Details

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UNICOMP UNC160 – Industrial Radiography X-Ray Inspection System for Automotive Castings

Model: UNC160

Brand: UNICOMP

Product Type: Industrial Radiography / NDT X-Ray Inspection System

Application: Non-destructive X-ray inspection of aluminium castings, iron castings, automotive components, wheels, metal parts and industrial cast products

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Overview

The UNICOMP UNC160 is an industrial radiography X-ray inspection system designed for non-destructive testing (NDT) of automotive castings, metal components and other industrial products.

Equipped with a 160 kV X-ray source, high-definition detector and multi-axis C-arm inspection mechanism, the UNC160 enables operators to inspect internal structures and identify hidden defects without cutting or damaging the component.

The system is particularly suited for aluminium casting inspection, where internal defects such as porosity, voids, cracks, shrinkage and inclusions may affect the structural integrity and quality of the finished component.

Its programmable motion control and five-axis C-arm mechanism allow the workpiece to be examined from multiple positions and angles, helping reduce inspection blind spots when evaluating complex casting geometries.

The UNC160 also incorporates image-processing, measurement and CNC programmable inspection functions to support both routine manual inspection and repeatable inspection of batch-production components.

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Applications

The UNC160 is suitable for industrial NDT applications including:

• Automotive aluminium castings

• Aluminium die-cast components

• Iron castings

• Automotive components

• Automotive suspension components

• Wheels and wheel castings

• Metal parts

• Cast components

• Pressure-vessel components

• Steel pipes

• Cylinders

• Epoxy resin defect inspection

• Tyres and related components

• Refractory materials

• General industrial cast products

Typical industries include:

• Automotive manufacturing

• Automotive component manufacturing

• Aluminium die casting

• Foundries

• Metal fabrication

• General engineering

• Industrial quality control

• Non-destructive testing laboratories

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Typical Defects Detected

Depending on the material, component geometry and inspection parameters, X-ray inspection can be used to identify internal conditions such as:

• Porosity

• Gas pores

• Shrinkage cavities

• Internal voids

• Cracks

• Inclusions

• Foreign material

• Internal structural abnormalities

• Casting discontinuities

• Incomplete filling

• Internal defects not visible from the component surface

Actual defect-detection capability depends on the material thickness, density, defect size, inspection angle and selected X-ray parameters.

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Key Features

• 160 kV industrial X-ray inspection system

• Designed for automotive and industrial casting NDT

• Maximum penetration up to approximately 100 mm aluminium

• Maximum penetration up to approximately 20 mm iron

• High-definition X-ray imaging

• Flat-panel detector configuration available

• Optional 17 × 17 inch FPD

• 139 µm detector pixel size

• Multi-axis C-arm inspection mechanism

• Five-axis motion capability

• Multi-angle inspection for complex components

• CNC programmable motion control

• Automatic positioning for repetitive inspection

• Manual inspection mode available

• Adjustable movement speed for each motion axis

• Image enhancement and processing functions

• Dimensional measurement functions

• Image annotation and result-saving functions

• Servo-driven motion system for stable operation

• Radiation-shielded inspection enclosure

• X-ray leakage specification of ≤1 µSv/h

• Optional industrial cloud and data-traceability interface

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Technical Specifications

Parameter	Specification
Model	UNC160
Brand	UNICOMP
Equipment Type	Industrial Radiography / NDT X-Ray Inspection System
Primary Application	Aluminium Casting, Iron Casting, Automotive Parts, Wheels and Metal Products
X-Ray Tube Voltage	160 kV
X-Ray Tube Power	480 W
Focal Spot Size	0.5 mm
Standard Detector Image Area	145 × 145 mm
Detector Resolution	3.0 LP/mm
Optional FPD Image Area	17 × 17 inch
Optional FPD Pixel Matrix	3072 × 3072 pixels
Optional FPD Pixel Size	139 µm
FPD Frame Rate	9 fps (1 × 1) / 30 fps (2 × 2)
Maximum Penetration – Aluminium	100 mm
Maximum Penetration – Iron	20 mm
Detection Range	Ø500 × 800 mm
Maximum Load Weight	50 kg
Machine Dimensions	2100 × 1549 × 2468 mm (L × W × H)*
Machine Weight	Approx. 3.5 tonnes
Power Consumption	Approx. 6 kW
Installation Power	Three-Phase Five-Wire AC 380 V
Operating Temperature	5–40°C
Operating Humidity	≤80% RH
X-Ray Leakage Dose Rate	≤1 µSv/h
Motion System	C-Arm Five-Axis Motion Mechanism
Motion Control	CNC Programming / Manual Operation
Certification	CE

