Elektromagnetika

Kelas C
Muhammad Wisnu Cakrawiguna
11/318537/TK/38103
Ali!ation o" Magneti! #arti!le $nse!tion in the %ield o" the &o!omoti'e
$ndustr(
A)stra!t* The magnetic particle method is established since 80 years as a method for the prove of
surface cracks in ferromagnetic material. The MT method (MT = magnetic testing) is one of the most
simple and most sensitive methods in NT. !sing MT surface defects can be detected safely even along
comple" geometries. The most important cause of a damage# the crack# the surface of a component is t$o
times $eaker than the inside. This leads us to the fact that the highest forces affect the $eakest regions of a
part. ue to this# surface crack detection once more sho$s its significance in mass production. %ince the
MT results are al$ays pictorial the magnetic particle testing method is a integral NT method that
perfectly matches the sensory needs of the human inspector. ue to this and due to the fact that the process
of magneti&ation and spraying can be applied upon the $hole surface of the component in one go# the MT
method sho$s a very high potential to be fully automated and production line integrated. The follo$ing
passages $ill sho$ e"amples from the locomotive industry that $ill give an idea ho$ magnetic testing
combined $ith machine vision and a self controlling structure turns into a fully automated and production
integrated NT method.
Ke(words' Non(destructive Testing# Magnetic )article *nspection# +ocomotive *ndustry#
Machine ,ision
$ntrodu!tion
Material defects are un$anted
contaminants right from ra$ material to
furnished products due to inade-uate
process adopted during metallurgical
change manufacturing etc. Material
defects can be appeared in different
forms. .s an e"ample the some defects
have to be mentioned here non metallic
inclusions defects# manufacturers
defects# high surface decarburi&ation
defects# bad microstructure defects#
surface corrosion defects# mechanical
damage defects# surface defect# *nternal
defects etc.
The represented e"amples don/t
have to lead to the failure of the material
in every case. These are merely
e"amined on the material surface and
material insides as $ell as of structure
anomalies# $hich differs from the
standard. efects play a crucial role in
influencing the various materials
properties# and e"hibit comple" structure
on varying length scales from electronic
structure of the defect core (sub
nanometer and belo$) to elastic fields of
the continuum (micrometer and beyond).
efects in materials may be
detected by various processes such as
Magnetic particle inspection# 0(ray
radiography# 1amma radiography#
!ltrasonic ( testing# 2lectrical method#
amping test# Non(magnetic method of
non(destructive testing# 3ptical
holography method and 4ardness test.
This study is limited to
surface5subsurface imperfection $hich
is detected through magnetic particle
crack detection techni-ue each process is
re-uired visual inspection. %o it is
$orking to discuss about visual
imperfection.
,isual testing is probably the
most important of all magnetic particle
crack detection tests. *t can often provide
valuable information about defects. The
visual inspection ho$ever should not be
confined only to the structure being
investigated. *t should also include

neighboring structures# the surrounding
environment and the climatic and
services condition. This test report helps
the component authority to allo$ their
safe use in the installation. ue to time
constraints it $as decided to take up
only magnetic particle crack detection
testing of locomotive components. %o
this is an attempt to learn about the
magnetic particle crack detection testing
of materials in general# but locomotive
gear components in particular.

1+ Magneti! testing o" dri'e sha"ts
3ne application from the field of
the sub suppliers of automotive parts is
the fully locomotive inspection of drive
shafts. 2"ample# rive shafts are
cylindrical parts of a length of 600 mm
to 780 mm and a diameter of 9: mm to
6; mm.
<ig. 9' rive shaft# length' =90 mm
<igure 9 sho$s such a shaft that
is toothed and hardened at both ends.
Typical fla$s on this components are
material a hardening defects. <igure;
sho$s a materials defect after
magneti&ation and spraying $ith M)*
test ink under !, light. The system
basically is designed as a $alking beam
that leads the parts into the single
stations of the inspection process. <igure
6 sho$s the part entrance of the machine
that is designed as a slope on $hich the
parts are piled up in a ro$.
<ig.;' Material defect under !, light
<ig. 6' )art entrance of the M)* system
The $alking beam al$ays takes
out the first part ofthe ro$ and transports
it into the magneti&ation and spraying
station. <igure > gives a vie$ on the
$alking beam transport into the
direction of the magneti&ation station.
<or themagneti&ation of the shafts a
combination of current flo$ and
magnetic flu" method is used. 4ereby
the current flo$ indicates the transversal
and the magnetic flu" method indicates
the longitudinal defects. .bove the
magneti&ation station one can the
spraying device $ith its si" spraying
no&&les. The follo$ing station in
transport direction is the inspection
station. *n case of the drive shaft
inspection system it is designed as a
clamping and turning device (<ig.8). The
illumination is reali&ed by t$o !,
tubes. The camera station $hich is
located above the clamping device
(<ig.=) consists out of eight ??
cameras.

