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Crack detection system for gear switch forks requires
innovative test approach |
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Until now, eddy
current crack detection on parts was limited to symmetrical components.
This was because either the test part or the probe would rotate around
to detect flaws. However, crack testing on gear switch forks at the area
of highest stress had to be different. (Note the area to be tested in
the photo.)
ibg reacted to a customer who needed automated crack
detection to replace labor-intensive, unreliable magnetic particle
inspection.
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The parts are
fed via a gripper to where they are positioned in the test station.
Then, the area of the fork to be tested is scanned with a contacting
probe, which is protected from wear by a ceramic probe holder.
During
testing, the probe transmits the test signals to an eddydector ® test
instrument which is calibrated with a defined artificial crack. After
the test, each part is paint-marked according to the test result and is
discharged to an OK or NOK chute. The test cycle is eight seconds per
part.
A master part is fed into the system at programmable intervals to
guarantee a consistent and faultless test.
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Automatic crack test system monitors
22-pound hollow trailer axle shafts |
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An automatic crack detection system was designed and
manufactured for an American supplier of trailer axles. The parts are
cold-extruded hollow shafts which , serve as bearing seats. The weight
(22 lbs.) and geometry of the parts challenged ibg to some special
design work.
The system works as follows: A gantry robot places the test parts in
pairs on an indexing table, which takes them to the crack test station.
There, the parts are rotated and a probe scans the entire outer surface
of the shaft for both longitudinal and circumferential cracks. An
eddydector® instrument is used for detection in 54-second cycle times. |
In addition, the test system can be extended with a further station
for structure testing, where parts are checked for correct hardness at
different locations or for material mix.
Among the advantages of a system A such as this automatic NDT test is I
that results do not depend on human eyes, and are always repeatable by
the electronic test instrument.
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Crack detection and a new inner diameter test coil procedure are
highlights of this issue
Crack detection via eddy current is a valued method to test components for
surface defects today. In a few words, it is fast, reliable, repetitive,
non-destructive and it can be automated. As it is replacing the human eye more
and more these days, it deserves being featured in this issue of our newsletter.
With automatic crack testing, you can test ball studs, brake discs, hubs,
bearings and many other parts that are critical to the safety and integrity of
automobiles. ibg can apply some of the latest innovations and developments to
find sub-surface defects or scan part geometries for flaws.
Also in this issue is news of a new development by ibg. This involves inner
diameter coils which can reach into inner zones of components such as the bells
of CV joints to test for correct structure. The story about this is below
on the left.
Technical Seminars./Workshops took place in March and April of this year all
over the world, and more than 200 participants were involved in Europe and the
U.S. alone. Further such events are scheduled for later in the year in Europe
and South America. If you missed this year's sessions in the southeast U.S., be
sure to watch for listings for 2004.
Sincerely,
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Test part being fed to the test coil by a vibration bowl.
Following the test, parts are sorted into OK and NOK lots. Cycle
time is approximately one second.
Heat treatment specialist for
small, vital parts utilizes eddyliner®
P for testing
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For over a
half-century, Härterei Gerster in Switzerland has specialized in
heat treatment for very small parts for clocks and watches,
critical safety parts for the automotive industry and other
components. For the automotive industry in particular,
heat-treated parts are required to be 100% tested to verify
correct heat treatment and part geometries to avoid wrong
heat-treated and incorrect parts being installed.
ibg's eddyliner®
P instrumentation is applied with multi-frequency technology to
the automotive parts. Two test systems do semi-automatic
testing, while automatic testing takes place for large batches
with vibration bowls and other feeding devices. Changing to
different part types takes only minutes, allowing small batch
sizes to be tested efficiently. |
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Tube, bar and wire testing for alloy verification with
eddyliner®
P
The eddyliner®
standard test instrument using Preventive Multi-Frequency Technology has
been used for hundreds of applications in the automotive field worldwide.
Now it can be applied to tube, bar and wire manufacturing to verify correct
alloy.
As material is continuously passed through the test coil, measuring is
triggered at defined intervals to find differences in the structure due to
wrong alloy. After the material exits the test coil, a PLC decides if the
test part is OK or NOK --i.e. if it is the correct material alloy specified.
Five such systems were installed in Europe and Asia in 2002.
ID coils test inner surfaces of automotive components
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A new capability of ibg involves coils for
applications requiring the testing of the inner diameter of components.
The usual procedure for eddy current structure
testing is to use encircling coils. Test parts are positioned in the
coil and testing is carried out. Applications requiring testing on the
inner diameter of a component have been difficult because this
area cannot be reached by encircling coils from the outside, as this
zone can not be sufficiently penetrated by a magnetic field. Typical
examples of this situation are bearing races on the inside of the bell
of a CV joint or tripod.
Now, ibg can test these ID areas to verify
correct hardness and case depth with satisfactory sensitivity and
reliability using inner diameter coils custom-made for customers'
applications. The ID coils can be supplied .in diameters from 5 mm.
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ibg
workshops draw hundreds of participants
Our workshops have evolved into an international
forum for informing attendees generally on component testing as well as
focusing on special applications. More than 200 persons attended
workshops in March and April this year in Stuttgart, Wolfsburg and
Besançon overseas, plus Atlanta and Nashville in the U.S. Later this
year, further events are scheduled in Great Britain, Mexico, Brazil and
France. |
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"Modular" training for
operators and others now available from ibg
Demand for customized training has
increased over the years, and ibg is responding to these needs. Whether
it involves operator training in crack and structure testing or a
general introduction and training for a large group of participants,
explaining the basics of eddy current testing of components has become
an obligation of ibg. The actual training session depends on each
individual case, and can be held at the ibg office or at a customer's
site.
If you are interested in training, please contact our U.S. headquarters
office, or call 248-478-9490.
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ibg's new Web site shows test instruments and sample systems
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The Web site for ibg has been revised to show an
array of eddy current instruments and systems for the non-destructive
testing of components. Separate sections show hardness, structure and
materials testing instruments, with a selection of systems; plus crack
and flaw testing instruments, also with example systems. At least 15
different systems are shown in the site, including the components they
test. |
In addition, the new Web elements include detailed
characteristics of the major products, involving the eddyliner®
eddynomic®, eddysort®,
eddydector®, and eddyscan®
products, plus coils and probes. Also included is background on ibg, the
company, and a listing of some of the companies for whom systems have
been produced.
The new site should be up and running on the Internet about the time
this issue of TEST Patterns is published. Look for it at:
www. ibgndt. com. |
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20793 Farmington Road |
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Farmington
Hills, Ml 48336 |
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248 478-9490 |
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Fax: 248
478-9491 |
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www. ibgndt. com |
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E-Mail:
sales@ibgndt.com
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