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Automatic crack detection on hubs beats eyeballing |
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Traditional methods of crack detection
usually involved decisions based on examination by the human
eye. But the limited ability of the eyesight to detect all
defects runs a high risk of defective parts being processed
without detection. With so much production now automated,
eyeball inspection becomes completely impossible.
Eddy current crack detection has become the preferred and most
successful method for component crack testing. Its main advantages
relate to its excellent automation opportunities and to its reproducible
results, as the decision is reliably made by the eddy current
instrument, not by an operator.
The system pictured here scans the bearing journal and the radius
transition to the flange of a hub for cracks, without contact. The test
process is automatic, and the system was integrated into a production
line, with cycle time for each part at 12 seconds. An additional
capability of the system is a laser marking station at which each tested
part receives an ID. |
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Cylinder liners tested for cracks and
pores, as well as for case depth in the I.D. bore |
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For many years now, the detection of
surface defects on cylinder liners has been a standard application for
ibg systems. Dozens of ibg crack detection instruments we call the
eddydector® are in use around the world in this application. Most of
these cylinder liner tests are for cars. But now, ibg has developed and
manufactured a system to test cylinder liners for construction machinery
and for trucks. To do this, special design measures had to be considered
by our engineers, due to the dimensions required for the test system.
The dimensions of the cylinder (shown in the photo) are 120 to 130 mm
(about five inches) in diameter and approximately 300 mm (11.8 inches)
in length. In the system, the test at
the first station is for structure. Each cylinder is examined at six
selected locations to verify correct case depth according to ibg's.
Preventive Multi-Frequency Technology with eight test frequencies. Then,
at the second station, detection occurs for longitudinal and
circumferential cracks and pores. At a third station, marking takes
place with the "OK" parts being engraved.
The test system processes up to 110 cylinder liners per hour. |
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by Bill Buschur -
General Manager
Every two years, ibg has an international technical meeting
for us to learn new developments, thereby maintaining the ibg
know-how by means of workshops and seminars. More than 40 people
attend these meetings, which— in turn—allow us to convey the
latest in eddy current technology to you, our customers.
This issue focuses on crack detection
systems, a major topic at last year's international meeting.
These systems have been integrated into automated production
lines. It's important that we learn the latest in this field,
because eddy current testing is ideally suited to such
applications due to its ability to be automated. Parts are not
contaminated, and testing is at production-line speeds.
As a matter of fact, ibg test systems are used
by all internationally- known automotive manufacturers and their
suppliers.
Bill Buchur |
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System performs
inline test on automotive piston pins
Automotive manufacturers in the U.S. are expected to do 100% testing for heat
treatment on certain components. Typical of this is the piston pin, the
cylindrical geometry of which makes this application quite simple.
The text part slides down a chute with the feed
rate controlled by two friction wheels. At the test coil, the ibg
eddysort single-frequency instrument performs the test. Parsts not correctly
heat treated are sorted out and sent to a lockable box, while good parts
continue to the next process. Typical cycle time for this testing is
approximately one second per part. By using change parts, piston pins of
different lengths and diameters are tested, with changeover performed in tests
less than 20 minutes.
Web site bulletin:
Now available in Spanish
Due to the increasing demand for access by engineers in Mexico, South America
and Spain, the ibg international Web site is now available in the Spanish
language. Visit it
at www.ibgndt.co.uk or www.ibgndt.de
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Fuel injection system components receive
various tests
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With the latest developments in diesel and
gasoline fuel injection systems, new applications for eddy current
testing are upon us, requiring new test methods. One concern is for
relatively small parts that must withstand high pressures within the
injection systems. Such components must be 100% tested on their
complete I.D. and O.D. surface areas for small cracks. Verification
of correct hardness on carbonitrided parts is another test by ibg.
ibg is a supplier to all known
manufacturers of injection systems around the world.
In the system illustrated, a thin walled tube
must be tested to detect circumferential cracks smaller than 2 mm
(about 8/100 of an inch) in length and 0.15 mm (6/1000 of an inch)
in depth on the inner and outer surfaces of the diameter, ibg
developed and manufactured a system which scans the entire part to
detect cracks at the rate of one part per second. This speed of
detection is achieved by testing three parts simultaneously.
Similar tests for cracks and structure
applications are being developed to customers' specifications.
Contact us for further details.
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The remarkable 10-ball test: material mix
and hardness
in 1/10th second!
A small ball tester designed by
ibg, of precision mechanical and electronic construction,
inspects balls with a diameter range of 1.5-6.0 mm. Up to 10 in one
second! And changeover from one diameter to another takes only a few
minutes. The balls are forwarded by
means of a transport disk to the test position, where each one is
examined for correct structure using ibg's Preventive Multi-
Frequency Technology. Each ball is sorted to an OK or NOK channel
within the system. |
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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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