Ibg Eddyvisor
Ibg Eddyvisor
Ibg Eddyvisor
®
eddyvisor
Digital eddy current test instrument for nondestructive testing
of components, mass produced parts and semi-finished products
for cracks, pores and grinder burn using Preventive
Multi-Filter Technology and for material properties such as
hardness, case depth, structure, tensile strength, heat treatment
or alloy using Preventive Multi-Frequency Technology.
www.ibgndt.com
digital
®
eddyvisor
The eddyvisor distinguishes itself with its high perfor- new standard for quality in crack and grinder burn
mance modular concept with max. 16 independently detection by the eddy current method.
working crack detection channels and max. 32 struc-
During material data recording (calibration) with PMFT,
ture test channels all in a very compact design. Addi-
surface areas of several good parts are scanned. The
tionally, it offers unique features for the realization of
good surface eddy current “noise“ is recorded simul-
sophisticated test tasks using the eddy current tech-
taneously in each of 30 band pass filters. Tolerance
nique, combining that with the well known ibg test
zones, enveloping 360 degrees, are automatically
reliability and ease of operation.
created within each filter band, capturing the allow-
The ergonomic interface enables easy and simple opera- able eddy current “noise“ from good parts. Good
tion via touch screen. All functions and test results are part noise signals result from allowable variations in
captured at a glance. Digital processing of the mea- surface roughness and material properties. Thus, the
suring signal with unique processors, immediately af- thirty tolerance zones store the part specific finger-
ter the pre-amplifier guarantees the greatest possible print of the good parts. Edge effects, hardness profile
stability of test results. run out, eccentricity, etc. of the good parts are cali-
brated during material data recording. Thus, pseudo
The eddyvisor is based on the long proven ibg sys-
rejects are reduced considerably without losing visi-
tem concept. All coils, probes, rotating heads and
bility to real flaws.
other system components are standardized world-
wide. So eddyvisor is the solution for new tasks and The unique “good-part-only-concept“ enables setup
to upgrade existing production machines to equip within a few minutes. Simply scan and record an ad-
them with state of the art eddy current technology. equate number of good parts. Tolerance zones within
each of the 30 PMFT filter bands are automatically
In the field of crack and grinder burn detection, the
generated capturing the allowable noise from the
need for trained experts to perform the sophisticat-
good parts to form good part finger prints in each of
ed and time consuming tasks of manual determina-
the 30 PMFT filter bands. After material data record-
tion and setting of suitable filter band, phase angle
ing, one key press switches to Preventive Multi-Filter
and gain is eliminated by ibg’s exclusively developed
Test, and the test can start. Done! Faster starting yet
Preventive Multi-Filter Technology (PMFT), which au-
more reliable eddy current testing is not possible.
tomatically creates tolerance zones by simply scan-
ning good parts. This quantum leap in eddy current
technology, unique to ibg worldwide, establishes a
digital
®
eddyvisor
Crack and grinder burn detection
Efforts to reduce content of valuable raw materials and
of energy bring reduced cross sections in high volu-
me components in the fields of mechanical enginee-
ring and automobile components. The resulting re-
duced cross sections and stricter material properties
requirements have incentivized manufacturers to gu-
arantee correct structure and crack and grinder burn
free condition by increased nondestructive testing.
The eddy current test method can be applied for all
materials with electrical conductivity or magnetic con-
ductivity (permeability). This includes all metallic ma-
terials. The eddy current crack and grinder burn test
can be adapted to many test tasks by selecting the
suitable crack detection probe and transmitter fre-
quency. As a matter of principle, mainly surface open Crack detection probe box for contacting testing on ec-
or flaws close to surface and pores are detected. centric parts like camshaft lobes for cracks and grinder
burn; large diameter range is covered; up to 300 rpm
The test resolution and effective scan width of a crack (depending of part geometry), ceramic supports for long
detection probe is dependent on core size and type life-time. Solutions for structure test on camshafts on re-
(between 0.5 and 5.0 mm). When testing, a relative quest.
movement of probe to surface of test part is always
required. In order to test rotationally symmetrical parts
for cracks, either the test part is rotated and the probe
stands still or the test part stands still and the pro- more complicated mechanical handling systems. Our
be is rotated around the part by means of a rotating own special machine manufacturing group is always
head. If more than one line shall be tested additio- pleased to work with you to design and build a test
nal feed forward is needed. Thus complete surfaces system for your 100 % testing.
can be scanned. More complicated surfaces require
Steering nut in an automatic ibg test system. Detection of cracks and grinder burn defects on the race inside. With camera inspection
system to capture part type specific QR-code.
