Abstract: Magnetic Particle Inspection is one of the most commonly used non-destructive testing method for detecting surface and limited sub-surface indications in ferromagnetic materials. When a component undergoes forging process, due to excessive stresses while manufacturing there occurs a change in its grain structure which may lead to cracks on it. The aim of this project is to retrofit manually operated Magnetic Particle Inspection (MPI) machine for performance optimization. To cope up with the problem associated with existing machine the changes that have been incorporated include design of automatic coil movement with continuous solution spraying and maintaining solution concentration, current and voltage monitoring to ensure appropriate amount of magnetic field induced. The MPI machine is retrofitted with sensors, actuators and PLC. These sensors have been integrated with a PLC to monitor the input and make decisions based on the custom program to achieve required output. The designed components are analyzed for bearing expected load. Incorporation of higher levels of automation and digitization has led to reduced human intervention and work time. The present project work is helpful in industries like Forging Shops, Aircraft Overhaul Stations, Heat treatment Plants.

Keywords: MPI, PLC, Sensors and actuators, CFD Analysis

| DOI: 10.17148/IARJSET.2021.8602