Crack Detection - Autoflux® Cracklight

Autoflux Cracklight

Overview

Autoflux® Cracklight is a crack detection system for magnetic powder inspection (magnetic particles or flux) or penetrating test (PT). It replaces UV radiation with blue LED light and significantly improves the defect detection rate.

Advantages

Using blue light to illuminate parts during crack detection eliminates numerous disadvantages of the method which previously seemed unavoidable:

  • UV protective clothing isn't required. Thus 30-year documentation of the UV exposure of employees isn't required (OStrV)
  • The energy consumption of the LED based technology is only a fraction of the consumption of conventional UV lamps
  • Radiated heat is reduced by a large amoun

The test booth is much cooler as a result, reducing operator fatigue. The significantly cooler hands of the inspection personnel in particular receive very positive feedback. Portable, battery-powered operation becomes a possibility. Integrating the extraordinarily durable and robust system into any testing process is correspondingly easy and fast. In addition to all of these advantages, the crack testing results – manual or automated – are also significantly improved in comparison to conventional systems. See for yourself, ideally during a no-obligation crack detection workshop.

Principle

Depending on the method and the material being tested, the test part is wetted with a magnetised (MT) or unmagnetised (PT) fluorescent testing agent, which accumulates along any invisible cracks which may be present. Then the Autoflux® Cracklight system illuminates the treated part without using dangerous UV radiation. The fluorescent crack detection medium is excited optimally by the blue light, and contrast is in fact even improved significantly. The Autoflux® Cracklight is available from Automation W+R GmbH in a stationary version and in a battery operated portable light version for manual inspections. Our automated crack detection systems use this highly reliable method as well.

Applications

The Autoflux® Cracklight system is available in several versions to meet the different crack detection requirements:

  • Portable Autoflux® Cracklight
    Battery operated inspection lamp. With a weight of only approx. 750 grams and a power consumption of 20 watts, the system can be used for portable flux crack detection with a runtime of up to three hours. Meets DIN EN 62471/2. IP65 protection rating. The portable system allows for easy inspection of larger parts such as steel beams, etc.
  • Stationary Autoflux® Cracklight
    Uniform illumination for manual workstations, with a power consumption of just 50 watts. A work area of approx. 20x40 cm is illuminated with a power of up to 100 W/m² for crack detection. Meets DIN EN 62471/1. Protection class: IP 54
  • Fully automated crack detection Autoflux® Cracklight
    The parts to be inspected are sorted, magnetised and treated with testing media (fluxed) in an enclosed robotic handling system. This is followed by fully automated crack detection using a camera and image processing software. The parts are sorted into OK / NOK and output separately. A typical application for this system is the manufacturing of safety-critical forged parts, e.g. for the automotive industry. Many of our customers also have additional inspections, such as geometry or surface inspections, seamlessly integrated into this automated testing process.