Inspection Method – Verifying Braid and Coil Density PDF

Page 1 of 4 Document Number: Revision: Document Name: Effective Date: 3543 2 Inspection Method – Verifying Braid and Coil Density 8/15/2023 1...

Page 1 of 4 Document Number: Revision: Document Name: Effective Date: 3543 2 Inspection Method – Verifying Braid and Coil Density 8/15/2023 1. Purpose: The purpose of this document is to demonstrate how to inspect braided or coiled products manufactured by Putnam Plastics Corporation with braided (pic) or coil (wrap). 2. Scope: This procedure applies to all braided and coiled products produced at Putnam Plastics Corporation. 3. Responsibilities: 3.1. It is the responsibility of all individuals handling braided and coiled products to understand and use these criteria. 4. Reference Documents and Forms: 4.1. In-Process and Final Inspection work instruction (#1151) 4.2. Good Documentation Practices (#1029) 4.3. Incoming Inspection Procedure (#1156) 4.4. Control of Nonconforming Product (#1018) 4.5. Product or customer specific specification/documents (Quality Inspection Plan, etc.) 4.6. Operation of the Vision System (#1866) 4.7. Operation of the Quadra-Check 200 Vision System (#1881) 5. Definitions: 5.1. Wire: metal in the form of a usually very flexible thread or strand. 5.2. Filament: strands made from non-metallic materials; this could vary from polymers, fiberglass, composites, or natural fibers. 5.3. Coil: a continuous wire or filament wrapped in one direction around the product. 5.4. Wrap: a section of coil that encompasses one rotation (figure 1). 5.5. Left or Right Hand: Coils can be wound in either the left- or right-hand direction. The direction of wind may be specified depending on the application. 5.6. Braid: an interlaced series of windings of wires or filament. Figure 1, one wrap Figure 2, one pic Figure 3, one pic on a multi-wire braid Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 2 of 4 Document Number: Revision: Document Name: Effective Date: 3543 2 Inspection Method – Verifying Braid and Coil Density 8/15/2023 5.7. Pattern: is the configuration of a braid such as: Multi-wire (figure 3), Full load, Half load, or Diamond pattern. These will be explained as necessary in the product specification. Coil is, in itself, the pattern. 5.8. WPI: unit of measure for coils “Wraps Per Inch”. 5.9. PPI: unit of measure for braid “Pics Per Inch”. 5.10. Pitch: the measurement of individual wraps or pics in a coil or braid. 5.11. Pic: the intersecting wires of a braid. 6. Safety Precautions: Use the safety precautions for the area/process as applicable; there are none specific to this inspection procedure. 7. Process: 7.1. Collect sample size in accordance with QIP, standard inspection procedures, or customer specifications, whichever is greater. Preparing the sample will be the same for all braid/ coil types. 7.1.1. Prepare sample by wrapping tan masking tape around the coiled product to secure the wires on both ends of the sample (figure 4). Blue masking tape will lose adhesion over time, causing samples to unravel in the future. Figure 4 7.1.2. Cut through the middle of the tape on both ends of the sample (figure 5). Unless otherwise specified, length of the sample should be 4”-6” in length to ensure the pattern is acceptable. This size is appropriate to facilitate handling and use with the vision system. Figure 5 7.1.3. Place the sample on the vision system stage so that you can observe the pattern (figure 6). Figure 6 Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 3 of 4 Document Number: Revision: Document Name: Effective Date: 3543 2 Inspection Method – Verifying Braid and Coil Density 8/15/2023 7.1.4. Measure the sample according to one of the following methods: For Pitch see 7.2. For Pic Rate see 7.3. For Variable Pic/ Wrap Rate see 7.4. 7.2. Pitch: Measure the width of each individual pic/ wrap length according to the specification given. 7.2.1. For coiled product: Line the coiled sample up with the horizontal axis of the scope crosshairs as well as possible; centering the crosshairs on one edge of a coil as it wraps over the profile of the sample (figure 7). 7.2.2. Zero your scope’s X-axis. 7.2.3. Measure the distance to the same edge of the next wrap. Figure 7 7.2.4. For braided product: Line the braided sample up with the horizontal axis of the scope crosshairs as well as possible; centering the crosshairs on one edge of an intersection of the wires or filaments (figure 8). 7.2.5. Zero your scope’s X-axis. 7.2.6. Measure the distance to the same edge of the next intersection of the wires or filaments. 