<ig. >' @alking beam in transport
direction
<ig.8' ?lamping and turning device in
inspection station
3ne of the eight cameras is
mounted to a linear positioning system.
This enables the machine to adAust itself
to the different shaft length thatare
processed in the system.
<ig. =' ?amera station
<ig. 7' rive shaft $ith material defectB
1rey scale image of the MT indication
<ig. 8' rive shaft after image analysis
of the machine vision
The figures 7 and 8 sho$ the
component in a grey scale image taken
by the system before and after image
analysis. <or the image analysis of the
shaft every camera is $orking along a
specific area of interest (.3*). 3nly the
first and the last camera is $orking $ith
t$o different areas of interest since they
picture parts of the shaft surface and the
toothed ends of the component. @hile
the splines of the shaft are inspected
only on transversal cracks# the rest of the
surface is tested on longitudinal and
transversal defects. The reason for this
can easily be seen in <ig.7 and 8. ue to
the geometry and shape of the spline it is
impossible not to collect M)* po$der in
the grooves during the MT process. .
machine vision algorithm# like it $as
used at the time this system $as build#
$ould al$ays classify such a indication
as a critical effect and mark the part as
bad. This $ould al$ays lead to a very
high number of reAected parts. . solution

to prevent false reAection in this case
$ould be a kind of a peeling algorithm
that can distinguish bet$een a real crack
and a false indication. %uch an algorithm
peels off the circumference of an obAect
$ith a one pi"el $idth. ue to the fact
that a realcrack indication is much more
narro$ than the false indication of a
groove it is easy to see that a real crack
$ould vanish after one or t$o goes
$hile the indication of the groove $ould
still remain. *n this $ay the automatic
decision $hether a indication is a crack
or a false indication can be made very
easy and safe. The camera set up used in
this machine is fully synchroni&ed to
meet the customers cycle time needs.
.ppending to the inspection station the
$ork piece gets demagneti&ed. This
process is carried out in a yoke the is
build in the same $ay as the yoke in the
magneti&ing station. .fter
demagneti&ation the components are
handed over to a$ashing machine.
<igure : sho$s the technical data of the
drive shaft testing system.
<ig.:' Technical data of the MT shaft
system
<ig. 90' )osition of the shafts inside the
drive section of a locomotive
<igure 90 sho$s $here the drive shafts
are mounted in the drive section of a
locomotive.
,+ Magneti! testing o" !rank sha"ts
<igure 99 sho$s a fully
automated and production integrated
magnetic particle crank shaft testing
system. This type of system is in
1ermany already used by t$o crank
shaft manufacturing companies.
<ig. 99' %ystem for automated magnetic
testing of crank shafts
This system is based on a
magnetisation bench $ith moving coil
and turning yokes. The magnetisation
method is a combination of current flo$
for longitudinal and coil magnetisation
for transversal cracks. uring the
magnetisation process# the test li-uid
$ill be applied by a sho$er that is
integrated into the moving coil. <igure
9; sho$s the magneti&ation station of
the system. The crank shaft is inserted
into the pneumatic $ork piece holder via
a overhead conveyerthat loads the shaft
through the roof of the darkening booth
into the machine. The $ork piece holder
adAusts the crank shaft in bet$een the
yokes that are designed as a clamping
station. .fter the yokes closed# the $ork
piece holder $ill release the shaft. The
shaft is no$ only held in position by the
clamping force of the yoke. uring the
magnetisation the crank shaft $ill be
magnetised by the yokes and at the same

