CIRCOGRAPH® DS 6.430

� Eddy current testing system with digital systemstechnology for automatic, high-resolution,multi-channel on-line flaw testing of wires, barsand tubes made from ferromagnetic, austeniticsteel and nonferrous metal

� Universal testing system, adaptable for individualapplications and requirements

� WINDOWS-based operator guidance with appli-cation assistants

� Real-time visualization of the test process withoriginal signal display

� Comprehensive test documentation for eachcomponent and each flaw

� Continuous monitoring of operating safety

� Clearance compensation with au-tomated adjustment

Features

� The new FOERSTERnet enables free access tothe CIRCOGRAPH DS by any number of comput-ers

� An Ethernet interface and TCP/IP protocol enableunrestricted network integration in existing pro-duction and quality systems

� The operating software is based on WINDOWSNT and provides Active X interfaces to other WIN-DOWS programs

� Optimal local flaw resolution and minimal signalgate resolution according to the probe track width

� Segment allocation of flaws in the same longitudi-nal section enables flaw marking in the correct or-der using several marking units

� Simplified device adjustment based on materialand test line data

� Tested adjustment sets can be stored on the harddisk or centrally in the network

� Work instructions for the operator can be definedwith the adjustment set

� Comprehensive adjustment and function testswith multi-channel synchronous signal display

� Continuous process control with display andmonitoring of the noise level response

� The specified test report in accordance withEN12084 can be adapted to meet cus-tomer-specific requirements

� The test results are saved in a database. Addi-tional evaluations can be implemented easily us-ing standard software, e.g. MS ACCESS

� Sensitivity adjustment can be automated with testflaw or noise level as reference parameters

� Operator interface protected against unautho-rized access by an access code

� Dialogue language of the operator interface canbe extended by loadable translation files

� Context-sensitive online help with additionallyloadable languages

Application

� Eddy-current testing of ferrous, austenite andnonferrous round stock (wires, bars and tubes)for surface flaws (longitudinal flaws) with scan-ning probes in accordance with DIN 54140

� Material surface devoid of scale, bright if possible

� Material diameter from 2 to 130 mm,with rotating sensor system:� Ro 20 2 to 20 mm� Ro 35 2 to 35 mm� Ro 65 5 to 65 mm� Ro 130 10 to 130 mm

� Testing without omission in continuous throughput

� Test speed up to 3m/s depending on sensor system

� Flaw depth resolution from 30 µm

� Single-frequency operation from 30 kHz to 3 MHz

� Number of channels depends on the sensor sys-tem

� Test channel sensitivity correction through auto-matic clearance compensation if the test piece isin an eccentric position in the sensor system

� Extension with a DEFECTOMAT® channel foradditional surface testing of transverse flaws orpoint flaws in connection with a H or M sensorsystem and encircling through-type coils

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Typical applications

Piece testing

The purpose of semi-finished materials testing is notonly to determine whether a test part is flawed orflaw-free, but also where exactly which flaws are lo-cated, as further processing or use can depend onthis.

In many cases, flawed sections can be cut out andthe remaining length can be used; or a part can be re-used after small flawed spots are ground out; or theparts are sorted in different quality classes with vary-ing surface quality, in which not only flaw depth butalso flaw frequency may be relevant.

For all of these cases, the CIRCOGRAPH DS sup-plies the necessary information and control functionsin fully automatic mode.

For this purpose, the length and circumference of theflaw occurrences are evaluated. The decisive factorfor the flaw length recorded is always the componentin the throughput direction (Event Evaluation).

Continuous testing

Evaluation operating mode for testing continuousmaterial without a subsequent cutter.

The CIRCOGRAPH DS adds up the flaw occurrencesover sections of preselectable length and evaluatesthe sections on the basis of the flaw density.

The flaw density is the quotient of the sum of the flawlengths and the section length, and is stated as a per-centage in the protocol.

The evaluation of sections is based on limit values forthe flaw density, not on flaw lengths (Statistical Eval-uation).

Cutting to length

Evaluation operating mode for testing continuousmaterial which will be cut into lengths after testing.

The flaw occurrences are delayed from the test loca-tion to the position of the cutter according to the cur-rent testing speed, and are summed there. After thepieces have been cut, the accumulated sums areevaluated, so that the same result formation and log-ging process applies for the pieces cut into lengths asfor piece testing (without this delay).