 

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Detector System

The UNC160 can be configured with a detector according to the inspection requirement.

Standard Detector

• Image area: 145 × 145 mm

• Resolution: 3.0 LP/mm

Optional Flat-Panel Detector

A larger flat-panel detector configuration is available for applications requiring a wider imaging area.

Specifications shown for the optional FPD include:

• Detector size: 17 × 17 inch

• Pixel matrix: 3072 × 3072 pixels

• Pixel size: 139 µm

• Frame rate: 9 fps at 1 × 1

• Frame rate: 30 fps at 2 × 2

Final detector configuration should be selected according to:

• Component dimensions

• Material thickness

• Required defect sensitivity

• Field of view

• Inspection speed

• Required image resolution

• Production throughput

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Image Processing Functions

The UNC160 software provides multiple functions for inspecting, enhancing and analysing X-ray images.

Available image-processing functions include:

• Brightness adjustment

• Contrast adjustment

• Frame stacking

• Window-width adjustment

• Window-level adjustment

• Image enhancement

• Image filtering

• Image sharpening

• Image inversion

• Relief processing

• Bubble measurement

• Image movement

• Zoom in

• Zoom out

• Image scaling

• Mouse-pointer image-coordinate display

• Grey-value display

These functions allow operators to optimise the X-ray image according to the component and defect being evaluated.

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Image Measurement Functions

The inspection software also provides measurement and annotation tools including:

• Distance measurement

• Radius measurement

• Polygon measurement

• Angle measurement

• Arrow annotation

• Text annotation

• Processed-image saving

These tools can support defect review, dimensional comparison and inspection reporting.

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Motion Control

The UNC160 incorporates programmable motion control to support both manual inspection and repetitive production inspection.

Functions include:

• Speed adjustment for individual motion axes

• CNC programmable inspection

• Manual operation

• Multi-position inspection

• Multi-angle positioning

• Repeatable inspection sequences

For repeated inspection of similar workpieces, CNC programming can be used to reduce positioning time and improve inspection consistency.

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Five-Axis C-Arm Inspection

The system uses a C-arm five-axis motion mechanism to provide flexible positioning between the X-ray source, detector and inspected component.

This configuration allows the operator to inspect complex components from multiple directions rather than relying on a single fixed projection.

The multi-axis design is particularly useful for components such as:

• Automotive castings

• Structural castings

• Suspension components

• Wheels

• Cylindrical components

• Parts with complicated internal geometries

By changing the inspection angle, areas that may be hidden in one projection can be evaluated from another direction.

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CNC Programmable Inspection

For batch production, the UNC160 supports CNC programmable motion.

Inspection positions can be programmed to enable repeatable examination of the same locations across multiple components.

This can help:

• Reduce repetitive manual positioning

• Improve inspection consistency

• Reduce inspection time for batch components

• Standardise inspection points

• Improve operator productivity

• Support production quality-control routines

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System Protection

The UNC160 incorporates electrical and operational protection functions including:

• Voltage regulation

• Electrical isolation

• Electrical filtering

• Grounding protection

• Radiation shielding

• Controlled X-ray operating enclosure

These functions are intended to support stable operation in industrial inspection environments.

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Optional Data & Traceability Function

An industrial cloud interface can be provided as an optional configuration.

