrated.
5.4 Measurement of Deviation

Fig. 3. Perspective view of a movable mechanical supporting unit

for the three Photo detectors.
Fig.1. Generation of a planar laser beam
In Fig.3 a mechanism for adjusting the cells 14-16 to various
predetermined heights within the respective planes of beams F4, F5 and
F6. A support member 13, having mounted there on photo detectors
14-16 is adapted to slide on two vertically disposed slide bars, 19
and 20. Detector 15 is centrally located having an optical axis directed
perpendicular to the front face of member 13, while detectors 14 and 16
are mounted having respective optical axis disposed at 45 with respect
to the front face. An adjustable knob 21 controls rotation of two pinions
Magnetization
a function
applied field.
Note that
Fig.bars
is
22,Fig.
23 1.
which
mesh withasracks
24, 25ofrespectively
secured
to slide
abbreviated. There is a period after the figure number, followed by one
19 space.
and 20.It The
common
axle
of
pinions
22,
23
and
the
axle
of
knob
21
is good practice to briefly explain the significance of the figure
areinmounted
in member 13.
the caption.
Another adjustable control knob controls the clamping screw, the end
of which provides locking of the position of member 13 on the slide
bar. It should be appreciated that the pinions 22, 23 and clamp can be
controlled to adjust member 13 sequentially to a plurality of
predetermined heights in accordance with a preset program by a
computer controlled automatic mechanism.

The distance information of an FSA is based on optical devices of a

device operating on the principle of structured light triangulation
would require on the one hand a laser imaging system with a beam
splitter and on the other hand a further arrangement of four mirrors.
The Optoelectronic system has a laser transmitter and also
comprises a receiving device for receiving light that has been
reflected from the FSA. The laser transmitter and the receiving
device are located coaxially, for optically splitting of laser scan
sector to obtain multi-perspective imaging of FSA, where the Time
of Flight technique is used with modulated beams. Optical splitting
comprises an arrangement of optical mirrors whose mirror-surfaces
are correspondingly facing each other under a predefined angle.

5.2 Straightness Checking of FSA

An Optoelectronic system includes an illumination device which
sends light towards the object and a receiving device which receives
light reflected from the object. The apparatus includes means for
optically splitting the field of view of the Optoelectronic sensor
system into a plurality of sectors. Each of these sectors covers at
least a partial view of the object under inspection from a unique
viewing point. The arrangement of the optical splitting means is
selected so that based on the respective field of view.

5.3 Polygonal Mirror Unit

A polygonal mirror unit receives laser light and reflects it in a fanshaped form toward a stationary angled mirror unit, which directs the
light towards a double-curved stationary mirror unit which reflects
the beam onto the FSA. The individual mirrors of the polygonal unit
are adjustable.

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Fig. 4. Cross sectional view of Structural Arrangement

5.5 Parallel and Titled Mirror Arrangement

The first mirror and second mirror are tilted out of a horizontal
plane, deflecting the light from the central area between the
mirrors
the lower part
the mirror
arrangement,
theFig.
central
Fig. 1.inMagnetization
as aoffunction
of applied
field. Note that
field
view is removed.
For titled
arrangement
of two
is of
abbreviated.
There is a period
aftermirror,
the figure
number, followed
by onewith
space.
It is that
goodplaces
practicethe
to briefly
theout
significance
mirrors
a tilt
upperexplain
mirror
of a plane
figure in the caption.
thatofistheperpendicular
to the optical plane, avoids masking of
field of view.

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VOLUME 3 ISSUE 1 JANUARY 2015 - ISSN: 2349 - 9303

Fig. 5.Graphical representation of Sensing distance Vs Voltage

without Deviation of FSA
Fig.7.Parallel Mirror Arrangement.