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Markieren

Marking

ProtokolldruckerReport printer

FOERSTER CIRCOGRAPH DS 6.430

RotierkopfRotating head

Sortieren

Sorting

EinlaufrollgangEntry roller conveyor

Auslaufrollgang SortiermuldeExit roller conveyor Sorting trough

VereinzelungSeparation

Fig. 1 Piece testing

Markieren

Marking

ProtokolldruckerReport printer

FOERSTER CIRCOGRAPH DS 6.430

RotierkopfRotating head

Sektion wählbarer LängeSection of selectable length

Fig. 2 Continuous testing

Markieren

Marking

ProtokolldruckerReport printer

FOERSTER CIRCOGRAPH DS 6.430

RotierkopfRotating head

Sortieren

Sorting

TrennvorrichtungCutter

Fig. 3 Cutting to length

Wire testing

Evaluation of f law occurrences for testingquasi-continuous material, e.g. in winding units.

The evaluation can take place either statistically bysection as in the ‘Continuous’ operating mode, or inrelation to events as with piece testing (e.g. in accor-dance with EN1971).

Additionally, the remaining section at the end of thecoil will be evaluated in relation to the remaininglength and an overall statistic will be formed.

This includes the tested length, the number of sec-tions and the total flaw densities, i.e. the total flawlengths over all sections divided by the tested length.

Testing for longitudinal and transverse flaws in the finishing stage

The combination of the CIRCOGRAPH DS and anadditional DEFECTOMAT channel provides thehighest degree of efficiency. The CIRCOGRAPH DShas a flaw detection capability for longitudinal

cracks, e.g. on polished bars, of approx. 30 µm. In ad-dition, the DEFECTOMAT channel reliably indicatestransverse flaws and short flaws.

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Markieren

Marking

ProtokolldruckerReport printer

FOERSTER CIRCOGRAPH DS 6.430

RotierkopfRotating head

Sektion wählbarer LängeSection of selectable length

AbwickelnUncoiling

AufwickelnCoiling

Fig. 4 Wire testing Coil to Coil

ProtokolldruckerReport printer

FOERSTER CIRCOGRAPH DS 6.430 CIRCOGRAPH DS 6.430+ DEFECTOMAT

Markieren 1 + 2

Marking 1 + 2

RotierkopfRotating head

Sortieren

Sorting

Vereinzelung

SeparationDurchlauf-PrüfspuleEncircling Test Coil

Fig. 5 CIRCOGRAPH with DEFECTOMAT-Channel, Piece testing

Operating principle

The sensor systems Ro xxx operate with the eddy cur-rent principle in accordance with DIN 54 140. Rotatingprobes rotate at a short distance and at a high speedaround the longitudinally moved test piece and heli-cally scan its surface without physical contact.

The rotating probes scan discrete points, merely reg-istering a small portion of the overall surface at anygiven moment.

In relation to the relatively small registered materialsurface, every material flaw that the probe passesover represents a ‘large fault’.

Therefore, the rotating probe detects extremely smallmaterial flaws with a high resolution.

Each time the rotating probe passes over, extendedmaterial flaws generate a signal so as to ensure thatthe full length of the flaw is indicated.

If a suitable material transport speed (‘test speed’) ischosen, the probe’s test tracks follow in uninter-rupted succession so as to ensure complete scan-ning of the material’s surface.

The maximum test speed is the result of the rotatinghead speed, the number of probes and the probetrack width.

With two probes or four probes, offset by 180° or 90°,the tracks follow in succession without gaps or over-laps when the test piece is transported forwards byone track width in every half or quarter revolution.

The signals picked up by the probes are transferredto the electronic test unit by the sensor system forevaluation.

The field current for powering the probes and theprobe output signals are transmitted without physicalcontact by rotating transformers.

The electronic unit consists of a process-controlledelectronic testing and evaluation unit featuring inter-active operation and convenient display and docu-mentation possibilities.

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SondenwirkbereichEffective probe area

SondenrotationProbe rotation

Riß Crack

RotiersondeRotating probe

Fig. 6 Rotating probe on material flaw

Rotiersonde

Rotating probe

Gesamtfehlersignal

Overall flaw signal

Abtastspuren Scanning tracks

Fig. 7 Scanning track and flaw signals

AbtastspurenScanning tracks

212 21

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1

Fig. 8 Scanning tracks, two probes offset by 180°

Device structure

A complete testing system consists of the followingcomponent devices:

� Electronic test unit (1)

� Operating computer (2)

� Software (3)

� FOERSTERnet (4)

� Housing (5)

� Rotating head (6)

� Motor control (7)

� Accessories and options (8)

