NDT test facilities


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NDT test facilities

MT test facilities

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Prüftisch 051-100 - Test equipment for magnetic particle testing

The 051-100 test table is designed for testing the following test objects

  • cylindrical
  • rectangular
  • irregularly shaped

The magnetic particle testing system is equipped with

  • 2 x 230 V sockets for connection of a hand magnet
  • 2 x UV lamps type ZERO 400/3 with swivel arm
  • Hydraulic power unit
  • Hydraulic drive for rotation of cylindrical test objects
  • Collecting basin with drain
  • Control cabinet
  • Control panel with foot switch for left/right rotation

Technical data

Supply voltage3 x 400 V 50 Hz
Control voltage230 V 50 Hz
Power consumption1.5 kVA
Drive power of hydraulic unit1,500 W
Intensity UV illumination (at a distance of 400 mm)approx. 3,800 µW/cm2
Roller diameter150 mm
Roller speed (steppless adjustable)0 min-1 - 50 min-1
Test table dimensions1,500 mm x 1,000 mm x 1,000 mm
Height worktop590 mm
Weightapprox. 300 kg
Test part:
Dimensions (on roller guide)L = 250 mm - 1,000 mm
∅ = 100 mm - 650 mm
Weightmax. 1,000 kg
Item number :139.900.051
Min: 1
Step: 1
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HELLMAG Universal crack detection bench

The crack detection bench HELLMAG Universal 500 AC, HELLMAG Universal 700 AC and HELLMAG Universal 1000 AC are designed for small series testing as well as for practical testing in the training area.
  • Mechanical clamping of the test object via two quick-action clamping devices for optimum electrical and magnetic contact
  • 2 individually switchable magnetisation circuits (alternating current flooding / alternating current yoke magnetisation)
  • Operation via colour touch panel "KTP 600" (Siemens)
  • Storable test current settings
  • Powerful UV LED stationary lamp
Technical data HELLMAG Universal 500 AC HELLMAG Universal 700 AC HELLMAG Univeral 1000 AC
Art. no. 139.900.330 139.900.310 139.900.320
Clamping length 60 mm - 500 mm 60 mm - 700 mm 150 mm - 1.000 mm
Current flow 1,200 A eff. 1,200 A eff. 2,000 A eff.
Field flow approx. 12,000 Aw approx. 12,000 Aw approx. 20,000 Aw
Duty cycle 40 % 40 % 40 %
Data storage yes yes yes
Data transmission yes yes yes
Mains connection 400 V 50 Hz 32 A 400 V 50 Hz 63 A 400 V 50 Hz 125 A
Power consumption max. 18 kVA max. 28 kVA max. 55 kVA
Dimensions (without cabinet) approx. 125 cm x 64 cm x 160 cm approx. 160 cm x 50 cm x 165 cm approx. 250 cm x 80 cm x 140 cm
Weight approx. 303 kg approx. 480 kg approx. 790 kg


HELLMAG Universal 500 AC
HELLMAG Universal 700 AC
HELLMAG Universal 1000 AC
Item number :139.900.330
Min: 1
Step: 1
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HELLMAG Vario 2500 AC crack detection bench

HELLMAG type Vario 2500 crack detection bench is used for combined MT testing of wheelset shafts for longitudinal and transverse defects.
  • Component holder can be moved manually, with pneumatic clamping
  • Turning device for component rotation
  • 2 stepless adjustable magnetisation circuits (alternating current flooding / field flooding by alternating current coil magnetisation - overflow coil)
  • Enclosure with darkening via curtains and roller shutters
  • Horizontally movable, powerful UV LED stationary lamp
  • Communication via industrial ethernet
  • Siemens Simatic PLC with control panel and touch panel
  • rinsing by means of ring shower and hand shower
  • Detection medium tank with circulation pump
  • Control cabinet with control and power unit

Technical data

Supply voltage 3 x 400 V / 50 Hz / 125 A
Power consumption 75 kVA
Duty cycle 60 %
Clamping length 500 mm x 2,500 mm
Current flow max. 3,000 A stepless
Field flow max. 2,500 Aw stepless
Control voltage 24 V DC
Diameter test object min. 170 mm, max. 350 mm
Weight test object max. 500 kg
Operation Control panel, foot switch
Operating modes Magnetisation
Dimensions 4,500 mm x 2,500 mm x 3,000 mm
Weight approx. 2,000 kg
Item number :139.900.000
Min: 1
Step: 1
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ZER-O-MAT® magnetisation system

ZER-O-MAT® test system enables rapid magnetic particle testing in continuous operation on the

  • Outer surface of pipes, billets, rods, hollow sections and similar test parts.
  • Quadratic/rectangular cross sections, irregularly shaped objects and pipe ends can also be inspected
  • Use of the patented U-shaped ZER-O-MAT coil developed at HELLING
  • Magnetisation in longitudinal and transverse direction
  • Contactless magnetisation (avoidance of contact or burn-in points)
  • Effective magnetisation of the surface to a depth of approx. 1.5 mm (skin effect)
  • Continuous operation with helical transport of the test part through the magnetising coil (max. ED 100 %)
  • Demagnetisation realised by the process
  • Powerful UV LED stationary lamp for inspection
  • Height adjustment of the ZER-O-MAT coil for the Adaptation to test object diameter
  • Siemens Simatic PLC with control panel and touch panel Communication via Profibus or Industrial Ethernet
  • Integrated flushing with 2 x 40 L detection media container
  • Compact system design with ventilated Darkening cabin and extraction channel for e.g. grinding work
  • Separate control cabinets for control and power unit

