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Turnkey Automated Ultrasonic Testing Systems / Plants
High test speeds, High test densities and Exactly reproducible test reporting
Ultrasonic test equipment and machines are used for fully automatic testing of semi-finished or other products within the manufacturing process. High test speeds, high productivity, good coverage of the profile and exactly reproducible test results are achieved by this method. State-of-art multichannel electronics ensure fast data processing and ease of operation. We offer these state-of-art ultrasonic testing systems from our principal company M/s KARL DEUTSCH GmbH, Germany.
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| Immersion testing for bars & tubes |
Contact free, water jet coupling |
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| Partial immersion for bars & tubes |
Water gap coupling | |
In the design of such testing systems, water is agent used as a coupling medium for the ultrasound to be transmitted into the specimen. The coupling techniques that is commonly used depending upon the specimen's profile is as shown below.
The evaluation of ultrasonic signals in these testing systems is carried out by multichannel electronics. The signals from all the channels are processed real-time. All parameters can be individually set for each channel. The electronics is fast, reporting and documentation is very modern. A fast programmable Time Corrected Gain (TCG) is implemented which compensates for acoustic damping with increasing travel time, so as to achieve a very even testing sensitivity level. One important feature of every automated system is use of precise ultrasonic probes and the physical properties of the probes need to be properly controlled during the production.
Testing System Solutions for various semi-finished profiles:
Strip/Plate Testing System, BAPS - ECHOGRAPH
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The most common application is the pre-inspection of strips which are later used for the manufacturing of ERW-pipes. Many different configurations were built so far: The inspection can be carried in straight test traces or with an oscillating movement of the probes.
ERW Pipe Testing System, SNHF - ECHOGRAPH
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The family of SNHF-ECHOGRAPH-systems allows for the weld inspection of ERW-welded tubes, also with full body and pipe end testing. For online testing, the probe systems are positioned on top of the endless tube directly after the welding point. For the off-line inspection, the probe systems are mounted to a carriage which is linearly moved along the tube; or the tube is moved by means of a trolley and the probe systems are mounted to a stationary boom.
LSAW Pipe Testing System, SNUL - ECHOGRAPH
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For testing longitudinally welded SAW tubes, we offer the SNUL System which provides for inspection of longitudinal flaws, transverse flaws, laminations and an automated weld seam tracking facility in it. A vertically movable machine frame carries all the probe systems and the tube is moved by a test carriage underneath it.
Spiral Pipe Testing System, SNUS - ECHOGRAPH
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The SNUS System is an offline testing system mounted to a machine frame. A pipe carriage produces spiral transportation of the pipe and several probe pairs, with aid of laser-optical seam trackers, inspect the weld in 12 o'clock position. The no-of testing mechanics for probes depends upon the configuration. Longitudinal defects, on-bead transverse flaw detection, tandem testing, sizing with TOFD, lamination testing, pipe end testing, testing of cross welds etc can be realized as per client's needs.
Quadratic and Round Billet testing, KNPS - ECHOGRAPH
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The KNPS System is best suited for testing heavy billets by continuous cast process or billets from cast ingots method. The probe carriers are very tolerant to straightness deviations and testing can be carried out at high speeds with short untested ends. Upto 4 probe holders using highly sensitive, peizo composite, round immersion probes can be used to check the billet from all its four sides.
Black Bar Testing System, STPS - ECHOGRAPH
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The key properties of the STPS System for black bar testing are its high testing speed and the simultaneous adjustment of the probe holders. Various setup configurations can be offered, depending upon the profile to be tested, its dimensions and its coverage needs. Core and internal flaw detection is carried out by straight beam probes and surface near flaws are targeted by angle beam probes.
RPT - ECHOGRAPH for tube and bar testing
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The RPT System concept utilizes a rotational mechanism for the specimen under test, while a testing traverse carriage with ultrasonic probes is moved translationally. Many systems are in use worldwide to test tubes and solid bars (aluminum, steel etc) with this testing system concept.
RPS - ECHOGRAPH for tube and bar testing
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The RPS System concept also utilizes a rotational mechanism of the specimen under test, while a stationary and compact probe holding system from below, ensures a good coverage of the cross section. Incase of tube testing, longitudinal flaws, transverse flaws, oblique flaws, wall thickness and tube diameter measurements are achieved. And in case of bar testing, longitudinal flaws, core and internal flaws, oblique flaws are reliably detected.
HRP - ECHOGRAPH for tube and bar testing
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The HRP System is a very advanced system providing very high inspection speeds, high throughput rates, the highest testing sensitivity and 100% coverage of the specimen cross section. This concept uses a water chamber in which test cassettes are inserted from the top. Full coverage of the near-surface region is accomplished with angular sound incidence produced by line-focussed foil-probes. Incase of bar testing, Straight-beam incidence with several immersion probes with round crystal ensures full coverage of the core section. Incase of tube testing, longitudinal flaws, transverse flaws, wall thickness measurement etc in very high diameters can be achieved.
SCHN - ECHOGRAPH for Rail Testing
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The SCHN System incorporates many probes in holders which can be freely positioned over most of the rail profile. SCHN incorporates 7 probes for inspection of the rail head, 6 probes for the web and 3 probes for checking the rail base. Free water jet coupling leads to short change over times and little wear of the mechanics.
STFL - ECHOGRAPH for gas cylinder testing
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The STFL System employs probe carriages from the top and tests the cylindrical part of the pressure cylinder in a helical testing trace. While the cylinder is rotating, probes are linearly guided along the longitudinal axis of the cylinder. Detection of longitudinal defects, transverse defects, laminations, wall thickness measurements etc can be achieved in this system.