Woodpecker WP-632AM User manual

Please read this manual carefully before
using the Woodpecker WP-632AM in order
to understand its features and make full
use of its functions & capabilities.
contents
1. Features
2. Applications
3. Parts Identification
4. Precautions
5. Operation
6. Care and Cleaning
7. Parts Replacement
8. Customer Support
9. Specifications
10. Rules and Regulations
11. Warranty and Disclaimer
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Tapping Exfoliation Detector
WOODPECKER
WP-632AM
Instruction Manual

1. Features
The detection of debonds in honeycomb structures or the delamination of laminates
have been performed by skilled inspectors, who tap the testing surface with a
hammer (e.g.- coin) and detect debonds by listening to the difference in tone. The
Woodpecker WP-632AM displays this quantitatively by detecting the spring effect,
i.e. - modulus change in the structure.
The Woodpecker WP-632AM functions and detects in the same way as the former
WP-632 Handpiece. However, it has the additional facility of an LCD display with the
option of mapping the area under test. It meets the latest JIS standard and other
relevant regulations. The Woodpecker WP-632AM specification is as follows:
Tapping system is same as previous models
Standard and threshold values are set in the same way as the WP-632 and
WP-632M.
LED display is same as previous model
The optional acquisition of positional data (X-Y coordinates) is to be acquired using
an optical mouse module and result can be displayed on a PC/PDA in real time.
The tapping hammer is driven by a solenoid & the degree of the defect is detected
by a sensor fitted to the hammer & a microprocessor built into the system. The
degree of debond is displayed by a series of light emitting diodes (LED's: green,
yellow, and red) & an alarm. Also, it converts the data into quantitative numbers,
which show the differences compared to the standard value. In addition, Woodpecker
WP-632AM can detect the position of core materials and/or reinforcement materials
in a mixed structure. The WP-632AM also numerically shows the measured data &
automatically stores up to 7700 points, which can be viewed or downloaded to a PC
if required.
Therefore the Woodpecker WP-632AM represents a revolutionary advance in
inspection. Unlike conventional manual tapping, it quantitatively shows the degree
and transition of a debond even in a noisy environment. The device is accurate, light
& compact, requiring little operator knowledge.
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2. Applications
For the detection of:
Debonds in honeycomb structure between skin & core
Damage behind honeycomb, eg. crushed core
The position & shape of inserts within honeycomb structures
Inter laminar delamination
Delamination of composite joints
Position of strengthening members, eg. ribs & spars within composite structure
Delamination of steel clad sandwich structure
Debonded tiles
Note: The Woodpecker WP-632AM has been developed mainly for the detection of
debonds in aerospace materials & is therefore suitable for honeycomb inspection
having thinner skins & FRP or AI laminates, etc.
For flexible materials such as: rubber, paper or leather products, the impact force of
the hammer may be absorbed. Detection may also be difficult when: the test
materials is thick relative to the diameter of the debond, when the surface has a
rough, sandpaper-like texture or is lined with a material such as paper or leather.
Examples of the results of inspection for aluminum honeycomb & laminated FRP
honeycomb are shown in the graph below. The Woodpecker WP-632AM is designed
for plates with a skin thicknesses up to 4mm (with acrylic Hammer Head) and below
approximately 5mm (with Alminium Hammer Head).
Debond Dia' (mm)
Skin Thickness (mm)
AL - Honeycomb
FRP - Honeycomb
0
8
16
24
32
40
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3. Parts Identification
'READY' LED lit when 'Standard' set
'BATTERY' LED lit when batteries need replacing
Power 'ON' button
Display of Average number of taps / Frequency
Display of 'STANDARD'/Reference value
Display of 'MEASURED' value
Display of Tapping point number
Display of 'DEBOND' or 'INSERT' mode
AVE_SET button
'DEBOND' or 'INSERT' button
'+' or '-' count button
'STANDARD'/Reference value button
Indication LED's: Green (1), Yellow (1) & Red (2)
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Tapping
Average
Speed / Frequency (Hz)
2
2
2
2
4
4
4
4
8
8
8
8
F = 16
F = 16
F = 16
F = 16
1
2
4
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3. Parts Identification (cont.)
A. Function of each button
'POWER' button:
Turns the power 'ON' after it has timed out (30 seconds)
'AVE_SET' button:
Selects the hammer speed. By pressing the button you can select the various
options as follows:
The default set is AVE1-2 (average every tap, with a frequency of 2 Hz).