7.2.7. Repeat this measurement for the number of pics/ wraps called for in the specification. 7.2.8. Each pic/ wrap width must be within tolerance. 7.2.9. Record this on the inspection record and verify that it meets the specification. Figure 8 7.3. Pic Rate: Count the number of Pics/ Wraps per inch according to the specification given. 7.3.1. For coiled product: Line the coiled sample up with the horizontal axis of the scope crosshairs as well as possible; centering the crosshairs on one edge of a coil as it wraps over the profile of the sample (figure 7, above). 7.3.2. For braided product: Line the braided sample up with the horizontal axis of the scope crosshairs as well as possible; centering the crosshairs on one edge of an intersection of the wires or filaments (figure 8, above). 7.3.3. Zero your scope’s X-axis at this point. 7.3.4. Traverse the sample with the crosshairs, counting the number of complete wraps/ pics you cross over for 1 inch. Unless otherwise specified, you should “round” to the nearest pic/ wrap. (see section 7.5. ‘Rounding’) 7.3.5. Record this number on the inspection record and verify that it meets the specification. Note: It is normal for each individual wrap/ pic to vary slightly. Extreme variation may still fail visual requirements, please refer to your QIP or product specification. Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 4 of 4 Document Number: Revision: Document Name: Effective Date: 3543 2 Inspection Method – Verifying Braid and Coil Density 8/15/2023 7.4. Variable Pic/ Wrap Rate: Identify the transition length and measure the pics/ wrap rate for both the Proximal and Distal ends. 7.4.1. Variable pic products may have multiple different sections, the following instructions are for measuring one section, repeat as necessary to cover all sections. 7.4.2. Using the vision system, visually identify approximately where the pic or wrap rate begins to change on both the proximal and distal ends. 7.4.3. Using the method described in 7.2. ‘Pitch’, measure the number of pics or wraps called for in the specification to verify where the pitch changes (usually 3 pics or wraps). This is one end of the transition. 7.4.4. Repeat steps 7.4.1. -7.4.2. to identify the other end of the transition. If the specification calls for it, measure and record the length of the transition on the inspection record and verify that it meets the specification. 7.4.5. Once you have identified the transition, use the method described in section 7.3. ‘Pic Rate’ to measure the pic/ wrap rate on either side of the transition. 7.4.6. Record these numbers on the inspection record and verify that they meet the specification. 7.4.7. Pease refer to your product specific inspection work instructions or speak with the engineer assigned to the product if you have any questions. 7.5. Rounding: To “round” while measuring the pic/ wrap rate, follow a process similar to what you would do with numbers. 7.5.1. While counting pics/ wraps, if you have not covered more than half of current the pic/ wrap, round down to the last whole number. 7.5.2. If you have crossed over more than half of the current pic/ wrap, round up to the next whole number. 7.5.3. Please refer to your QIP or product specification to ensure rounding rules apply. 7.6. Visual inspection criteria are found in the product specification or QIP and are in addition to this procedure. 7.7. If any nonconformance is noted, reject in accordance with Control of Nonconforming Product (#1018). 8. Revision History: Revision Number Date Explanation Including Change Number If Applicable 00 10/31/13 ECO #02237 – Original Release CCO#0000294 Placed into the latest template and corrected the pictures from covering 1 11/03/15 up the word content. CCO #4320 2 8/15/2023 1. Document title changed to; “Inspection Method – Verifying Braided and Coil Density”. 2. Changed Purpose Statement to new focus of document. 3. Changed Scope and Responsibilities same as for Purpose. 4. Included specific instructions on how to prepare the sample. 5. Expanded definitions. 6. Updated sample length requirements, added a provision for customer specified sample length. 7. Addressed sample length for Variable Pic Braids or Coils. 8. Added instruction for identifying and ensuring a variable pic braid or coil meets specification. 9. Step 7.2 removed instructions to use a glass slide. 10. Separated sections for “Pic rate” and “Pitch” and defined inspection procedure for both. 11. Added and updated illustrations throughout. Previous Revisions See revision history file in Document Control Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15