An eddy current test system developed by ibg tests planetary gear pins at high speeds-up to 1,125 per hour. Each pin is tested for correct induction hardening and cracks on the outer diameter surface.

Hardness pattern runout testing to confirm soft pin ends is accomplished by two test coils clamped over both the pin ends at the first test station. At another station, each part is tested by a coil for case depth and to detect soft areas in the hardened zone. The testing uses ibg's preventive multi frequency testing technique, assuring that each gear pin is correctly induction hardened along the center section, but has soft ends (note illustration above).

For crack testing, the pins are clamped on centers between cones, and are put into rotation. Once rotating, the entire diameter of the pin is scanned for cracks by a non-contacting probe.

The test system is very compact, having been designed to fit into a limited space, yet all operating components of the test apparatus are easily accessible. Actual testing for hardness is by ibg eddyliner® and for cracks by eddydector® crack test instrument.

As many as 13 different part numbers are tested, with diameters of 8 mm to 13 mm, and lengths of 63 mm to 126 mm. Changeover from one part to another takes less than 10 minutes.

ibg system w performs 100% hardness testing of cam rollers

A compact system for 100% high-speed testing of cam rollers produced by a major automotive bearings component manufacturer has been developed by ibg. The customized system is composed of an eddy current test instrument (eddyliner® P4), PLC, parts exchange and a (Quatro Sorter) sorting mechanism, mounted on a metal rack equipped with rollers for movability.

With manufacturers of bearings and bearing components facing strict requirements for 100% defect free shipments, eddy current testing at production-line rates via Ofeg's Preventive Multi-Frequency Testing (PMFT) method is effective for discovering defects due to incorrect heat treating. The recently installed system examines five parts per second, testing each part at eight different frequencies, inspecting 18,000 parts per hour.

Designed by ibg engineers, the system passes cam rollers via two feed channels to two twin sorters (with OK and NOK parts receptacles), running in synchronously. Four test coils inspect every part using the PMFT methodology. The sorters are driven by a brushless DC motor with worm gear. Rocker arms provide precision feeding of the parts.

A tool chest in the system allows for changing part sizes, with quick changeover facilitated by exchange parts equipped with quick-acting locks.

Many material properties-hardness, case depth and hardness pattern-are determined by heat treat processes that are subject to variations. 100% testing at high speed to detect all hardness defects from such heat treat variations-without slowing the production process-is the task carried out by such ibg systems.

New eddyscan® H63 rotating scanner expanded for testing larger diameters

ibg has expanded the capability of the eddyscan rotating scanner to accommodate larger diameter parts. Previously limited to 30 mm, the new eddyscan H63 is an expanded version, and has performed automatic crack detection on parts such as piston pins up to 40 mm in diameter (lengths from 45-100 mm). Scanning at a speed of 200 mm per second, the two channel head rotates at 6,000 rpm, testing pins at the rate of 7,200 to 16,000 per hour (depending on length).