time by themoving coil $hich can be
seen on the left side of fig.9;. .fter the
magnetisation process is carried out# the
coil moves back into its initial position
and the crack detection se-uence begins.
The crank shaft has to be turned to
enable the machine vision system to
inspect it. ueto the fact that such a
shaft has got no symmetrical shape# the
fully automated inspection by cameras is
not trivial. <or the magnetic particle
testing of finished crank shafts the
inspection of all machined surfaces are
necessary. <or a four cylinder crank
shaft# like sho$n in fig.9;# this means
that four Aournals and five main bearings
have to be inspected. )lus several
fittings for counter$eights.
<ig. 9;' Magnetisation station $ith yoke
and coil
3n crank shafts that are designed for a
higher number of pistons very often t$o
related Aournals are not separated but
combined to each other like sho$n in
figure 96.
<ig. 96' 90(cylinder crank shaft (upper
image)# combined Aournals (arro$)B
Material defect on crank shaftB MT
indication
+ooking on the geometry and shape of a
crank shaft it is easy to see that a
inspection using fi"ed cameras $ill not
lead to proper inspection results. uring
one turn of the shaft the Aournals are
moving on a circular orbit around the
main bearings.
<igure 9> sho$s such a set up in
principal.
3ne can see that the obAect to be
inspected $ill constantly change its
position in vertical direction $ithin the
field of vie$ as $ell as its distance to the
camera it self.
<ig. 9>' iagramm of the orbit of a
Aournal
<ig. 98' iagramm of the camera
positions that realise a constant field of
vie$
To realise constant boundary
conditions for the imaging of the
Aournals the cameras have to follo$ the
motion of the shaft. This makes a
hori&ontal and a vertical motion
necessary like sho$n in figure 98. The
hori&ontal motion# that means the motion
that reali&es the stabilisation of the

distance bet$een camera and Aournal#
could theoretically be replaced by using
motori&ed &oom optics. Cut due to the
fact that these kind of optics change their
transmittance in dependence of the focal
length this solution is not practical
compared to the use of a linear a"is.The
variation in transmittanceleads to the
problem that t$o obAects# comparable in
si&e and brightness# in different distances
to the camera $ill be displayed in
al$ays the same si&e but in different
brightness.This means that a $orking
measuring system based on a &oom optic
al$ays has to match its sensor sensitivity
in dependence to the focal length.
<ig. 9=' ?amera station of the crank
shaft inspection system $ith 6(d
positioning unit
<igure 9= sho$s camera station
of the crank shaft MT system. *t is
e-uipped $ith t$o cameras $ith 68 mm
optics. 2very imaging unit is mounted to
6(d positioning system that consists of 6
linear a"is each. *n this $ay al$ays t$o
Aournals can be inspected at once. The
illumination system is e-uipped $ith
t$o !,(+2 sources on each side (<ig.
9= yello$ arro$). The first automated
crank shaft system from year ;000 $as
carrying mercury lamps as illumination
sources (<ig. 97).
<ig. 97' *llumination system of a crank
shaft system $ith mercury lamps
(yello$ arro$)
<ig. 98' Technical data of the system for
crank shaft testing
Anal(sis
The test specimen is adAusted in
the !niversal magnetic particle crack
detection or )ortable magnetic particle
crack detection tester. +et us supply
alternating current through the test bench
$hich causes the generation of magnetic
field and then the magnetic flu" at the
probe ends longitudinally. @hen

dielectric li-uid solution (of kerosene oil
and iron o"ide particle) is made to flo$
over the specimen# therefore the cracks
are clearly visible and can be measured
$ith the help of measuring scale. To
measure the transverse cracks either of
the follo$ing steps are used'
i+ .dAust the specimen as done for
longitudinal cracks. No$# allo$ flo$ of
direct current instead of alternating
current. %o# magnetic flu" generated is
perpendicular to the longitudinal a"is B
thus#transverse cracks are visible and can
be measured.
ii+ ?ontinue to supply the alternating
current to the universal5potable
test bench and rotate the test specimen
bet$een t$o prods by :0 D so that
longitudinal cracks in step (i) become
the transverse cracks in step (ii) and the
transverse cracks in step (i) become the
longitudinal cracks in step (ii). 4ence#
the transverse cracks can be detected and
measured.
Con!lusion
3n the basis of this study# the follo$ing
conclusions may be dra$n'
i+ ,isual techni-ue is useful to find out
the condition of sample and helpful to
get ready for future NT operation.
ii+ Magnetic particle crack detection can
detect transverse as $ell as longitudinal
cracks $hich can be identified and
-uantified.
*t can be concluded that M)?
evaluation must be conducted on
manufactured e-uipment prior to use# so
that failure of e-uipment in stipulated
time could be prevented. *t is also
suggested that condition of vital
components must be subAected to their
condition monitoring at certain interval.
-E%E-E.CE/
Cet& ?2 (9:88). )rinciples of
Magnetic )article Testing#
.merican %ociety for
Nondestructive Testing# ). ;6>#
*%CN
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agnetic()articleFinspectionE.
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