1 st Edition 2014 Contents ECHOMETER 1077: Precision Milling ECHOMETER 1077: Precision Milling 1 FLUXA : New Inspection Medium for Magnetic Particle Testing 2 DEUTROMAT: Magnetic Particle Crankshaft Testing at VOLVO in Sweden 3 The Starrag Group is one of the leading manufacturers of high-precision machine tools for mechanical processing of metal and composite parts of any size. As part of this group the Dörries Scharmann Technologie GmbH in Mönchengladbach, branded Scharmann, produces amongst other things horizontal processing machines for complete machining of very large parts. DEUTROMAT DKM8: Automatic Surface Crack Detection in 12 s Cycles 4 LEPTOSKOP 2042: Coating Thickness Measurements on Dashboards 5 Well-earned Retirement: Technical Director Dr. rer. nat. Michael Platte 5 Erects New Hall at Works 2 6 New Employees 7 The horizontal processing machine ECOSPEED with a SonicEye attached to the machine spindle for precise measurements of remaining wall thicknesses. Fairs and Events 8 Contact Pruef- und Messgeraetebau GmbH + Co KG Otto-Hausmann-Ring 101 42115 Wuppertal Germany Phone (+49-202) 71 92-0 Fax (+49-202) 7149 32 info@karldeutsch.de www.karldeutsch.de Exchangeable front units form the basis for their technical solutions. The series ECOSPEED was specifically designed for processing large aluminium structural parts for the aerospace industry, such as aircraft wings. Together with an ultrasonic measurement tool with the name SonicEye was developed for this machine series. The SonicEye is based on the precision wall thickness gauge ECHOMETER 1077 in combination with the ultrasonic probe S 12 PB 1-7 and a 25 mm delay line. During the milling process the SonicEye monitors the wall thickness periodically to assure that the specified tolerances are precisely met. Up to now this has been performed manually and the whole machine had to be secured every time before the inspector entered. To achieve this task we developed a changeable tool which contains both the ultrasonic probe and Continued on page 2
News From Your Partner for NDT At the moment, a cable connection is used for power supply and data transfer, which requires a socket in the machine frame. For further projects cord- Continued from page 1 the electronic measurement equipment in one compact case. The ultrasonic probe is spring-mounted on one side in a specifically fabricated housing. For measurements the milling head is automatically dismounted from the machine spindle and replaced by the SonicEye through a tool feeder. The ultrasonic probe is then placed on the part together with the whole unit and an automatic adjustment is performed. Afterwards defined positions for wall thickness measurements are approached. By means of a special data interface the test parameters and results are checked and transferred to the machine control system. The further milling process is accordingly optimized and the measurements are reproducible with a variation of less then 5 µm. The SonicEye during adjustment on a calibration block. In front of the ultrasonic probe a nozzle sprays cooling lubricant on the surface for coupling. In the left upper corner an automatically docking connector for data transfer and power supply is shown. the machine control system. The coupling of the ultrasonic probe to the part is achieved by means of the cooling lubricant which is sprayed on the surface anyway for the mechanical processing. less communication and power supply through WLAN and wireless charging are planned. Ki Different wall thickness ranges demand different configurations of the ultrasonic system. These are stored in the ECHOMETER 1077 and activated by Products» Wall Thickness Gauges» Gauges» ECHOMETER 1077 FLUXA : New Inspection Medium for Magnetic Particle Testing You want a ready for use, water-based inspection medium for magnetic particle testing in a convenient aerosol can? We realized this customer request and from now provide our established magnetic particle concentrate FLUXA HRS ready-to-use and environmentally friendly in a handy aerosol can. As there are no flammable propellants used in the bottling process, the medium can even be used in small or poorly ventilated rooms where it was not possible to use aerosol cans before (e. g. with vessel manufacturing). Furthermore the new product is VOC-free. Therefore an already diluted, waterbased inspection medium in a convenient aerosol can is available for magnetic particle testing, complying with EN ISO 9934-2, SAE AMS 3044 as well as ASTM 14444. We gladly provide samples for your own tests free of charge. Rb Products» Magnetic Particle Testing» Inspection Media and Accessories» FLUXA Inspection Media 2