6 RESULT AND DISCUSSION

1) Fresh Sub assembly are brought under inspection is removed from
the cask and is positioned on the pit dimensional inspection set up
using FSTG.
2) The power to the control panels LCPFB are switched ON
3) Visual examination of the surface of Sub assembly is done by
Fig. 1. Magnetization
as aCCTV
functionmonitor.
of appliedIffield.
Note that
observing
the images on
required,
theFig.
camera
is
abbreviated.
There
is
a
period
after
the
figure
number,
followed
support platforms can be moved using pan facilities.
by one space. It is good practice to briefly explain the significance
4) Serial
number
the sub assembly is manually fed into the
of the figure
in theofcaption.
application program on the panel.
5) Using the vernier depth gauge, the level of the head of the sub
assembly is measured from the top flange of the pit. This gives the
length of the subassembly. Thus noted value of the length is
manually is fit to the application program.
6) A straightness checking of three planar laser beams are passed to
the sub assembly an illumination device comprising a laser
transmitter.
7) A device for receiving light that has been reflected from the
object, the receiving device having a field of view, such that the laser
transmitter and the receiving device are located with the laser scan
sector overlapping the field of view.
8) The optical splitting means arranged for shared use by the
illumination device and the receiving device, in order to maximize
an area of the object surface that is visible from at least one of the
viewing points and means for causing the scanner device to sweep
the laser beam over the object.
9) The lamp Sub assembly Straight comes ON, if the straightness
checking is being performed and analysed from the deviation.
10) The accurate measurement are made with field view analyse, at
minimum deviation of 2.5mm is measured at supply voltage of 25V
DC supply.

Fig. 1. Magnetization as a function of applied field. Note that Fig. is

abbreviated. There is a period after the figure number, followed by one
space. It is good practice to briefly explain the significance of the figure
in the caption.

Fig.6. Graphical representation of Sensing distance Vs Voltage

with Deviation of FSA at sensing distance of 2.5mm.

Fig. 1. Magnetization as a function of applied field. Note that Fig. is

abbreviated. There is a period after the figure number, followed by one
space. It is good practice to briefly explain the significance of the figure in
the caption.

101
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INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY

VOLUME 3 ISSUE 1 JANUARY 2015 - ISSN: 2349 - 9303

7 CONCLUSION
Using the optical system with the source of planar laser beam,
Inspection is made by checking the straightness of the Fresh
Subassembly which is being sensed at the sensing distance of 2.5mm
from deviation.The different technique of mirror arrangement is used
that deflects light from central area. Polygonal mirror is rotated at
high frequency where the scanning is performed. Tilting of mirror at
small angle cause the beam to sweep over the object. Upper and
lower mirror are used is used to avoid shadowing of beam. The
advantages of using the planar laser beams are,
1) Cost effective system with lower complexity.
2) Accurate Measurement.
3) Fast response.
4) Accurate deviation of FSA is computed from the pulse generated
and it is determined at the Control System.
Supply Voltage: 24V DC.
Sensing Distance: 2.5 mm.

REFERENCES
[1]
[2]
[3]
[4]

[5]
[6]
[7]

[8]

Shri Jose Varghese , P&I Diagram for inspection of fresh sub

assembly ,PFBR/RG/35150/SP/2101 R-0.
Shri Jose Varghese, Design specification for nitrogen Filling
Facility, PFBR/RG/35150/SP/1001 R-B.
Shri Jose Varghese , General Assembly of fuel sub assembly
PFBR/RG/31110/SP/1300 R-6.
Shri Jose Varghese , Technical specification for manufacture of
Fresh
Sub
Assembly
Inspection
Facility
PFBR/RG/35141/SP/1070 R-0.
Shri Jose Varghese , Shri D.Rengaswamy,Specification for
manufacture of F SA PFBR, PFBR/RG/35141/SP/1007 R-0.
General Assembly of control and safety
rod sheath
PFBR/RG/35141/SP/1070 R-0.
Shri Jose Varghese , Shri D.Rengaswamy, Dimensional
specification of Fresh sub Assembly, PFBR/RG/35141/SP/1170
R-0.
M. Hain E. Kawate, Nan electronics Research Institute, IEEE,
An Optical Method for the Measurement of Shape Deviations of
Elliptical Mirrors, Volume 7, Section 3, No. 2, 2007.

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