Finding Welds In Automotive Wire
June 17, 2011
In addition to finding butt welds in automotive wire, the Minimac is also capable of detecting laps, seams, slivers, and cracks in magnetic and non magnetic grades of wire at speeds up to 4000 ft/min. Test frequencies can range from 2.5 Hz to 2 MHz.
Magnetic Analysis Corp.’s Minimac® MAC 40 is being successfully used to detect butt welds in stranded copper automotive wire ranging from 10 gage to as small as 24 gage, during the extrusion and coating process. Typically, large spools of wire are run through an extrusion line, which applies a coating, at speeds of 1200 ft/min to 3500 ft/min. However, because it is difficult and time consuming to thread the wire when the end of a coil is near, the beginning of the next coil is welded to the end of the previous one to maintain a constant run. The Minimac instrument uses eddy current technology with high speed test coils to detect the weld and provide outputs that are tracked by the customer’s PLC to allow the weld zone to be cut out down-line, before shipment to the end user.
The Minimac is a high performance, low cost, compact eddy current tester designed for production line applications. The unit is set up and controlled using a separate monitor and keyboard. Complete networking capabilities are included. In the installation described above, the customer uses a portable monitor and keyboard for setup and then allows the tester to run unmonitored until there is a change in the size of the wire being inspected.
In addition to finding butt welds in automotive wire, the Minimac is also capable of detecting laps, seams, slivers, and cracks in magnetic and non magnetic grades of wire at speeds up to 4000 ft/min. Test frequencies can range from 2.5 Hz to 2 MHz.
Optional software can extend its application with the use of instantaneous suppression of the relay output for unwanted signals, and a System-Not-Ready control can stop the line, if there is a problem with the tester or test coil. Test data, including a virtually unlimited number of setups can be stored, recalled, annotated, and printed using a keyboard or keypad.
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Detecting Flaws and Conditions in Wire
June 16, 2011
MAC instruments can handle a range of metal wire including cut lengths, continuous production, stranded, multi conductor, cold drawn, fine diameter, and insulated cable. Carbon steels, stainless alloys, copper, aluminum, titanium and other non ferrous metals can be inspected.
Magnetic Analysis Corp. supplies Eddy Current, Ultrasonic, and Flux Leakage test systems to wire and bar manufactures worldwide. Applications include Eddy Current testers for in line testing with cold heading operations such as spring makers and other parts formers. MAC’s MultiMac® Electronics and Rotary Probe can detect long continuous surface and subsurface defects such as seams and welds, while short defects such as cracks and laps are detected using encircling or segmented test coils. By using the Varimac® or Production Comparator eddy current testers, alloy differences, hardness, and heat treatment may be detected in cut lengths or continuous wires. MultiMac can also be used to check alloy, continuity, and locate welds and splices in insulated cable.
MAC instruments can handle a range of metal wire including cut lengths, continuous production, stranded, multi conductor, cold drawn, fine diameter, and insulated cable. Carbon steels, stainless alloys, copper, aluminum, titanium and other non ferrous metals can be inspected.
Additional items such as markers, controls, demagnetizers and components for mounting the coils or rotaries, and positioning and driving of the material through the test, are combined with the instrumentation to make up a complete test system.
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MAC’s First Multiplexed UT Rotary System Successfully Installed
June 16, 2011
MAC’s new multiplex 180 mm Echomac® ultrasonic rotary system was recently installed in a Russian plant that produces oil country tubular goods (OCTG). The unit is part of a test station that inspects welded ERW line pipe and casing tube up to 168 mm diameter and 7.5 mm wall thickness for lamination, wall thickness, and transverse/longitudinal defects.
Responding to the need for more test channels to detect smaller and smaller defects without sacrificing speed, Magnetic Analysis Corp. engineers developed a new multiplexed ultrasonic transducer design for the way transducers send and receive signals. MAC’s new multiplex 180 mm Echomac® ultrasonic rotary system was recently installed in a Russian plant that produces oil country tubular goods (OCTG). The unit is part of a test station that inspects welded ERW line pipe and casing tube up to 168 mm diameter and 7.5 mm wall thickness for lamination, wall thickness, and transverse/longitudinal defects. Using the new, fully multiplexed 32 transducer elements that feed 20 channels, results were excellent even when testing to 5% threshold, meeting API standards.
MAC’s ultrasonic unit is mounted on a Triple Drive Roll Bench installed as part of the customer’s in-line test system. MAC’s bench provides constant centering which reduces vibrations and allows for leading and trailing upset ends to be accommodated. The entire plant’s production passes the test station which has integrated the MAC ultrasonic system with an existing magnetic flux leakage test unit. MAC’s bench was synchronized with the customer’s conveyor test speed, height, and logic controls. A new multi-collector computer receives data from all testing stations and presents a single traceable report for each tube. The multiplex feature will also be extended to other ultrasonic rotaries in MAC’s product line. MAC also offers flux leakage and eddy current systems for testing tube, bar, wire, and parts. For more information, email info@mac-ndt.com.
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