DEUTROMAT: Magnetic Particle Crankshaft Testing at VOLVO in Sweden A customer-specific magnetic particle testing machine (Type DEUTROMAT) was built for the new VOLVO crankshaft manufacturing line in Skövde, Sweden. The testing machine is automatically loaded and unloaded by means of a portal. Crankshafts of various lengths can be tested. The machine is equipped with MEMORY parameter storage which stores all relevant test parameters and communicates with the higher-ranked control system of the manufacturing line. Thus, the DEUTROMAT automatically adjusts itself on the respective crankshaft type. The machine was designed as a turn table with four stations. In station No. 1, the crankshafts are loaded and unloaded. The fine-positioning of the crankshaft is also done automatically. The yoke distance of the magnetization station (No. 2) is automatically adjusted in accordance with the crankshaft length. Magnetizing station with spraying device Oil-based magnetic particle concentrate is evenly sprayed onto the entire surface. The viewing station (No. 3) allows a joy-stick operated roller unit for visual test on the entire crankshaft 2 3 4 Station for visual test under UV-LED light 1 surface. A UV-LED lamp provides good contrast. The demagnetization station (No. 4) is very similar to station No. 2, i.e. using a similar yoke pair. Since oilbased test liquid is used, demagnetization needs to be carried out after the visual test. The entire testing machine is conform to the current VOLVO specifications and was successfully put into operation in September 2013. Bl Inside view of the crack detection machine with four stations 3
News From Your Partner for NDT DEUTROMAT DKM8: Automatic Surface Crack Detection in 12 s Cycles A magnetic particle testing system of type DEUTROMAT DKM8 was delivered to the company Hirschvogel Eisenach GmbH in Marksuhl, Germany, last year. The Hirschvogel Eisenach GmbH is part of the Hirschvogel Automotive Group with its headquarters in Denklingen, Germany. The Hirschvogel Automotive Group develops and produces highly stressable steel and aluminium forgings for use in motor vehicles of any kind at a total of nine facilities in Germany and abroad. Inspection rotary table with large-sized UV-LED units Chain conveyor and encapsulated quadruple magnetizing station This special crack detection system features four high current circuits for current flow with 1000 A eff each and two magnetic field circuits in an open yoke design for field flow. With this setup it is possible to test eight casings of diesel injection systems for surface cracks in all directions during a single machine cycle. The machine cycle time is 12 s. Four centre contacts for high inspection throughput With the use of centre contacts eight casings can be placed on universally designed adapter prisms and are transported through the machine by means of the established chain conveyor system. At the loading position a visual inspection for coarse forging flaws (e. g. underfilling or forging laps) is performed. Specifically designed showers and nozzles assure a reliable spraying of the test parts in the encapsulated quadruple magnetizing station. At the machine outlet the magnetized parts slide onto a rotary inspection table with a diameter of 1600 mm. At this table two inspectors visually examine the test parts for crack indications. Standardcompliant UV illumination is provided by two Large Area UV-LED lamps, which can be switched to white light as needed. After inspection the flawless parts are placed on belt conveyors and demagnetized in coils of ESV 200 S type with an opening of 200 mm x 200 mm. On customer request an additional test for material mix-up is performed before the parts are dropped into respective collection boxes. The parameter storage DEUTROFLUX MEMORY keeps all of the product-related inspection parameters and logs them to assure that all details can be accessed by inspection task or injector casing type. After inspection all relevant machine parameters and statistical data about defective and non-defective parts are stored in a CSV file and can be transmitted via the corporate internal network as needed. With the DEUTROMAT DKM8 the company Hirschvogel is able to inspect approximately 30,000 injection casings for surface cracks per day and thus is well prepared for future capacity increases. MR Products» Magnetic Particle Testing» Stationary Test Benches» DEUTROMAT Chain Conveyor 4