Electronic test unit

19’’ card rack with 8 height units to accommodate thefunctional units. The equipment varies depending onthe rotating head connected and whether aDEFECTOMAT channel is installed

� One or several test channels� Test channels with

5 switch-selectable test frequencies(30kHz, 100kHz, 300kHz, 1MHz, 3MHz)

� Automatically adapted filters� Phase adjuster

� Clearance channel

� Digital signal processing� Signal evaluation with 3 amplitude thresholds

Vector signal orY component

� alternatively phase-dependent sector evalua-tion with up to 4 sector areas, each with 3 am-plitude thresholds

� Evaluating computer� Test evaluation in feed direction with a resolu-

tion corresponding to the probe track width(depends on the transport speed)

� Selectable point flaw suppression or recogni-tion of flaw groupings in accordance withEN1971

� Flaw designation with maximum amplitude,phase angle, flaw threshold, position on thetest piece and extent in feed direction

� Flaw number evaluation with adjustable flawseparation

� Part evaluation (sorting class) depends onpermissible flaw numbers or accumulatedflaw lengths

� Automatic part recognition as well asselectable masking of part entry and exit

� Automatic part allocation in the case of cuttingto length after the sensor system

� Direct 3-way sorting with polling signal� Speed measurement by measuring running

time between 2 light barriers or by sending atiming signal in the range 10 pulses/mm to 1puls/mm

� Automatic test operation control with testreadiness signal and noise signal

� Device and sensor monitoring:Continuous noise level monitoring,Monitoring of feed rate with clock check,temperature monitoring of the sensor systemand the electronic test unit

� All line connections with screw terminals for24V DC on the rear panel of the electronic testunit, floating, selectable polarity, inc. 24V sup-ply

� Power supply230V/400V, 50Hz or 60Hz

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FÖRSTER

Fig. 9 Structure CIRCOGRAPH DS

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Operating computer

PC with WINDOWS NT operating system, Ethernetplug-in card, operating software installed and opera-tional.

� Integrated PCDisplay and operation in cabinet/housing� Powerful Pentium computer, all operating ele-

ments located in cabinet/housing� TFT tilting colour display� Hinged keyboard� Touch screen operation:

All mouse functions are triggered by touchingthe screen directly with fingertips or a pen

� Standard mouse parallel to the touch screen

� Built-in PCMonitor and keyboard separate� Powerful Pentium computer installed in cabi-

net/housing� 17" monitor� Industrial keyboard and mouse separate for

operation on a desk

� Stand alone PCInstallation on a desk next to the electronic testingunit or as an additional computer for additionaloperating stations� Powerful Pentium computer in the desktop

housing� 17" monitor� Industrial keyboard and mouse

Software

� Base software

� Operating software on WINDOWS NT for oneoperator terminal

� Guided device adjustment

� Adjustments can be saved

� Automatic adjustment procedures

� Original signal display

� Test result display and logging

� Positionally accurate flaw marking

� Direct 3-way sorting

� All test results are stored in an open database

� Automatic administration of the database sizeto prevent hard disk overflow (holds the last100,000 pieces)

� Result investigation (optional)

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Fig. 10 Dialogue screen Fig. 11 Prompted operation

New adjustmentCIRCOGRAPH

Start adjustment

New adjustmentDEFECTOMAT

Allocation Rights

Assistant Installation

Start Setup

Assistant Setup

Adapt Setup

Load Setup

Start New Report

� Graphical research mode using the stored re-sults with every part and every flaw displayed

� Printout of the stored results in every level ofdetail

� Copies of Test Request Results into a MS AC-CESS database for saving purpose or for ad-ditional evaluations

� With FOERSTERnet option possible from ev-ery PC in the network

� Tail marking (optional)� Control of a maximum of 3 marking guns to

mark the tails of the test pieces according tothe sorting result, independent of and in addi-tion to the standard positionally accurate flawmarking

� Selectable marking length and position mea-sured from the end of the test piece

� Compensation of the response delay� Possible via the same marking guns in combi-

nation with flaw marking

� Circumferential marking (optional)Only with cabinet/housing or swivel cabinet� Distinction of the flaw position on the circum-

ference of the part� Up to 9000 rpm 4 circumferential segments� Up to 6000 rpm 8 circumferential segments� Up to 3000 rpm 16 circumferential segments� Segments are distinguished and displayed

during flaw evaluation and can be marked in-dividually (marking assignment depends onthe segment and the type of flaw)

� Includes 16 additional marking connectionswith screw terminals for 24V DC on the rearpanel of the electronic test unit, floating

