For details, please refer to the PDF file of the "Modern Parts" 2007 issue 5 or the bottom of the download page.
With the recent development of China's automobile industry, the output and variety of automobiles have increased tremendously. As a professional manufacturer with an annual output of nearly 600,000 transmissions, in order to further improve the product quality and reduce the defect rate of parts, and change the previous situation of using metallographic sampling to test the hardness of products, we started to study the eddy current on-line detection technology and in the production process. It is clearly stated that eddy current is used to detect hardness. This process can be used for automated on-line inspection of various types of gears and brackets in the production process, greatly improving the detection efficiency. It is a detection method that can detect the hardness of the product 100% and ensure that the product is not damaged.
Eddy current testing principles and characteristics <br> <br> eddy current testing for the basic principles of electromagnetic induction. When the detecting coil carrying the alternating current approaches the tested conductive test piece, eddy current is induced on the surface and the near surface of the test piece due to the action of the detecting coil magnetic field. The size, phase and flow trajectory of the eddy current are related to the electromagnetic characteristics, geometrical dimensions and physical properties of the test piece. The magnetic field generated by the eddy current causes the impedance of the detection coil to change. Therefore, by measuring the change in the impedance of the detection coil, the quality or characteristic information of the workpiece to be inspected can be obtained. This detection method does not need to damage the workpiece, so it is called non-destructive testing, and is used for flaw detection, material sorting, heat treatment hardness sorting, conductivity measurement, coating thickness measurement and the like. The comparison between eddy current technology and metallographic technology is shown in Table 1. It can be seen that the eddy current on-line detection technology can completely replace the metallographic sampling detection technology in the production process. Therefore, the application of eddy current on-line detection technology in the production process is feasible, reliable, economical and necessary.
Eddy line detection equipment exploration and research <br> <br> according to product design requirements, we have developed a workpiece eddy current testing and process requirements (planetary gear, for example).
1. Detect the workpiece (see Table 2)
(1) Main reduction planetary gear Figure No. 24217378, material: AISI-SAE5120M (20CrHM).
(2) Follower carrier planetary wheel Figure No. 24217371, material: AISI-SAE5120M (20CrHM).
(3) Output bracket planetary wheel Figure No. 24217369, material: AISI-SAE5120M (20CrHM).
2. Process requirements According to the above-mentioned test workpiece and process requirements, through the international bidding, the products of the two companies meet the technical requirements of the bidding, and the comparison table is made through research and comparison, as shown in Table 3.
Through the fair and impartial assessment, the company's products were finally selected. The specific system is described as follows:
All the machines except the eddy current mainframe are designed and manufactured by a Canadian company. The eddy current host adopts the German Roman online eddy current detector.
German Roman eddy current detector IS, the main performance indicators are as follows:
(1) Function 1 application: Industrial online eddy current testing host, which is generally used to evaluate the conductivity and magnetic properties of conductive materials or parts, identify material anisotropy and hardness deviation of raw materials or parts, and has hardness sorting function, with dual channel and independent Adjustable to effectively suppress interference.
2 Hardness sorting: Configure the hardness sorting sensor to perform effective automatic sorting on the specified parts.
3 Thresholds and alarms: Threshold alarms include Y+ and Y-, X+ and X-amplitude thresholds and box-shaped alarms, vector alarms; alarms can be triggered as sound, light or external alarm lights.
4 interface: RS232/RS485 interface can be connected to the host computer control system or printer.
5 status indication: LED is used to indicate power status, system error, threshold alarm, etc.
6 outer casing: closed die-cast aluminum alloy casing, IP54 industrial protection standard.
(2) Parameters...
Through the implementation of the project, the on-line detection of eddy current hardness of all planetary gears in the "4T65-E" project was completed. Not only one line can complete the inspection tasks of all three parts, saving nearly 60% of the investment, more importantly, we have mastered the most advanced eddy current testing technology abroad, which fills the blank of the eddy current online testing of our factory, which is of great significance. "The replacement of metallographic hardness test by eddy current on-line detection technology" has been listed as a new process development project of our 11th Five-Year Plan.
