Automatic In-line Hardness Testers for Rockwell, Brinell methods

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The modern production process requires faster and more accurate quality control and documentation of the test process. Conventional Brinell and Rockwell hardness tests are very time consuming and labor intensive when each test is carried out by an operator, especially in high volume testing or testing of large and heavy test pieces. Add to that, surface preparation and optical evaluation of the test results, and the cost savings of an automated inline hardness test system becomes even greater (“easy to justify” or “even more evident”). In most modern manufacturing industries, it is of upmost importance to deliver maximum efficiency at minimum expense. The use of an automatic hardness tester for Rockwell and Brinell testing with an integrated test surface preparation and optical evaluation has the following advantages:

• Increased productivity
• Quality control of each piece
• Elimination of operator errors
• Documentation of the test process

Our inline hardness testing systems have been designed and developed in order to:

• Be fully incorporated into a production line (no operator is needed)
• Incorporate necessary surface preparation by milling or grinding systems
• Incorporate automatic handling of large number of test specimens
• Operate together with current process control system and contribute with relevant hardness testing results

The inline Hardness testing systems from Qualitest are designed around our high quality hardness testers:

BRINELL HARDNESS TESTING

BRE-AUT is in most cases the best suited tester for brinell testing applications. The Bre-Aut tester is also available as a high volume bench-top or floor standing tester for applications where inline testing is not feasible. To find out more detailed information on the Bre-Aut system in general please follow this link http://www.worldoftest.com/bre-aut.htm.

ROCKWELL HARDNESS TESTING

For inline Rockwell testing, Qualitest engineers match the most suitable tester to your the specific application. In most cases that will be a load cell driven twin Rockwell tester that is able to test for both superficial and regular Rockwell hardness.

The automatic hardness tester works according to the Rockwell and Superficial Rockwell principles with loads from 15kgf to 187.5kgf (147.1N to 1,839N).

Our special patented clamping device facilitates testing that is not affected by deflection of the test specimen, resulting in more accurate measurements.

Standardized Solutions Cuts Cost

We offer a number of pre-designed machines for inline hardness testing; these testers can be modified to your specific needs at a much lower cost compared to designing a new unique tester for your needs. Below follows a brief introduction and application examples for Qualitest inline Brinell and Rockwell test systems, for further information and customized solutions please contact Qualitest:

Brinell Solutions

BRE-AUT S.O.R.

Qualitest offers a number of pre-designed machines for inline hardness testing. These testers can be modified to meet your specific needs at a much lower cost compared to designing a new, unique tester. Here are application examples for Qualitest inline Brinell and Rockwell test systems in operation today.

For more information and customized solutions, please contact a Qualitest engineer at (877) 865-TEST (8378).

This solution was initially developed for high volume inline pipe testing and has since then been integrated in several applications involving other cylindrical components. The system is designed with built-in surface preparation equipment and can be fully integrated into most production processes. Thanks to its high productivity, the BRE-AUT S.O.R. has been universally implemented for automatic testing of oil pipes.

Technical Characteristics:

• Digital Brinell reading
• Test loads

     750kgf (7,357N) to 3.000kgf (29,420N)

• Built-in milling machine for test surface preparation
• Testing time (surface preparation + hardness testing): approx. 25 seconds
• Adjustable milling depth

BRE-AUT B.R.G.

The BRE-AUT B.R.G was developed to handle very large test specimens and specimens of complicated geometry (max. specimen height 1600mm, or 63inches).The rotating arm allows for a radius of 180° to be covered and potentially tested. The design and reach parameters of this tester can be modified upon request. The automatic image analysis system measures the size of the indentation automatically and dramatically improves the accuracy of the test results. The integrated milling machine prepares the test area prior to the indentation. The Bre-Aut B.R.G is also available without the integrated surface preparation.

Technical Characteristics:

Technical Characteristics:

• Optical Brinell reading
• Test loads (as per customers request, but typically) 500kgf (4,903N) - 750kgf (7357N) - 1000kgf (9,810N) - 3000kgf (29,420N)
• Test surface preparation by integrated milling unit
• Maximum milling Ø 40mm, 1.6”
• Milling from 1mm to 4mm depth (40-160thou)
• Adjustable milling speed according to the hardness of the test material.

BRE-AUT M.A.R.

The Bre-Aut M.A.R is a very versatile base frame, specially designed to handle round test specimens. Round components are tested within a very wide diameter range; from Ø 10mm (0.4”) up to train wheels with a diameter of Ø 1400mm (55”) and a weight of 1100kg (2425lb). (See train wheel application below).

The Bre-Aut series test head allows the BRE-AUT M.A.R. to ensure high productivity. The automatic image analysis system is engineered for quick optical measurement of the indentation.

The Bre-Aut M.A.R. system is supplied with an integrated milling or grinding device for proper surface preparation of the test point.