LEPTOSKOP 2042: Coating Thickness Measurements on Dashboards An interesting inspection task was requested by Volkswagen AG in the German town of Wolfsburg: The dashboards of different model series of the Volkswagen Group are covered with a PVC skin, which visually and haptically is relatively close to leather coatings. For optical reasons these PVC skins contain grooves in specific areas. Measurements of these grooves were performed destructively so far by cutting Modified probe with extended pin them out and mechanical determination of the thickness. We solved this task with a coating thickness gauge LEPTOSKOP 2042 and a modified magnetic inductive probe. This special version of the probe features an extended pin, which sticks out of the probe housing and can thus be placed directly in the 3 mm wide groove. Due to the small pin diameter of approximately 1.5 mm an undesirable elastic deformation of the PVC skin is minimized at the positions to be measured. This way the PVC coating thickness can be measured nondestructively with an accuracy of ± 0.02 mm. With the supplied inspection system Volkswagen AG is now able to Measurement in a beading perform the required examinations with comparable accuracy, considerable time saving and without destruction of the PVC skins. MR Products» Coating Thickness Gauges» Gauges» LEPTOSKOP 2042 Well-earned Retirement: Technical Director Dr. rer. nat. Michael Platte A long-serving and respected employee retired at the end of the year 2013. Dr. Michael Platte substantially influenced our company for many years, so this was a sad moment for all of us. After his graduation in physics at the RWTH Technical University in Aachen, Germany, Dr. Platte earned a doctorate at the local Institute of Technical Acoustics in the year 1984. During a visit of Prof. Volker Deutsch in Aachen the contact to was established. Back then, specific line-focussed probes for tube and bar testing were required. As part of his thesis Dr. Platte examined piezoelectric PVDF material, which allows the development of curved probes without the need of acoustic lenses. That was how Dr. Platte started at in 1985 and led the ultrasonic probes division very successfully. Modern measurement equipment was purchased while novel ultrasonic probes and manufacturing methods were developed. Additionally the documentation of the ultrasonic probes was brought to perfection. This way, managed to produce large series with high accuracy, an absolute precondition for automated ultrasonic testing, e. g. testing of heavy plates or pipeline testing with pigs. In 1991, as one of two recipients, he achieved the renowned Berthold Award of the DGZfP (German Society for Non-Destructive Testing) for the enhancements in ultrasonic probe development. He became division manager for ultrasonic testing instruments and technical director of the entire company in 1994. Dr. Platte was also the technical managing director until Dr. Dr. Michael Platte at his farewell in the R&D-department together with Dr. Michael Lach (Head of Probe Division, left) and Dipl.-Ing. Stefan Grünewald (Deputy Head of R&D, right) Wolfram Deutsch, as a member of the third generation of the Deutsch family, took over the company management. Besides this he always remained closely connected to the Continued on page 6 5
News From Your Partner for NDT Continued from page 5 ultrasonic probes division, now led by Dr. Michael Lach. As a perfectionist it was a logical consequence that Dr. Platte devoted to quality management. Already in 1993, was certified in accordance with the (then) new DIN 9001 standard, shortly after its introduction. To formalise and establish repeating processes in production and service is essential for success in the quality industry. Dr. Platte was particularly proud of the steady decrease in service cycle time. On average, a repaired or certified device leaves our house within 5 business days, or even faster on customer request. Dr. Platte retired at his own desire. On the last working day, his colleagues from the R&D department handed over an ultrasonic flaw detector built in 1973. This ECHOTEST instrument is still fully functional until today. Back then, it was the first digital ultrasonic instrument worldwide and a long way ahead of its time. Two ultrasonic special probes based Managing director Dr. Wolfram Deutsch thanks Dr. Platte for his successful long-term employment on ideas presented in Dr. Platte s doctoral thesis were manufactured and successfully connected to the instrument. A newly installed MP3 player extends the functionality of the device to keep his new owner in a good mood. The last meeting of the management board with Dr. Michael Platte Dr. Michael Platte will continue to assist the company as a consultant to ensure a continuous transition. His successor as head of the R&D department will be his former deputy and long-term employee Dipl.