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digital
®
eddyvisor
In the past the eddy current crack test would be set to be produced. However, there are physical limits of
to optimally detect an artificially generated (EDM) the eddy current crack detection relative to that wish.
defect master. But artificial defect masters show dif- We have committed ourselves to move these limits
ferent eddy current behaviour (i.e., phase shift, etc.) further in the direction of smaller, detectable “discon-
than natural defects. Thus, natural defects could go tinuities” without increases in pseudo rejects and un-
undetected. Now the ibg technique with its eddyvi- der production conditions. The exploitable sensitivity
sor instrument family walks on new paths. Thanks to of the eddy current crack test depends on several
the Preventive Multi-Filter Technology the instrument parameters:
is not set to an artificial defect anymore but to the
• Surface roughness - detection of small defects is
eddy current pattern of “healthy” surfaces of several
better the smoother the surface is. The limit is at de-
OK parts. Automatically 30 tolerance zones over the
fect depth equal to 5 times roughness depth, but not
entire spectrum of filter bands are formed which in
less than 50 μm.
fact picture the “healthy” surfaces in the test instru-
ment. As soon as one of these tolerance zones are • Material - use of differential probes generally sup-
exceeded by the eddy current signal a NG signal is presses noise inherent to different materials. But the
triggered, no matter if caused by an artificial or by a material tested is a factor. For example, the detection
natural defect. limit for lamellar cast iron can increase to approx. 150
μm due to carbon needles in this material.
For proof of test sensitivity, an artificial defect is put into an
OK part by EDM processes. This defect must be 100 % • Distance probe to surface - increasing probe dis-
detected by the instrument for validation of the me- tance reduces sensitivity, while decreasing probe di-
thod and of the test system. The limit defect of your stance enhance sensitivity to surface roughness and
application is determined beforehand in our lab du- eccentricity of the test part. A good compromise for
ring a feasibility study. It results in definition of directi- most applications is the ibg standard probe distance
on and dimension of the smallest reproducible defect of 0.7 mm.
that must be 100 % detected without or without sig-
• Direction of defects - the direction of a defect re-
nificant pseudo rejects.
lative to the probe trace direction also influences the
The well-known note “surface to be free from cracks” test sensitivity. This can be influenced by choosing
on drawings suggests a wish for perfection of the part the suitable ibg probe system.
ibg lathe for lab tests, feasibility studies and small series in crack detection with eddyvisor. Speed max. 850 rpm, chuck up to 68 mm
diameter, with trigger sensor, flexible probe movement.
digital
®
eddyvisor
ibg mainly applies differential probes for crack They are also relatively immune to variations in test
detection. The differential principle reduces the part structure such as different batches, allowable
very large receiver signal almost to zero by use heat teat variations, etc. These characteristics are im-
of two compensating counter rotating recei- portant for avoidance of pseudo rejects when doing
ver windings. This enables very high amplifi- 100 % testing.
cation of very small signals from flaws without
overloading the input of the test instrument. Further-
more, ibg places high standards for precision for its
own probe manufacturing, further enabling higher
amplifications. On the noise side, ibg instruments
employ extremely low noise signal processing, ear-
liest possible digitalization and smart signal proces-
ses. Thus, ibg is able to combine very high flaw signal
amplification with very low noise signal processing
allowing larger distances between test probe and test
surface without loss of test sensitivity. The advantage
realized is that ibg test probes can be held 0.7 mm
off of tested surfaces without sacrifice of test sensiti-
vity and test resolution. The small flaws are detected. Simulation of the eddy current density generated by a dif-
Other manufacturers only guarantee similar sensitivi- ferential probe on the surface of a roller. It shows disruption
ty with 0.2 - 0.3 mm probe distance. But probes so of the eddy current caused by an EDM crack as detected
close see more good part noise, and there are more by a crack detection probe. Left: typical Spec crack with
3 x 0,1 x 0,1 mm. Right: same crack, but with a length of
pseudo rejects of good parts. In general, differential
only 1 mm.
probes are highly sensitive for local surface defects.
ibg crack and grinder burn master with EDM cracks and
pores for simulation of surface open defects and with laser
defects for simulation of grinder burn; intensity mere residu-
al stress (cutting far left) and beginning annealing zone (left).
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digital
®
eddyvisor
Features crack and grinder burn detection
• Probes • Displays
A selection of probes for crack detection is avail- Display of test results as bargraph, xy-diagram with
able which vary in trace width, sensitivity and shape. tolerance zones and x(t) and y(t) or three-dimensional
Customised probes for special applications are de- C-scan display can be selected. The C-scan (or water-
signed and manufactured in house. Compact and fall diagram) is a rotationally synchronized display of
highly precise ibg rotating heads eddyscan H and test signal from part circumference enabling local al-
eddyscan F are available, in many cases installed for location of defects on the surface.
optimization of cycle time. They work together with
the test instrument eddyvisor. Cable break monitor- • Frequency range
ing offers high security in continuous operation. The carrier frequency is selectable within a range of
3 kHz to 10 MHz in 21 steps. The filter frequencies
• Probe distance of the 30 band pass filters distribute in the range of
ibg probes are by default manufactured for a large 6 Hz to 20 kHz.
probe/part distance of 0.7 mm. Thus, demands on
part exactness and test mechanic are relaxed con- • Trigger of test
siderably. Manually on the instrument, via PLC or by optional
start button.