Technical Characteristics:

• Digital Brinell reading
• Test loads: 750kgf (7,357N) - 1000kgf (9,806N)
• Test surface preparation by milling or grinding unit
• Testing time (surface preparation + hardness testing): approx. 40 seconds
• Input parameters can be entered for high/low tolerance sorting, data
• Records, statistics, hardness number
• Readout and additional customized features as needed

BRE-AUT M.A.R. Train Wheel Application

This machine was specially designed for an Automatic in line application for brinell hardness testing of train wheels.

• Fully automated cycle with integrated milling/grinding device for preparation of the test area
• Automatic Brinell hardness control
• Automatic Brinell optical scanning system
• Testing time (surface preparation + hardness testing + optical scanning): less than 60 seconds (transfer of the wheel) 30 seconds

BRE-AUT Brinell T.D.M.

The Bre-Aut T.D.M system meets the special needs of hardness testing of gas cylinders. Our design performs high volume batch testing of cylinders with diameters from 80mm (3.15”) to 350mm (13.80”). The system has an integrated motorized roller line and surface preparation by sanding.

Technical Characteristics:

• Digital Brinell reading
• Test loads
• 750kgf (7.357N)
• Surface preparation by built-in sanding system
• Testing time (surface preparation + hardness testing + selection): approx. 40 seconds (1 test for each bottle)
• Preparation and testing can be carried out simultaneously on two cylinders
• Adjustable sanding depth
• This hardness testing system can be integrated into a production line
• Surface preparation and hardness test are automatic
• A motorized roller way facilitates the handling of the cylinders
• Several hardness tests on the same bottle can be performed on request

 

Rockwell T.D.M.

The Rockwell T.D.M system has been developed to cater to meets the special needs of Rockwell hardness testing of gas cylinders. Our design is aimed at performs high volume batch testing of cylinders with diameters from 80mm (3.15”) to 350mm (13.80”). The system has a double motorized roller line and test surface preparation by lamellar grinding disc for inline testing.

• Digital Brinell HB30 and Rockwell HRC reading (other scales on request)
• Test loads

     187.5kgf (1840N) 150kgf (1471N)

Technical Characteristics:

• Surface preparation by means of built-in lamellar grinding disc
• Testing time (surface preparation + hardness testing + selection): approx. 40 seconds (2 tests at 180° for 1 bottle)
• Preparation and testing can be carried out simultaneously on two cylinders
• Adjustable sanding depth
• This hardness testing system can be integrated into a production line
• Surface preparation and hardness tests are automatic
• A motorized roller way provides for the handling of the cylinders
• Several hardness tests on the same bottle can be performed on request

Rockwell T.D.M. double automatic line

Rockwell V.E.C.

This is an automatic motorized Rockwell and Superficial Rockwell hardness tester designed for high volume batch testing

Technical Characteristics:

• Pre-loads: 3kgf-10kgf (29.4N-98N)
• Test loads:
• 60kgf-100kgf-150kgf (588N-980N-1,471N) (Standard Rockwell)
• 15kgf-30kgf-45kgf (147N-294N-441N) (Superficial Rockwell)
• 15.6kgf-31.2kgf-62.5kgf-125kgf-187.5kgf (153.2N-306.5N-612.9N-1,226N-1,839N) (Brinell)
• Indenter’s stroke: 45mm (1.8”)

Different solutions for surface preparation can be integrated with the system. The components, which may be of different size and geometry, are positioned on specially designed plastic supports, then transported one-by-one to the test area under the hardness tester, clamped by a pneumatic system, and tested.

Note:

The process used for hardness testing, a variation of the Rockwell principle, allows for testing even when there are small deflections in the specimens. Surface preparation is required only in the immediate test area.

General Parameters for Qualitest Control and electrical systems for inline hardness testing solutions:

These parameters can be customized to suit your specific needs

FOCUS ON

All significant parameters for an accurate hardness test, such as scale, tolerance and file description, can be set directly on the integrated touch screen panel, and then automatically sent to the hardness test control displays.

The touch screen panel also allows for setting all the parameters concerning the test specimen. This allows for a fully automatic test cycle that remarkably increases the production rate and prevents any operator error.

The hardness test results are directly shown on the hardness testing control display, one for each hardness tester involved in the system.	Special attention has been given to the electronics in order to satisfy even the most sophisticated requirements and to guarantee continuous working without any interruption; even in critical environments such as heat treating facilities, foundries and other rough production environments.

Automatic Image analysis provides fast and extremely accurate optical analysis of the indentation.

(to be combined with electronics 7)
It is possible to set the parameters for the hardness test directly through the integrated keyboard or mouse. Our inline hardness testing systems make use of Profibus communication system. On request it is possible to implement the software for exporting data to a main data processing system. On request our inline hardness testers can be integrated with most data process systems for exporting data directly to your quality or process control system.

For further information or to place an order for the Automatic In-line Hardness Testers for Rockwell, Brinell methods, please CLICK HERE, call us Toll-Free at: 1.877.884.TEST, or click on the "HOW TO ORDER" Button