� Log design (optional)� The design of test logs can be chosen freely� All test results, adjustment data and constant

texts can be used� Type size and format can be selected freely� Log templates can be saved and used to

make a log printout at any time

FOERSTERnet (optional)

� five software licenses for parallel operation ofone electronic test unit from several PC usingEthernet connection

� Each operator terminal has fully functional ac-cess, can be configured and operated inde-pendent of the other operator terminals

� Setting mode can be delegated to every PC inthe network

� Connection to any TCP/IP-capable network(e.g. Internet) via gateway

� Software interface (optional)

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Fig. 12 Test results display

Hierarchical structure

List of testrequests

One test request

Series of parts

One part

Flaw characteristics

Overview

Details

Fig. 13 Log design

� Call-up of operating functions from other WIN-DOWS applications via TCP commands

� All setting parameters can be read individuallyor in groups and can be written individually

� Control of the internal setting archive throughremote call-ups

� Notification of new test results in the result da-tabase for synchronization of the result transfer

Housing

� Compact housing� Sheet steel housing (12 height units) for the

electronic test unit and integrated PC orbuilt-in PC

� IP54� Lockable front glass door� W=555 D=700 H=595

� Cabinet housing� Steel cabinet (37 height units) for the elec-

tronic test unit and integrated PC or built-in PC� free cabinet space (25 height units) can be

used e.g. for printer drawer� IP54� Lockable front glass door� W=600 D=800 H=1800

� Swivel cabinet� Steel cabinet (37 height units) with swivel

frame for the electronic test unit and inte-grated PC or built-in PC, all rear connectionsaccessible from front

� free cabinet space (20 height units) can beused e.g. for printer drawer

� IP54� Lockable front glass door� W=800 D=800 H=1800

� Printer drawer 19“ 6 height unitsFor printer up to a maximum of W=400 D=440H=260(only for cabinet housing or swivel cabinet)

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Fig. 14 FOERSTERnet, distributed terminals Fig. 15 FOERSTERnet, centralized terminal

Fig. 16 Compact housing 12 height units, electronictest unit, integrated PC, schematic

1 Electronic unit PCB2 TFT-Display3 PC4 Hinged keyboard5 Power supply6 Sensor connection and I/O port7 FOERSTERnet port8 Power supply

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Rotating heads

The sensor systems Ro xx have their own Leaflets.Detailed information can be found in the Leaflets:

Order no.Sensor system Ro 20 P 6.460 161 167 4Sensor system Ro 35 P 6.461.01 163 854 8Sensor system Ro 35 L 6.461.21 163 856 4Sensor system Ro 65 6.452 134 546 0Sensor system Ro 130 6.453 134 550 8

� Ro 20 P - standard guidance� Application:

Winders, spoolers Coil-to-coil drawingCoil to piece drawing (part machines)Finishing stage

� Maximum18000 rpm with 2 pin probes� Diameter range from 2 to 20 mm� Mounting dimension in the line approx. 280 mm

� Ro 20 P – Precision guide� Application:

Copper tube windersPrecision pipesBright steel bars,

� Maximum18000 rpm with 2 pin probes� Diameter range from 2 to 12 mm� With a special nozzle set for exact material

guidance and optimum flaw sensitivity� Mounting dimension in the line approx. 280 mm

� Ro 35 P – standard guidance� Application: Wire winders, spoolers� Coil-to-coil pulling� Coil to piece pulling (part machines)

� Finishing� Maximum 9000 rpm with 4 pin probes� Diameter range from 2 to 35 mm� Mounting dimension in the line approx. 310 mm

� Ro 35 P – Precision guide� Application:

Copper tube windersPrecision pipesBright steel bars

� Maximum 9000 rpm with 4 pin probes� Diameter range from 2 to 25.4 mm� With a special nozzle set for exact material

guidance and optimum flaw sensitivity� Mounting dimension in the line approx. 310 mm

� Ro 35 L - standard guidance� Application:

Wire bull-block machinesSteel pipes

� Maximum 9000 rpm, with 4 movable test levers� Diameter range from 5 to 35 mm� Mounting dimension in the line approx. 310 mm

� Ro 35 L - robust guidance� Application:

Coil-to-bar drawing up to a maximum of 35mmmaterial diameter

� Maximum 9000 rpm, with 4 movable test levers� Diameter range from 5 to 35 mm� With special guide nozzles for bull-block ma-

chines and exit-end roller guide� Mounting dimension in the line approx. 310 mm

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Fig. 17 Sensor system Ro 20 P Fig. 18 Sensor system Ro 30