• Lift-off compensation
If a part is very eccentric, the distance of probe to
test part may be additionally balanced electronically
by use of the optional lift-off compensation. Special
lift-off compensation probes are supplied for this
function.
• Suspend
The suspend function blanks out areas not to be
tested like holes or similar.
Highest test reliability and sensitivity - different kinds of probes for crack and grinder burn detection. Back left a rotating head eddyscan
H for testing a string of parts and bars, back right a rotating head eddyscan F for testing of boreholes and surfaces.
digital
®
eddyvisor
Crack detection of a wheel hub at six locations on inside and outside. Each location has its own reference
data generated from good parts. View of the test areas and their results colour highlighted on the screen.
Left: eddy current signals from grinder burn chatter is detected in a high filter frequency range.Test is on
bearing ring.
Right: signals of the same test on the same bearing ring but in a lower filter frequency range detect additional
grinder burn signals at two opposite locations on part circumference. These signals are due to grinder burn
caused by ovality of the inner diameter. Due to the Preventive Multi-Filter Technology with 30 simultaneously
working band pass filters, unexpected as well as expected defects are detected. Such unexpected defects
would be passed as OK by conventional instruments with only one frequency band.
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digital
®
eddyvisor
Structure test
A difficult problem for in process inspection of mass
parts is supervision of heat treatment results. Verifi-
cation of features like correct case depth and hard-
ness are of prime importance for meeting the quality
standards of the final product. These features can be
monitored by destructive methods like sampling but
with concurrent high personnel and financial effort.
Moreover, a sampling inspection is sensible for statis-
tically distributed defects only. During heat treat pro-
cesses in furnaces or induction hardening, accidents
involving single parts and that violate statistical distri-
bution laws happen. These “unexpected” defects can ID coil for structure test on a continuous velocity joint
be missed by sampling. 100% testing is required to for correct case depth and position of hardness zone.
reliably detect them.
Eddy current structure test utilizing the well known
Preventive Multi-Frequency Technology (PMFT) by compared with these good parts. That means that
ibg guarantees maximum test reliability in 100 % no artificial defects are required for calibration, only
testing. Heat treatment results in serial testing can known good parts. Due to the high test speed and
be monitored cost efficiently, quickly and reliably, and the easy setup a new test task is ready to start within
unexpected defects are detected with highest reli- shortest time. Another advantage is the multi-dimen-
ability. The eight test frequencies of the fundamen- sional analysis of ibg test instruments. An individual
tal wave as well as analysis of two harmonics of the tolerance zone is formed for each test frequency. If
PMFT guarantee highest reliability. The field of appli- all tolerance zones are satisfied, one can assume that
cation for PMFT with simultaneous harmonic analysis the tested part is okay. Even one single not satisfied
is very wide and includes testing surface hardness, tolerance zone classifies the part as not good.
case depth, intermediate structure, material mix-up
and others. Eddy current tests are always comparative tests with
yes/no answer. Very small deviations in the group of
Setting of the instrument is done with good parts parts can be detected. Eddy current cannot answer
only. Ten to 20 parts are presented to the instru- why there is a deviation. In case of a bad part anoth-
ment, and tolerance zones are formed automatically. er test is recommended like metallurgical methods to
Eddy current signals from subsequent parts are now inspect the structure (cut) or a classic hardness test.
NEW: Temperature adaptive structure test iTAS tested, and this leads to an erroneous NG sorting.
ibg’s new Temperature Adaptive Structure Test (iTAS)
Eddy current testing is based upon the electric con-
considers the influence of temperature fluctuation on
ductivity and the magnetic permeability characteri-
the measuring values. If the temperature of the test
sing the material to be tested. Different materials and
parts is precisely enough captured by an on-site ex-
microstructures lead to little variations that can be de-
ternal sensor which is directly connected to the eddy-
tected. However, both sizes also show a temperature
visor, the influence of the temperature may almost be
dependency. The electric conductivity decreases, for
entirely compensated. Test parts appear as if tested
example, by 4 % per 10°C. Slow variations (e.g. of
at the same temperature. Pseudo reject is reduced
the ambient temperature) are compensated by ibg by
and the test will be more precise. The iTAS visualisa-
means of the differential coil principle where the test
tion enables quick cognition how big the temperature
part is compared with the compensation part.
influence is in comparison with other parameter fluc-
Test parts are often heated up due to the production tuations (batch and dimension differences etc.) at a
process, they cool down during pauses of producti- concrete test application.
on and have a different temperature when they are
• Tolerance zones
During material data recording the eddyvisor auto-
matically generates elliptic tolerance zones calcu-
lated for reliable testing. A tolerance zone editor is
integrated for special situations in the structure test
field, a skilful operator may freestyle the fields as
rectangle, or ellipse, reduced or expanded, rotated
or moved, etc.
