The Sonic FlexAxis Encoder – TS-FAE-09

The Sonic FlexAxis Encoder – TS-FAE-09

Spring-Loaded Scan Position Encoder for Manual and Semi-Automated Ultrasonic Scanning

The The Sonic FlexAxis Encoder – TS-FAE-09 is a rugged scan position encoder designed for manual weld scanning, corrosion mapping, encoded PAUT, UT inspection, scanner-mounted ultrasonic inspection, and custom NDT scanner integration.

The TS-FAE-09 uses a spring-loaded contact arm to maintain stable wheel contact with the inspection surface during scanning. This helps provide reliable position feedback even on curved surfaces, weld-adjacent areas, scanner frames, and field inspection setups where consistent encoder contact is essential.

The encoder converts scanner movement into accurate position pulses, allowing ultrasonic inspection systems to record data according to the actual scan distance. This supports accurate defect positioning, length measurement, encoded data acquisition, B-scan/C-scan mapping, and repeatable inspection documentation.

Product Overview

The FlexAxis Encoder is designed for applications where the encoder must maintain steady surface contact during scanning. Its spring-loaded tracking mechanism compensates for minor surface variations and helps reduce signal loss caused by wheel lift-off during manual or scanner-guided movement.

The encoder can be mounted on scanner frame bars, probe carriages, weld scanning fixtures, corrosion mapping frames, and customized inspection tools. It is suitable for field inspection, workshop inspection, fabrication inspection, petrochemical inspection, power plant inspection, marine inspection, and general industrial NDT applications.

Key Features

• Spring-loaded contact mechanism for stable surface tracking

• Suitable for manual, semi-manual, and scanner-mounted ultrasonic inspection

• Designed for PAUT, UT, TOFD-support scanning, weld inspection, and corrosion mapping

• Accurate scan-distance feedback for encoded inspection data

• 9.05 counts/mm encoder resolution

• 5 m standard encoder cable option

• Rugged industrial body for site and workshop use

• Watertight sealed construction for wet inspection environments

• Smooth contact wheel rotation for consistent position tracking

• Easy mounting on scanner frame bars and custom fixtures

• Compatible with flat, curved, pipe, plate, vessel, and tank surfaces

• Custom connector configuration available based on inspection system requirement

• Suitable for single-axis encoded scanning applications

• Helps improve defect location accuracy and inspection repeatability

Working Principle

The TS-FAE-09 FlexAxis Encoder operates using incremental rotary position encoding. During scanning, the encoder wheel rotates as the scanner, probe holder, or inspection fixture moves along the inspection surface.

The internal encoder converts wheel rotation into digital position pulses. These pulses are used by the ultrasonic inspection system to calculate scan distance and synchronize inspection data with actual scanner movement.

The spring-loaded arm maintains consistent wheel pressure against the surface, helping the encoder track movement reliably during inspection.

This position feedback supports:

• Accurate scan distance measurement

• Defect location tracking

• Defect length sizing

• Weld scan mapping

• Corrosion mapping

• Thickness profile documentation

• B-scan and C-scan generation

• Repeatable inspection reporting

• Position-based ultrasonic data storage

Technical Specifications

Available Models and Variants

Spring-Loaded Contact Design

The spring-loaded contact arm is designed to maintain constant wheel contact with the inspection surface during scanning. This design is useful where surface conditions, scanner movement, or inspection geometry may cause minor contact variation.

Advantages of spring-loaded tracking:

• Helps maintain encoder contact during movement

• Reduces wheel lift-off during scanning

• Improves scan-distance reliability

• Supports stable data acquisition on curved surfaces

• Useful for pipe, vessel, tank, and structural inspection

• Improves repeatability during manual scanning

Mounting Options

Frame-Bar Mounting

The TS-FAE-09 can be mounted on scanner frame bars for weld scanning and corrosion mapping applications. This configuration is suitable for manual scanners, semi-automated scanning frames, and modular inspection systems.

Probe Carriage Mounting

The encoder can be installed near the probe carriage to provide position feedback close to the inspection point. This is useful for encoded weld scanning and inspection setups where accurate scan tracking is required.

Custom Fixture Mounting

Custom brackets and adaptors can be supplied for integration with application-specific scanners, probe holders, special frames, corrosion mapping tools, and customized NDT inspection equipment.

Applications

The Sonic FlexAxis Encoder – TS-FAE-09 is suitable for:

• Encoded PAUT weld inspection

• Conventional UT encoded scanning

• TOFD-support scanner applications

• Manual weld scanning

• Semi-automated weld scanning

• Pipe girth weld inspection

• Pressure vessel weld inspection

• Tank shell inspection

• Structural weld inspection

• Corrosion mapping

• Thickness profile mapping

• Nozzle and branch connection inspection

• Scanner frame integration

• Custom ultrasonic scanner development

• Marine and offshore inspection

• Power plant inspection

• Petrochemical and refinery inspection

• Heavy fabrication inspection

Inspection Advantages

Using the TS-FAE-09 FlexAxis Encoder helps improve inspection quality by providing:

• Accurate scan-distance measurement

• Better defect positioning accuracy

• Improved defect length sizing

• Repeatable inspection records

• Reliable encoded data acquisition

• Better report traceability

• Reduced manual measurement error

• Improved B-scan and C-scan mapping

• Better comparison for future inspection monitoring

• More consistent tracking during manual and scanner-mounted inspections

Standard Supply Scope

• 1 No. TS-FAE-09 FlexAxis Encoder

• 1 No. Spring-loaded encoder assembly

• 1 No. 5 m encoder cable

• 1 Set mounting hardware

• 1 No. Selected connector configuration

• 1 No. Basic instruction sheet

• Functional test certificate, if required

Optional Accessories

Compatibility Statement

The TS-FAE-09 FlexAxis Encoder is designed for integration with standard industrial ultrasonic inspection systems that support encoder-based data acquisition. Connector type, wiring configuration, cable length, mounting interface, and output configuration can be customized based on customer instrument