� Ro 65 - standard guidance� Application:

Wire bull blocks� Steel bar finishing� Bright steel bars� Steel pipes� Maximum 6000 rpm, with 2 movable test le-

vers with 2 probes each� Diameter range from 5 to 65 mm� Mounting dimension in the line approx. 390 mm

� Ro 65 - robust guidance� Application:

Coil-to-bar pulling up to a maximum of 65 mmmaterial diameter,

� Rotating head maximum 6000 rpm, with 2movable test levers with 2 probes each

� Diameter range from 5 to 65 mm� With special guide nozzles for bull-block ma-

chines and exit-end roller guide� Mounting dimension in the line approx. 490 mm

� Ro 130 - standard guidance� Application:

Steel bar finishing, Bright steel barsSteel pipes

� Maximum 3000 rpm, with 2 movable test le-vers with 2 probes each

� Diameter range from 10 to 130 mm� Mounting dimension in the line approx. 440 mm

Motor control

For driving the rotating heads, dependent on the rota-tional speed necessary and the braking properties

� MOC E� Basic version for all rotating heads

Ro 20, Ro 35, Ro 65, Ro 130� Fixed rotational speed

9000 rpm for Ro 20,4500 rpm for Ro 353000 rpm for Ro 651500 rpm for Ro 130

� With protective motor switch, switch housingwith Start/Stop buttons and operating display

� Wall mounting,dimensions W=250 H=375 D=150

� The run-out time of the deactivated rotatinghead can be shortened for Ro 20 and Ro 35with the manually operated braking unit

� MOC EV� For increased rotational speed with Ro 20, up

to 18000 rpm continuously selectable� Frequency converter 0.75kW� Switch housing with rotational speed preselec-

tion, Start/Stop buttons and operating display� Dimensions W=600 H=1200 D=300

� MOC S� Maximum rotational speeds for rotating heads

Ro 35, Ro 65, Ro 130� Fixed rotational speed

9000 rpm for Ro356000 rpm for Ro653000 rpm for Ro130can be switched to half speed

� Switch housing with Start/Stop buttons andoperating display

� Dimensions W=600 H=1200 D=300

� MOC SB� With an electric brake for rotating heads

Ro 35, Ro 65, Ro 130� Fixed rotational speed

9000 rpm for Ro 356000 rpm for Ro 653000 rpm for Ro 130can be switched to half speed

� The electrical motor brake shortens the brakingtimes to approx. 1/10 (< 40s), switch housingwith Start/Stop buttons and operating display

� Dimensions W=600 H=1200 D=300

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Fig. 19 Sensor system Ro 65, bar testing

Fig. 20 Sensor system Ro 130, roller guides

Accessories and options

� Light barrierfor measuring the transport speed for each testparttransport speed range from 0.005m/s to 200m/s

� Motion transducerIncremental sensor for determining the transportspeed using a running wheel placed on the testpiece� Running wheel diameter 160mm

1 pulse per mmRecommended for varying transport speed(accelerated parts)

� Up to a maximum of 3m/s� Stand for motion transducer

Support for motion transducer with steplessheight adjustment over 200mm

� Lifter for motion transducer with standPneumatic-electric positioning and lifting ofthe motion transducer onto the test pieceControl signal 24V DC from the feeding con-veyor control (from the customer)

� Colour marking unit 1.176.11To mark the flaw spots on the material, see Leaf-let (1499525)� Connection to electronic test unit� Single-channel, no distinction between differ-

ent types of flaws� Two-channel, for distinction between different

flaws according to colour

� Calibrating setcalibrating or checking the test device� Guide nozzles and test rod with reference

flaws

� Demagnetization EMAG M 2.980see Leaflet (1597825)

� Laser printer with single sheet feeder

� Voltage adaptationto local power supply� All electronic components are designed for

230V, all power components for 3 x 400V50/60Hz with ground conductor

� Adaptation by means of an isolating trans-former for deviating supply voltages,e.g. 3 x 200V, 3 x 440V, 3 x 500V

� Suppression of mains interferencefor 3 x 400V

� Maximum power consumption 7.5kW� Fitted in motor control housing (for MOC E

separate installation)

� Cooling device for cabinet housing or swivelcabinet� With ambient temperature of > 40 to 50EC� With high level of air pollution from dust and

scale� Mounting on the rear door of the cabinet hous-

ing or swivel cabinet� W=320 D=110 H=600