• Test speed
High speed testing within milliseconds. Us-
ing eight test frequencies and standard set-
ting (25 Hz - 25 kHz), 141 milliseconds only NEW: the rapid AutoStart enables a much speedier and more
precise automatic triggering than up to now. An additional
are needed for the test. In high speed mode
graphic display eases the setting significant also for fast or
only 1 ms is needed for one test frequency dynamic tests.
> 5 kHz. This ease above all dynamic tests.
www.ibgndt.com
digital
®
eddyvisor
Highest test reliability and temperature stability - coils and probes offered by ibg.
digital
®
eddyvisor
Bargraph display of the latest test result of Survey of all test results of eight fundamental
eight fundamental waves (large) and the third waves in the relating tolerance zone
and fifth harmonic (small)
Single ellipse display of all test results at one Bargraph display of test result
fundamental wave frequency
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digital
®
eddyvisor
General features
12
14
16
18
20
22
24
26
28
30 realised with one eddyvisor
32 a second instrument is required
digital
®
eddyvisor
• Counter preset
The function “box counter” monitors the filling height
of containers to avoid overfilling. Testing is paused
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digital
®
eddyvisor
Connections Housing
• IO ports • Two models of eddyvisor are available: Desktop
An optically insulated interface with 32 in- and 32 version eddyvisor D (with retractable feet, inclined)
outputs is available for PLC connection. As option, or as separated switch panel version with operating
a further module with additional 32 in- and 32 out- unit eddyvisor HMI and measuring unit eddyvisor M.
puts can be installed. An allocation of the signals to
the IOs is free in the eddyvisor. • completely sealed and thus suitable for rough pro-
duction environment.
• Gigabit-Ethernet network
• XVGA
The screen may be displayed on another screen by Technical data
means of the XVGA-interface. Essential for train-
ings. Mains: 100 - 240 V, 50/60 Hz
Ambient temperature: 0 - 45°C
• Printer (desktop version 0 - 40°C)
A usual printer can be connected via USB 2.0 or Relative humidity: max. 85 %, non-condensing
Ethernet to print screens or protocols.
Dimensions (w x h x d) / Weight:
• USB 2.0 eddyvisor D 430 x 335 x 271 mm / 13 kg
Two USB 2.0 ports at the front, one underneath for eddyvisor HMI 410 x 308 x 96 mm / 6 kg
data storage. eddyvisor M 410 x 308 x 175 mm / 7 kg
Rear side eddyvisor, equipped with (from left) crack detection module 4-channel, structure test module 8-channel, IO module, mains
digital
®
eddyvisor
410
318
308
15
175,10 95,50
53,11
eddyvisor
22,50
5
25
7
32 25
88,02
24
270,70
front panel
housing
housing 5
308
5
Front USB front panel
eddyvisor
95,5
410
plug outlet
sealing
underneath
measuring unit
170 switch panel thickness
slots 1 - 4 for test boards 5
housing max. 3 mm
back panel housing
1 2 3 4
S C
inside of outside of
switch cabinet switch cabinet 5
308
back panel
inside of outside of
15
17,50 switch cabinet switch cabinet
175
inside of
screws
switch cabinet 4x M6x55
410
USB to HMI
+1
0
mains inlet
cut for switch
289
panel mounting
outside of
switch cabinet
switch panel
www.ibgndt.com
ibg
ibg partners
For more than 30 years, the ibg group has been The headquarters is situated in Ebermannstadt,
a market leader manufacturing eddy current test Upper Franconia, and together with subsidiaries
instruments and setting technology standards. in the US, Switzerland and Great Britain as
Whether for multi-frequency structure verification, well as a competent worldwide partner net-
automatic tolerance zone generation or multi-fil- work, we service our customers in industry and
ter crack and grinder burn detection - again and automotive engineering.
again innovations and inventions of the ibg devel-
opers shape the market and provide advanced
testing solution.
ibg Prüfcomputer GmbH ibg SWISS AG ibg UK Ltd. ibg NDT Systems Corp.
Pretzfelder Straße 27 Galgenried 6 33 Parkview Road 20793 Farmington Rd.
Copyright ibg 2014-04
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