Mechanical engineering

High level of automation and possibility of unmanned testing

From the production of agricultural equipment, construction machines or machine tools to cranes and car wash installations through to large industrial plants – hardness testing plays a very important role in quality assurance in mechanical engineering.

Specimens can vary widely in size – from small (e.g. gear wheels in gear motors) to large (e.g. in the testing of welded joints on components of a car wash installation or a gear wheel for a wind turbine measuring several metres in diameter).

Frequently, large numbers of the same part are tested, so a high degree of automation in the hardness testing process and the possibility of unmanned testing are key criteria in selection of the appropriate hardness testing machine.

Mechanical engineering

Our references

Palfinger AG - DuraVision & DuraScan

Weld seam hardness testing - with DuraVision and DuraScan

Tests for various materials
Testing procedures: single measurements, serial measurement, CHD measurement
Testing methods: Vickers, Rockwell, Brinell
Fully automatic evaluation
Large number of test points
Comprehensive visualisation of results
User friendliness
Product, service, and calibration from one provider

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"We provide premium quality. We are confident that EMCO-TEST products meet our quality requirements. Another important criterion for us was the service network and the competence of the employees. "

Bernhard Eicher, Head of the Palfinger CCF Analysis Center

Bosch - DuraScan

M + S Hydraulic - DuraVision

Rockmore - DuraScan

Wippermann jr. GmbH - DuraScan & areaMaster

Anonym - DuraJet

“

The fast and reliable functioning of the DuraScan 70 persuaded us on our first demonstration.

Matthias Richter

,

Engineering

“

We are confident that EMCO-TEST products meet our quality requirements.

Bernhard Eicher

,

Head of the Palfinger CCF Analysis Center

“

If we had to describe our hardness tester in just three words, we would call it fast, easy and convenient.

Jan Ivanov

,

Head of Physics Laboratory

Hardness testing in mechanical engineering

Application examples

Automated hardness testing - with DuraVision Semi-Automatic or DuraJet G5

It is possible to integrate a hardness tester into a production line via a hardware interface. This enables external control of the machine.

External machine control
Option to connect foot switch

Both the DuraVision Semi-Automatic universal hardness tester and the DuraJet G5 Rockwell tester are equipped with an additional interface. This additional interface allows 100% tests to be conducted without having to remove test specimens from the production process.

Another option is to connect the available foot pedal to the interface, in order to use this for performing the clamping movement to fix a workpiece. The significantly simplifies handling in tests on large, unwieldy components.

Test data management - with DuraJet G5

In order to save all available test data simply and clearly, the DuraJet G5 Rockwell tester can archive the data in a structured manner.

Standard test data management
Grouped test data management, e.g. for batches, departments, etc.

The preferred type of test data management is selected prior to testing. In the standard test data management system, all results are stored in a collective list.

If test data needs to be associated with individual users or user groups, specific components, batches or departments, then the grouped data management function should be used. All the determined test results are compiled in separate lists, allowing them to be clearly represented, exported or saved as a report. The groups created can be reloaded at any time and augmented with additional test results.

Weld sample mapping - with DuraScan Automatic (50, 70, 80) and areaMASTER software module

The fully automatic DuraScan micro hardness tester in combination with the areaMASTER software module is suitable for determining the hardness distribution of a weld sample and displaying it clearly.

Contour scan with edgeAssistant
Automatic test point distribution
Depiction of the hardness distribution

After selecting the test type (mapping) and test method (e.g. HV1) in the ecos Workflow operating software, the next step is for the contour of the specimen to be traced automatically with the help of edgeAssistant. Subsequently, all that remains to be done is to enter the required test point spacings. The software automatically distributes these across the specimen and the measurement can be started.

Once the measurement has been completed, a hardness profile of the weld sample (similar to a finite element analysis) is provided, which clearly displays the hardness distribution in a colour "hardness map" (in 2D or 3D).

More about the AareaMASTER

Micro hardness testing of welded joints - with DuraScan Automatic (70,80)

Weld sample testing according to DIN EN ISO 9050 can be conducted simply, in a time-saving manner, with the fully automatic DuraScan micro hardness tester.

Simple test sequence creation
Positioning with a panorama function
Time-saving template mode

First, the test type (sequential) and test method (HV0,1-HV5) are selected in the ecos Workflow operating software. The test points can be arranged conveniently in a grid pattern in the test point editor. The test sequences can be adapted automatically to the contours of the workpiece using the line and polygon tool. Another integrated tool makes it possible to adhere to the standard-compliant spacings. The position of the test sequences can then be defined simply and transparently in the real-time image. Larger specimens are likewise completely mapped using the panorama function.

A template for every measured and archived specimen is also created automatically. This template can then be used with the next weld seam and positioned on the workpiece using the rotation axis. In this way, even complicated test tasks can be carried out quickly in a matter of clicks.