19 / 24
Ausg.Nr._20/2017
19
Quality Assurance
diese lokalen Aufhärtungen mit-
tels mikromagnetischer Messef-
fekte bestimmt werden.
Die besonderen Stärken des
3MA-X8-Prüfsystems liegen in
der benutzerfreundlichen An-
lernphase bzw. Kalibrierung und
in einer variablen und robusten
Sensorgestaltung. Ein spezieller
Schwerpunkt liegt in der mehr-
kanaligen Echtzeitfähigkeit des
Prüfsystems.
Das 3MA-X8-Prüfverfahren wird
auf der Blechexpo in Stuttgart
anhand eines Messeexponats
demonstriert: Unsere Hightech-
Prüftechnik ist – wie unter realen
Bedingungen – in einer miniatu-
risierten Walzstraße integriert.
Hierfür werden Testbleche auf der
Walzstraße mit den Prüfverfahren
vermessen und entsprechend
ihren Zuständen als »Blech i.O.«
oder »Blech n.i.O.« erkannt und
gegebenenfalls sortiert.
Smart sensors
for efficient
processes
M
aterial defects in end
products can quickly
result in failures in
many areas of industry, and
have a massive impact on the
safe use of their products. This
is why, in the field of quality
assurance, intelligent, nonde-
structive sensor systems play a
key role. They allow testing com-
ponents and parts in a rapid and
cost-efficient manner without
destroying the actual product
or changing its surface. Experts
from the Fraunhofer IZFP in
Saarbrücken will be presenting
two exhibits at the Blechexpo in
Stuttgart from 7–10 November
2017 that allow fast, reliable,
and automated characterization
of materials and detection of de-
fects (Hall 5, Booth 5306).
When quality testing uses time-
consuming destructive test meth-
ods, it can result in enormous
costs due to damaging or destroy-
ing the products. And given that
testing is restricted to random
sampling, faults in processes
are often not found until a large
amount of scrap has already been
produced. Consequently, nonde-
structive testing method repre-
sent an alternative, and after ap-
propriate adaptation processes,
also a replacement for destructive
methods for the long run.
Cognitive sensors for quality
assurance in production
At this year's Blechexpo, our engi-
neers will demonstrate a robotics-
supported sensor system that can
rapidly and easily be integrated
into production processes. The
automated application of intel-
ligent, nondestructive sensor
systems is not only essential for
ensuring optimum product qual-
ity in production, it is also indis-
pensable for realizing current
machine learning concepts. The
potential use of such systems will
be demonstrated in an exemplary
case of robotics-supported test-
ing of press-hardened parts by
means of EMAT* and 3MA**. EMAT
allows couplant-free testing of de-
fects in sheet metal, while parallel
application of 3MA makes quan-
titative material characterization
possible.
Testing within seconds
The advantages of the robotics-
based combination of the two
sensors (3MA, EMAT) include
rapid testing in mere seconds,
determining and evaluating sev-
eral relevant quality characteris-
tics, as well as the nondestruc-
tive testing of sheet metal. "The
combined sensor-based testing
process allows early detection
of mechanical properties, e.g.,
the residual stress and the hard-
ness of steel, as well as defects
like cracks or necking. This will
save resources, reduce costs,
and contribute to strengthening
manufacturers' competitive po-
sition," explained Frank Leinen-
bach, development engineer at
the Fraunhofer IZFP. The institute
has decades of experience and
expertise in combining and au-
tomating nondestructive testing
methods for production.
Quality assurance during
steel production
The steel-producing and -pro-
cessing industries need non-
destructive testing methods in
quality assurance. Frequently
relevant quality characteristics
include hardness, case depth,
strength, and residual stresses.
In this context, nondestructive mi-
cromagnetic testing methods are
optimally suited for providing fast
and reliable statements on the
quality status of ferromagnetic
materials. "An inspection task
that is being requested frequently
is the monitoring of heavy steel
plates, and the related detection
of localized increases in surface
hardening," explained Sargon
Youssef, researcher and engineer
at the Fraunhofer IZFP. These lo-
calized effects can be detected by
means of micromagnetic measur-
ing effects when the 3MA-X8 test-
ing technology developed at the
Fraunhofer IZFP is applied. The
specific strengths of the 3MA-X8
testing system lie in its user-
friendly learning curve and cali-
bration, as well as in its variable
and robust sensor design. A key
point is the test system's multi-
channel real-time capability.
The 3MA-X8 testing method will
be demonstrated at the Blechexpo
in Stuttgart using a fair exhibit.
As under realistic conditions, our
high-tech testing technology will
be integrated in a miniaturized
rolling line. Here, sheet metal to
be tested will be measured us-
ing the testing method, detected,
and sorted – if necessary – into
"OK sheet metal" or "not-OK sheet
metal".
Text & Bild:
Fraunhofer-Institut für Zerstö-
rungsfreie Prüfverfahren IZFP
Campus E3 1
D-66123 Saarbrücken
Hall 7 Stand 7215