Depending on the final software configuration, this can support functions such as:

• Inspection-data upload

• X-ray image upload

• Real-time data collection

• Product inspection records

• Image traceability

• Historical inspection-data management

• Production quality analysis

• Large-data analysis

This option can be considered for manufacturers requiring stronger production traceability or integration with digital quality-management systems.

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Inspection Capacity

Maximum Penetration

The published system specification indicates maximum penetration of approximately:

Aluminium: 100 mm

Iron: 20 mm

Actual usable inspection thickness for reliable defect detection may be lower than the stated maximum penetration depending on:

• Material density

• Component geometry

• Defect size

• Required image quality

• Required sensitivity

• X-ray exposure settings

• Detector configuration

For critical applications, sample testing is recommended before final equipment selection.

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Detection Range

Maximum published detection range:

Ø500 × 800 mm

Maximum workpiece load:

50 kg

Final suitability should therefore be checked against the customer's actual:

• Maximum component diameter

• Maximum component length

• Component weight

• Required rotation and movement clearance

• Inspection orientation

• Required inspection angle

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Typical Automotive Casting Applications

Aluminium Casting

Suitable for inspection of aluminium components such as:

• Die-cast components

• Structural castings

• Automotive brackets

• Suspension components

• Housings

• Transmission-related castings

• Wheel components

• Other aluminium automotive parts

X-ray inspection can reveal internal casting defects that may not be visible through conventional external inspection.

Automotive Components

The UNC160 is suitable for quality inspection where the integrity of the component's internal structure is important.

Potential applications include:

• Suspension components

• Automotive structural components

• Wheels

• Cast housings

• Engine-related castings

• Transmission components

• Safety-related metal components

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General Industrial NDT

Beyond automotive applications, the system can also support inspection of:

• Iron castings

• Steel components

• Pipes

• Cylinders

• Pressure-vessel components

• Metal products

• Refractory materials

• Composite or resin-based products

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Available Configuration Considerations

The final UNC160 configuration should be selected based on the actual application rather than X-ray voltage alone.

Important information to review before confirming the system includes:

• Material type

• Maximum material thickness

• Overall workpiece dimensions

• Workpiece weight

• Expected defect type

• Minimum defect size to be detected

• Required image resolution

• Required inspection angle

• Number of inspection points per component

• Production quantity

• Required inspection cycle time

• Manual or automatic inspection requirement

• Data-traceability requirement

• Factory power supply

• Installation space

For production applications, representative samples should preferably be evaluated before final equipment configuration.

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Why Choose Us

UNICOMP

UNICOMP develops industrial X-ray inspection systems for non-destructive testing across automotive, electronics, semiconductor, battery and general manufacturing applications.

For casting inspection, its industrial radiography systems combine X-ray imaging, programmable positioning and digital image-processing technology to allow manufacturers to inspect internal structures without destroying the inspected component.

The UNC160 is designed specifically for industrial components requiring greater penetration and a larger inspection envelope than typical micro-focus electronics X-ray systems.

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UNC160 Industrial X-Ray Inspection System

The UNC160 is particularly suitable for manufacturers inspecting aluminium and metal castings where conventional visual inspection cannot reveal internal defects.

Its combination of a 160 kV X-ray source, multi-axis C-arm motion system and programmable inspection control enables complex components to be examined from multiple angles.

With published penetration capability of up to 100 mm aluminium / 20 mm iron, the system is suitable for a broad range of automotive and industrial casting applications.

CNC programmable positioning can further improve productivity when inspecting repeated batches of similar components.

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Redmark Industry

Redmark provides local consultation and technical coordination for industrial X-ray and non-destructive inspection projects in Malaysia.

Support can include:

• Application evaluation

• Sample and defect review

• X-ray system selection

• Detector-selection consultation

• Workpiece-size assessment

• Sample testing coordination

• Inspection-method discussion

• Installation coordination

• Operator training

• Radiation-safety coordination

• After-sales technical support

For automotive casting applications, Redmark can work together with the customer and manufacturer to evaluate component dimensions, material thickness, expected defects and inspection cycle-time requirements before the final machine configuration is confirmed.

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How the UNICOMP UNC160 Works