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Test Patterns

IBG participates in 2001 trade shows

lf you're planning to attend the Quality Expo at the Rosemont Expo Center in Chicago, April 24-26, or you're planning to show up at the Heat Treat Show in lndianapolis, November 6-8, look for ibg. Your high-speed eddy current test system specialist will have a booth at both shows, displaying some of the many systems developed for automotive and other suppliers that are manufacturing critical parts for engines, valve and power train systems, and other components such as bearings, forged and cast parts. Here's where you'll find us at each show

Quality Expo: April24-26
Booth: 14109
Heat Treat Show: Nov.6-8
Booth: 2024

NDT Talk

by Bill Buschur - General Manager

New products, new applications

This issue mentions four recent products not covered before in the TEST Patterns newsletter: our eddynomic PMFT structure test instrument, our eddysort® single-frequency test unit, lbg's new bulk loader/step feeder and eddysort® H63. All four of these are worthy of mention, because all of them have been put into action for customers and have proven to be top performers.

eddynomic is based on our proprietary preventive multi-frequency testing technology for structure (material mix, proper heat treatment, etc.), and has automatic freak recognition, while requiring only OK parts for calibration, eddysort, while using only a single frequency, is inexpensive and easy to operate--also for structure testing. The bulk feed system has been designed for gentle, high-speed bulk feeding of a wide variety of both small and larger parts. eddyscan® H63 expands the range of ibg rotating scanners up to 2.5-in. diameters.

Other articles in this edition are examples of the ongoing developments taking place at ibg NDT Systems. We are experiencing vigorous interest every month, and I believe you will be interested in the new applications of our eddy current component testing technology.

Rockers and pins at 8,400 per hour!

An automatic test for correct heat treatment of rockers and pins for engine timing chains has been developed by ibg using a compact eddyliner®P2 instrument and a twin sorter. Designed for a major automotive supplier, the system tests 32 different parts ranging from 3.3 mm to 5 mm in diameter and from 12.5mm to 55 mm in length.

Parts are fed into the system by means of a feeding tube, then are forwarded end-to-end continuously through the test coil. Changeover of the test system for various part geometries is accomplished quickly using change parts. The compact design of the test system allows it to be moved easily from one station to another.

bulk feeder system developed by ibg

Feeding of parts for testing from bulk containers has been developed by ibg. Here is a belt bunker and step feed system that can very gently handle up to 10,000 parts per hour (depending on part geometry). Designed by ibg engineers, the system's bunker can hold up to 550 lbs. (250 kgs) of test parts such as ball pins-and then forward them to the step feeder, Any falling parts are cushioned by a rubber mat.

A compact, reliable bulk feeder that's gentle with precision parts

New system tests for heat treat and cracks in planetary gear pins

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).

New eddy current instrument tests for material mix, structure

A new instrument for component structure testing, using ibg's Preventive Multi-Frequency Testing methodology, is now available. Known as the eddynomicf, the instrument is capable of very high repeatability and has been designed for high-speed production line testing for material mix, heat treatment, sinter density and other micro-structural variations.

Providing eight test frequencies, the eddynomic requires only "OK" parts for calibration. It is easy to operate and economically priced, yet offers maximum test reliability with millisecond test times. Its operation is supported by an on-board computer, simplifying calibration and sorting procedures.

Cylinder liners in engine block are tested for cracks and pores

A semi-automatic eddydector® system by ibg utilizes eddyscan® H3o to scan for cracks and pores in cylinder liners in engine blocks. Various configurations: 3, 4 or 6 cylinders in-line, as well as 6-, 8- or 12-cylinder blocks can be scanned.

A rotating probe automatically centers in the cylindrical bore hole and scans the entire lD surface for cracks and pores. An X-Y slide controls position tolerances and angle of the scanner in the bore hole automatically. Mounted on casters for mobility, the compact system is designed to be transported from laboratory to production line, where it can be directly integrated into the process.

eddysort® structure test instrument is now available

ibg has introduced an economical structure test instrument that uses single-frequency testing for simple sorting applications. eddysort automatically selects the optimum test frequency (from 48 frequencies) and includes automatic generation of tolerance fields.

With self -calibration capability, The eddysort performs highly repeatable testing within milliseconds, and is easy. to operate, even by semi-skilled personnel. The instrument can be integrated into automatic inspection lines via optoisolated interfacing.