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Start button PC portHammer Head & Feet

3. Parts Identification (cont.)
'INSERT / DEBOND' button:
To select 'DEBOND' or 'INSERT' mode. The default mode is 'DEBOND'.
'COUNT_+' button:
Use 'COUNT_+' button' to scroll up through the data measured. This may be pressed
to find a value from the first (0001) tow the last value (7700).
'COUNT_-' button:
Use 'COUNT_-' button to scroll down through the data measured. This may be pressed
to find a value from the first (0001) to the last value (7700).
To erase all measured data, except the 'STANDARD'/reference value, by press the
'COUNT_+' and 'COUNT_-' buttons at the same time.
'STANDARD' / Reference value button:
The Woodpecker WP-632AM establishes & retains in the memory a reference value
obtained by averaging the value of 8 taps. The 'READY' LED illuminates when the
reference is retained in the memory.
'START' button:
The 'START' button has the dual function of both starting and stopping measurement.
It is a trigger type of switch.
To start (lock): Press the 'Start' button once.
To stop (unlock): Press the 'Start' button again.
B. The INDICATOR LED's
The 'INDICATOR' LED's show the degree of disbond. The green LED, yellow LED, red
LED 1, red LED 2 or both red LEDs 1 & 2 will illuminate depending on the degree of
disbond.
In addition, a buzzer alarms whenever a red LED is on.
'READY' LED:
When you obtain the standard/reference value is set, the 'READY' LED illuminates to
green. The unit is now ready to scan the area under test. If it illuminates red, press
the 'AVE_SET' button again to obtain the standard/reference value.
'BATTERY' LED:
Battery LED illuminated when batteries need replacing/recharging. They need to be
replaced immediately to maintain accurate data.
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C. The Display
'AVE' (AVERAGE):
Shows frequency (Hz) and average number of taps
'STANDARD' (Reference):
Shows 'STANDARD'/reference value
'MEASURED':
Shows 'MEASURED' value
'TAPPING POINT':
Shows the point number measured.
'DEBOND / INSERT':
Shows if you are in debond or insert mode.
3. Parts Identification (cont.)
'DATA' LED's:
Condition of scanned area
Debond
Spring constant ratioLED
Red1 + Red2 + buzzer 0.30
Red2 + buzzer 0.50
Red1 + buzzer 0.75
Yellow 0.85
Bond Green 1.00
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!CAUTION
4. Precautions
A) Follow the battery installation instructions carefully. Ensure the +ve & -ve are
correctly installed into the 'BATTERY COMPARTMENT'. Either AA alkaline or AA
rechargeable (nickel-metal hydride) batteries. Change batteries when the 'BATTERY'
LED illuminates.
Data is kept when power is 'OFF'. However, data is lost when batteries are consumed,
except 'AVE/SPEED' and DEBOND/INSERT'.
B) Set the 'DEBOND' / 'INSERT' switch to suit for the purpose of testing; 'DEBOND'
to detect debond & 'INSERT' for core detection of inserts. The default mode is
'DEBOND'.
C) Use the strap to prevent dropping the handpiece.
D) The WP-632AM has memory (RAM) allowing up to 7700 points to be recorded.
This initiates automatically, but if 7700 is exceeded the user can still keep operating
the unit.
E) The 'STANDARD' / reference value needs to be reset each time a different
material is examined or the skin thickness of the material changes.
F) Keep the hammer as perpendicular as possible to the surface being tested. The
measuring allowance of inclination of hammer is about +/- 10 Celsius.
G) Detection may not be accurate if the surface to be tested is rough. In such cases,
increase the 'AVE_SET' mode value to operate the Woodpecker at a slower speed.
H) Move the Woodpecker carefully to prevent damage to the feet or hammer head
where steps exist on the surface of the item under test.
I) Detection may not be accurate and damage may occur to the surface to be tested
if the foot or hammer head is excessively worn. Replace worn parts immediately.
J) Detection may not be accurate if dust or dirt is on the surface to be tested. Make
sure the surface is clean and dry before testing.
K) Remove the batteries if the Woodpecker is not going be used for an extended
period.
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A) Power 'ON'
Install the batteries as specified (the backlight will stay on for 30 seconds). If the
batteries are installed & the screen is off press the 'POWER' button.
