Eddy Current Component Testing Experts

Eddy Current Crack Testing Systems - Ball Studs, Needles, Cylinder Liners

Test rate: 4,800 Parts per Hour (Twin System)

Ball Studs

Automatic Test of Ball Pins for Cracks at the Equator of the Ball, for Correct Hardness, for Cotter Pin Hole and for Damaged Thread with eddyliner® P2 and 2-Channel eddydector®

The crack detection station with the two clamping and rotating mechanisms and the test station for cotter pin holes (without transport wheel).
The thread test station with calibration rollers.
The parts are fed to the transport wheel via 2 rails, are unmatched and passed on to the test stations.
The crack and thread test stations are easily accessible via a maintenance slide.
Depending on the sorting decision, the tested parts are ejected into the appropriate sorting chute.
The exchange parts are well-arranged stored in a separate cabinet (chest of drawers).
  • Crack testing system shown at left
  • Illustrated part shows EDM master crack
  • Tests 36,000 needles per hour
Automatic Crack Detection system for Needles diam. 1.5mm - 3mm with eddyscan® H10


Crack depth

Crack width

Crack length

Test rate

Speed of rotating head

Rotating probes

≥ 0.050mm

≤ 0.070mm

≥ 3.000mm

≤ 36,000

= 6,000RPM

: max.2

When the lid is removed, the adjustable rotating probe is visible "keyholes" provide for easy disassembly.
For maintenance and resetting, the rotating head is brought into maintenance position.
The 2-channel rotating probe can be adjusted finely from 1.0mm to 15.0mm.
The integrated drawers offer sufficient space for master parts, tools and exchange parts.
Parts are fed in a flexible tube from the vibration feeder. They are transported through the rotating head via feed wheel at a constant velocity (v s 100mm/sec). After testing is completed, the parts go one by one to the ok parts box or the REJECTED parts box, depending on the sorting decision.
The control elements and the electrical components are integrated in the dust-proof steel cabinet. the frequency drive allows for the high speed of the rotating head (600 rpm).
Cylinder Liners
  • Crack Testing system shown at left
  • I.D. bore surface area and O. D. surface area are scanned completely for cracks & pores
  • Close up shows two probes scanning entire outer diameter of liner tested for cracks and pores
Crack Detection on Cylinder Liners with 3-channel eddydector®
on the Whole Inner and Outer Diameters
Parts Geometry:

Diameter OD

Diameter ID


Cycle time

Cycle rate

: 90mm

: 86mm

: 132mm

: 9 sec/part

: 400 parts/hour

Crack Specification:





: 0.7mm

: 0.075mm

: 5mm

: longitudinal and transversal




: 1.5mm

: 0.7mm

Two crack detection probes scan the whole outer diameter for surface flaws
The parts are separated gently at the test parts inlet and passed one by one to the test and discharge stations.
The I.D. crack detection probe in its protected home position awaits the next test part.
At the upper chute, OK parts are forwarded to the next processing step. The lower chute can hold up to five NOK parts.

The eddy current test instrument for crack detection with three crack test channels and oscilloscope.

Automatic Crack and Structure Test (Case Depth) of Cylinder Liners with 4-Channel eddydector® and eddyliner® P16

Cylinder liners tested are for trucks and construction machinery.

The system is designed for three different part types with part ranges:



Cycle Time:

Approximately 200 to 350mm

Approximately 120 to 130 mm

107 parts per hour

33.5 seconds per part

Crack and pore detection on the inner diameter and flange end faces.

Test for correct case depth at up to 16 locations.

Crack Specifications

Longitudinal Cracks:




≥ 0.500mm

≤ 0.080mm

≥ 5.000mm

Circumferential Cracks:




≥ 0.700mm

≤ 0.080mm

= 3.750mm




≥ 1.500mm

≥ 0.750mm

Structure Test Station
An I.D. coil tests pre-selected locations on the inner diameter for correct case depth.
Crack Test Station
The cylinder liner is rotated and the I.D. bore surface area plus the flange face are scanned for surface open cracks and pores.
After the part is marked, it is forwarded to the sorting station where it is sorted either into the OK or NOK chute.
The robust swivel arm transports the part from station to station.
Operating side of test system.
ibg NDT Systems has 30 years experience as a designer and manufacturer of state-of-the-art-non-destructive (NDT) eddy current testers, instruments, and systems for crack detection and flaw detection for automotive, bearing and other metal components including fastener, forged and cast parts, hard metals, precision stamped parts, etc.
ibg NDT Systems Corporation, 20793 Farmington Road, Farmington Hills, MI 48336
Phone: 248.478.9490, Fax: 248.478.9491
Website Design - Target Marketing Solutions