With the recent development of China's automobile industry, the output and variety of automobiles have increased tremendously. As a professional manufacturer with an annual output of nearly 600,000 transmissions, in order to further improve the product quality and reduce the defect rate of parts, and change the previous situation of using metallographic sampling to test the hardness of products, we started to study the eddy current on-line detection technology and in the production process. It is clearly stated that eddy current is used to detect hardness. This process can be used for automated on-line inspection of various types of gears and brackets in the production process, greatly improving the detection efficiency. It is a detection method that can detect the hardness of the product 100% and ensure that the product is not damaged.
Eddy current testing principles and characteristics <br> <br> eddy current testing for the basic principles of electromagnetic induction. When the detecting coil carrying the alternating current approaches the tested conductive test piece, eddy current is induced on the surface and the near surface of the test piece due to the action of the detecting coil magnetic field. The size, phase and flow trajectory of the eddy current are related to the electromagnetic characteristics, geometrical dimensions and physical properties of the test piece. The magnetic field generated by the eddy current causes the impedance of the detection coil to change. Therefore, by measuring the change in the impedance of the detection coil, the quality or characteristic information of the workpiece to be inspected can be obtained. This detection method does not need to damage the workpiece, so it is called non-destructive testing, and is used for flaw detection, material sorting, heat treatment hardness sorting, conductivity measurement, coating thickness measurement and the like. The comparison between eddy current technology and metallographic technology is shown in Table 1. It can be seen that the eddy current on-line detection technology can completely replace the metallographic sampling detection technology in the production process. Therefore, the application of eddy current on-line detection technology in the production process is feasible, reliable, economical and necessary.
Eddy line detection equipment exploration and research <br> <br> according to product design requirements, we have developed a workpiece eddy current testing and process requirements (planetary gear, for example).
1. Detect the workpiece (see Table 2)
(1) Main reduction planetary gear Figure No. 24217378, material: AISI-SAE5120M (20CrHM).
(2) Follower carrier planetary wheel Figure No. 24217371, material: AISI-SAE5120M (20CrHM).
(3) Output bracket planetary wheel Figure No. 24217369, material: AISI-SAE5120M (20CrHM).
2. Process requirements According to the above-mentioned test workpiece and process requirements, through the international bidding, the products of the two companies meet the technical requirements of the bidding, and the comparison table is made through research and comparison, as shown in Table 3.
Through the fair and impartial assessment, the company's products were finally selected. The specific system is described as follows:
All the machines except the eddy current mainframe are designed and manufactured by a Canadian company. The eddy current host adopts the German Roman online eddy current detector.
German Roman eddy current detector IS, the main performance indicators are as follows:
(1) Function 1 application: Industrial online eddy current testing host, which is generally used to evaluate the conductivity and magnetic properties of conductive materials or parts, identify material anisotropy and hardness deviation of raw materials or parts, and has hardness sorting function, with dual channel and independent Adjustable to effectively suppress interference.
2 Hardness sorting: Configure the hardness sorting sensor to perform effective automatic sorting on the specified parts.
3 Thresholds and alarms: Threshold alarms include Y+ and Y-, X+ and X-amplitude thresholds and box-shaped alarms, vector alarms; alarms can be triggered as sound, light or external alarm lights.
4 interface: RS232/RS485 interface can be connected to the host computer control system or printer.
5 status indication: LED is used to indicate power status, system error, threshold alarm, etc.
6 outer casing: closed die-cast aluminum alloy casing, IP54 industrial protection standard.
(2) Parameters...
Through the implementation of the project, the on-line detection of eddy current hardness of all planetary gears in the "4T65-E" project was completed. Not only one line can complete the inspection tasks of all three parts, saving nearly 60% of the investment, more importantly, we have mastered the most advanced eddy current testing technology abroad, which fills the blank of the eddy current online testing of our factory, which is of great significance. "The replacement of metallographic hardness test by eddy current on-line detection technology" has been listed as a new process development project of our 11th Five-Year Plan.
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