All data show as '0' on first use
Power will turn off automatically if unit is not used for 30 seconds after installation
of batteries or pressing the 'POWER' button. Press the power button to continue. If
measurements have already been taken, the display shows the previous data.
B) Setting the measurement value and tapping speed
Use the 'AVE' button to select the hammer speed. By pressing the button you can
select the various options. Use low 'AVERAGE 1 or 2' for smooth surface, and high
'AVERAGE 4 or 8' for rough surface.
Measurement Values:
In the AVE (average) 1 mode, the measurement value when the hammer taps
once is compared with the memorised reference value.
Similarly, in the AVE 2, AVE 4 & AVE 8 modes, the average measurement value of
2, 4 or 8 taps, are respectively compared with the reference value.
Choose the AVE mode most appropriate for the structure & condition of the surface
being tested.
Use low AVE modes (1 or 2) for uniform surfaces & high AVE modes (4 or 8) for
surfaces that are not so uniform.
Tapping Speed:
Four settings can be chosen for each AVE mode: 2Hz, 4Hz, 8Hz & F (Fast - 16Hz).
For quick scanning, set the tapping speed to F, using low AVE (1 or 2).
To increase accuracy by scanning slowly, perform the reverse operation, eg., a
high AVE mode with a slow tapping speed.
C) Setting the mode for detection
Select to work in 'DEBOND' or 'INSERT' mode by pressing the 'DEBOND/INSERT' button.
The default is DEBOND.
D) Memory
The Woodpecker WP-632AM has a built in memory which initiates automatically. It
allows up to 7700 points to be recorded, but if 7700 is exceeded the user can still
keep operating the unit. To clear the memory: 1) Press the '+' & '-' count buttons
simultaneously (the 'Standard'/reference value will be kept) OR 2) Remove/change
batteries (delete entire data). For using the software see separate instructions sheet.
E) Setting the 'STANDARD' / Reference Value
The Woodpecker WP-632AM establishes & retains in the memory a reference value
obtained from the average of 8 taps. The green 'READY' LED illuminates when the
reference is retained in the memory. The red 'READY' LED illuminates when the unit
fails to obtain the standard value. In such case, press the blue 'MEMORY' button
and measure the value again.
5. Operation
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5. Operation (contd.)
TIPS: You may move the Woodpecker WP-632AM slightly when you measure the
average value. This allows you to obtain a better average.
1. Ensure power is 'ON' (see paragraph 'A' on page 9).
2. Press the blue 'MEMORY' switch & move the unit slightly to pick up the average
value of the area.
3. The Woodpecker WP-632AM establishes, displays & retains in the memory the
reference value set.
4. The green 'READY' LED illuminates. The unit is now ready to scan the area
under test.
5. The 'STANDARD' / reference value can be reset by following this procedure,
when not in scanning mode.
Ensure a suitable location is used as the reference value or use a test piece. By
examining 2-3 areas in DEBOND mode, a better average can be measured /
determined. An area can be used as the reference in both 'DEBOND' & 'INSERT'
modes for strict measurements.
F) Scanning
1. Move the Woodpecker WP-632AM to the area that you would like to test. Place
the 'FEET' on the structure.
2. Push the green 'START' button. This has a function of both starting & stopping
the 'HAMMER':
Start: Push the 'START' button once Stop: Push the 'START' button again
3. Hold the WP--632AM lightly and scan the surface with deadload. To keep
accuracy, it is desirable to use a scanning speed of 16 cm / second or less.
4. The display shows the 'MEASURED' value and this is automatically saved with a
'POINT' number (up to 7700).
5. The 'INDICATOR' LED's shows the degree of debond. The green LED, yellow
LED, red LED 1, red LED 2 or both red LEDs 1 & 2 will illuminate depending on
response of the structure being tested. In addition, a buzzer alarms whenever a
red LED is on.
G) Continue the scanning
If you want to input the new data in addition to the existing ones, simply press the
start button again to continue. The unit will retail up to the 7700 points. Above
7700, the display shows 'FULL'; however, you can continue measurement.
If you wish to input the new data, you may press the 'COUNT_+' and 'COUNT_-'
button at the same time to erase the memory. You may want to send the data to
a PC for storage (follow separate instructions).
H) Look up the memory
You can look at previous data by pressing 'COUNT_-' button. When you count back to
'0000', you have reached to the last count number measured. You can scroll up to
the last number measured.
I) How to delete all data
Press 'COUNT_+' and 'COUNT_-' at the same time to reset the memory.
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