DEFECTOMAT® DS 2.815 .. Eddy-current testing system with digital systems technology for automatic, high-resolution multi-channel on-line flaw testing of wires, bars and tubes made from ferromagnetic, austenitic steel and nonferrous metal with encircling or segmented through-put coils .. Universal testing system, adaptable for individual applications and requirements .. WINDOWS®-based operator guidance with application assistants .. Real-time visualization of the test process with original signal display .. Continuous monitoring of operating safety .. Comprehensive test documentation for each component and each flaw resp. each section

2.815 – 08/2006 2 Features .. The FOERSTERnet enables free access to the DEFECTOMAT DS by any number of computers .. An Ethernet interface and TCP/IP protocol enable unrestricted network integration in existing production and quality systems .. The operating software is based on WINDOWS and provides TCP/IP interfaces to other WINDOWS programs .. Simplified device adjustment based on material and test line data .. Tested adjustment sets can be stored on the hard disk or centrally in the network .. Work instructions for the operator can be defined with the adjustment set .. Comprehensive adjustment...

3 2.815 –- 08/2006 • Connectable sensor systems: all usual coil types (encircling, segment and scanning probes) • Material diameter according to sensor system: • Test result logging: - Event-related with logging of each individual flaw in case of piece testing - statistics logging of flaw densities per sections in the case of wire testing - Calculation of a Quality Index for each section and for each coil of wire - all result information is referenced to the test piece resp. coil of wire and the test request - M40/90/170 - H40/90 - P12/40 - S(LSP/LSM) 1 to 40/90/170 mm 1 to 40/90 mm 0.3 to 12/40...

2.815 – 08/2006 4 Wire testing Figure 3: Wire testing Coil to Coil Evaluation of flaw occurrences for testing quasicontinuous material, e.g. in spoolers or hot wire mills. The evaluation can take place either statistically with flaw density by section, or in counting events as with piece testing (e.g. in accordance with EN1971 when testing Cu tubes). The statistical evaluation – typically used with hot wire testing – provides flaw densities per section and calculates quality indices for each section and for the total wire coil. Flaws at the end of the coil can be suppressed within a defined crop...

5 2.815 –- 08/2006 Operating principle Figure 5: Through-put coil with differential and absolute winding system The sensor systems operate according to the eddy current principle in accordance with EN 12084. The electrical test signals are generated by the electromagnetic interaction between the test object and test coil when the test object passes through the coil. Encircling test coils in a multi-differential configuration are used for most test tasks. Adjacent material areas are compared using differential coils. Short surface flaws that run deep into the material are detected by the differential...

2.815 – 08/2006 6 Device structure A complete testing system consists of the following component devices: • Electronic test unit (1) • Operating computer (2) • Software (3) • FOERSTERnet (4) • Housing (5) • Sensor system (6) • Magnetization if necessary (7) • Accessories and options (8) Figure 6: Structure DEFECTOMAT DS Electronic test unit 19" card rack with 8 height units to accommodate the functional units. The outfil depends on the number and type of used sensors • One or several test channels - Test channels with 8 switch-selectable test frequencies Standard set 1: 1–3–10–30–100–300–1000–3000...

7 2.815 –- 08/2006 Operating computer PC with WINDOWS operating system, Ethernet plug-in card, operating software installed and operational. • Integrated PC Display and operation in cabinet/housing - Powerful Pentium computer, all operating elements located in cabinet/housing - TFT tilting colour display - Hinged keyboard - Touch screen operation: All mouse functions are triggered by touching the screen directly with fingertips or a pen - Standard mouse parallel to the touch screen • Built-in PC Monitor and keyboard separate - Powerful Pentium computer installed in cabinet/housing - TFT monitor...

2.815 – 08/2006 8 Options Figure 9: Hierarchical structure of result display • Result archiving on CD - Possibility of archiving all test results in a open database for long term storage with the aid of a 2nd hard disk, a CD burner and the corresponding SW • Result investigation - Graphical research mode using the stored results with display of every part and every flaw, resp. each section - Printout of the stored results in every level of detail - With FOERSTERnet option possible from every PC in the network • Tail marking - Control of a maximum of 3 marking guns to mark the tails of the test...

9 2.815 –- 08/2006 Figure 11: FOERSTERnet, distributed terminals Figure 12: FOERSTERnet, centralized terminal • Software interface - Call-up of operating functions from other WINDOWS applications via TCP commands - All setting parameters can be read individually or in groups and can be written individually - Control of the internal setting archive through remote call-ups - Notification of new test results in the result database for synchronization of the result transfer Housing Figure 13: Compact housing 12 height units, electronic test unit, integrated PC, schematic 1 Electronic test unit PCB...

2.815 – 08/2006 10 Sensor systems The various sensor systems have their own leaflets. Detailed information can be found in these leaflets: Order no. Sensor system M 40 /M 90 / M 170 137 362 5 Sensor system P 12 /P 40 / P 40 T 138 133 4 Sensor system H 40 / H 90 137 364 1 Sensor system T 60 163 845 9 Sensor system S 136 056 6 The next larger sensor system in each case thus also covers the respective overall range of the smaller sensor system. Depending on the largest respective nominal diameter, the sensor systems M 90 and M 170 can be extended downwards to 1.2 mm nominal diameter using suitable...