-Ing. Dietger Schäle. WD Erects New Hall at Works 2 In recent years, the ultrasonic and magnetic particle testing system divisions often caused space constraints in Works 2. The expanding sector of KD-Check penetrant testing systems also had to fight for assembly space. Despite the extension buildings in 2004 and 2006, which doubled the assembly space, external storage room was often used. This is why the decision to build another new hall was taken in 2012. In summer 2013 the new hall was inaugurated. Now purchased parts can be acquired and stored in bigger quantities. The chemical division is satisfied about the extended storage capacities for efficient production of crack detection media. Additionally an application laboratory for ultrasonic testing systems was established where manifold experiments with a pass-through immersion tank will take place. The previous KD-Info leaflet reported more in detail about this laboratory. The old and new halls are connected by a roof providing Dipl.-Ing. Guido Trapp (Trapp architects), principal Dr. Wolfram Deutsch, Dipl.-Kfm. Ralf Wiemer (Financial Director at KARL DEUTSCH), and Dipl.-Ing. Holger Erke (Trapp architects) enjoy the new hall. best conditions for upcoming summer parties on rainy days. WD 6
New Employees Qualified and motivated employees are the key to our success. That is why we have expanded our team in all divisions. Timur Sayfullaev (Master of Engineering) is in charge of our newly installed application laboratory for ultrasonic testing systems since April 2013. As a warehouse logistics specialist Ramil Yevdayev manages our component storage since April 2013. Since May 2013 Andreas Göke (skilled goldsmith) strengthens our team at the ultrasonic probes division. Dipl.-Ing. Jürgen Sand is a competent point of contact for compact ultrasonic testing systems at our company since June 2013. As a packaging technologist Nicole Mahr supports the chemical products storage since July 2013. We have been able to gain Tobias Krumkamp (Master of Engineering) to extend our portable test equipment division since September 2013. Since January 2014 Dipl.-Ing. Anke Scholz is responsible for manifold documentary tasks. Dr. Benjamin Löhden (Dipl.-Phys.) strengthens our team at the application laboratory since January 2014. The software section of our ultrasonic testing system division obtained further qualified support by Frank Haller (Master of Computer Science). Welcome to the team of! 7
News From Your Partner for NDT Fairs and Events 07-11 April 2014 Tube 2014 International Tube and Pipe Trade Fair Messe Düsseldorf, Germany, hall 6, booth E21 06-09 May 2014 28th Control International trade fair for quality assurance Neue Messe, Stuttgart, Germany, hall 1, booth 1410 Lecture (Wednesday, 07 May 2014, 12:40 pm): Neue Geräte zur Ultraschallprüfung Lecturer: Dr. (USA) Wolfram A. Karl Deutsch 26-28 May 2014 Annual Meeting of the DGZfP Kongresshotel am Templiner See, Potsdam, Germany Lecture (Monday, 26 May 2014, 02:00 pm): New Instruments for Ultrasonic Testing (in German language) Poster presentation (Monday, 26 May 2014, 05:25 pm): Ultrasonic Immersion Tank Testing of Bars for Aerospace Applications (in German language) Lecture (Wednesday, 28 May 2014, 01:30 pm): Ultrasonic Phased Array Testing of Longitudinally Welded Pipes (in German language) Lecturers: Dr. (USA) Wolfram A. Karl Deutsch Dr.-Ing. Werner Roye 11-13 June 2014 ARoENd - 21st International Symposium Romanian Association of Non-Destructive Examinations Mamaia-Constanta, Romania 06-10 October 2014 11th European Conference on NDT (ECNDT) Prague Congress Centre (PCC) Prague, Czech Republic 13-16 October 2014 23rd testxpo International Forum for Materials Testing at Zwick, Ulm, Germany Dates, Events testxpo 13-16 October 2014 International Forum for Materials Testing at Zwick in Ulm, Germany About Pruef- und Messgeraetebau GmbH + Co KG The privately owned company was founded in 1949 and develops and produces instruments for non-destructive material testing. Portable instruments, stationary testing systems, sensors and crack detection liquids are produced by 130 motivated employees in two works in Wuppertal. Additional 20 employees in international offices and a worldwide network of dealers support the export business which accounts for more than 50% of the turnover. Characterised by continuous innovation and product reliability, the trade marks ECHOGRAPH, ECHOMETER, DEUTROFLUX, LEPTOSKOP, FLUXA, KD-Check and RMG are well-recognised. Our customers are metal producing and processing industries, e. g. steel works, automotive companies and bearing manufacturers. Typical test tasks are ultrasonic weld testing, detection of shrink holes in castings, crack detection in forgings with magnetic particles and dye penetrants, safety components for railway and aerospace as well as the wall and coating thickness measurement. 8 DIN EN ISO 9001 certified