Technical data

Mains connection3 x 400 V / 50 Hz / 250 A
Power consumptionmax. 70 kVA
Duty cycle100 %
Control voltage24 V DC
Magnetisation coilZER-O-MAT coil
Magnetisationmax. 12,000 Aw
Length test section600 mm
Test object diameter∅ 170 mm - 400 mm
OperationControl panel and foot switch
Dimensions (WxLxH)5,000 mm x 2,500 mm x 3,000 mm
Weightapprox. 2,500 kg
Item number :100.000.999
Min: 1
Step: 1
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ROD-A-FLUX wheelset testing facility

HELLING wheelset inspection system is designed for detecting

  • surface defects and
  • defects near the surface

determined in the longitudinal and transverse directions on railroad wheels by means of magnetic particle testing. The facility is suitable for testing

  • assembled wheelsets
  • during the production of rail vehicle wheels
  • during maintenance of rail vehicle wheels

The wheel disc testing system consists of a wheel disc holder with rotary drive, swiveling trapezoidal coil, walk-in collecting tray with grating and control panel with foot switch. The trapezoidal coil is used for contactless magnetisation of the wheel disc from the wheel rim to the basket arch. Wheel diameters of 900 mm - 1,200 mm or 700 mm - 1,000 mm can be tested.

The test is performed with a fluorescent water-based magnetic particle suspension under UV irradiation. For this purpose, the trapezoidal coil is equipped with an integrated magnetic particle suspension flushing system. The magnetic particle suspension is supplied from a 10 L, 20 L or 40 L detection medium container.

Technical data

Mains connection3 x 400 V / 50 Hz / 32 kVA
Power consumptionmax. 8 kVA
Duty cycle60 %
Control voltage24 V DC
Magnetic coil5-turn trapezoidal coil
Rotary drive0.4 kVA with frequency converter control
RPM controlstepless
Magnetising currentmax. 1,100 A, stepless
Max. load capacity 800 kg
OperationControl panel and foot switch
Dimensions2,000 mm x 2,000 mm x 1,600 mm
Weightapprox. 400 kg


  • Darkening cabin and UV illumination
  • Extension for UT testing (EMAT)
Item number :131.050.030
Min: 1
Step: 1
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ROD-A-MAT MT wheelset testing facility

MT wheelset testing system for combined magnetic particle testing of wheelset axle and wheelset wheels

  • Contactless magnetisation through coil system
  • Independent high current generators, thus simultaneous testing of wheel and axle is possible

The facility consists of:

  • Steel frame, optionally guided on rail to allow loading and unloading of wheelsets by crane
  • 2 trolleys (movable by hand), each holding a high current generator and a coil
  • Frame screwed to fundament
  • Double roller linear axis for height adjustment of the respective magnetising coil
  • Trapezoidal coil (tiltable) with handle and pushbutton for magnetising wheelset wheels (Ø = 800 mm - 1,200 mm)
  • Segment coil (half coil) with handle and pushbutton for magnetising wheelset shafts up to Ø = 250 mm
  • 2 high current generators with control and display unit:
    • 1x Hellmag 7k:
      3 x 400 V / 50 Hz / 32 A; ED 60 %;
      to supply the trapezoidal coil
    • 1x Hellmag 7k2:
      3 x 400 V / 50 Hz / 32 A; ED 60 %;
      to supply the segment coil
  • Distance monitoring to the wheelset via light sensor
  • Clamping of the height adjustment via lever

Optional extension

  • Distance monitoring to the shaft on the segment coil via light sensor
  • Clamping of the height adjustment via clamping lever
  • UT test system (EMAT)
  • Electrically driven axes
  • Distance measuring system (position indicator)
  • Positioning system of linear axis
  • Integrated image recording
  • Semi-automated testing system with integrated rinsing, UV illumination and powered wheelset pickup
Item number :131.050.045
Min: 1
Step: 1
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PT test facilities

Stationary test facilities - for penetrant testing

HELLING test facilities for penetrant testing are individually manufactured according to the customer's specification. The facilities are mainly made of stainless steel. The control systems are produced by well-known manufacturers.

A test facility is composed of the following process stations:

  1. Pre-cleaning
  2. Washing
  3. Drying  →  at up to 100 °C
  4. Cooling →   up to 40 °C
  5. Application of the penetrant
  6. Washing
  7. Emulsifying
  8. Re-washing
  9. Drying  →   at 60 °C
  10. Application of the developer
  11. Inspection

The equipment meets the requirements of the following regulations:

  • EN ISO 3452-1
  • SAE AMS 2644
  • MIL-STD-6866
  • MIL-I-25135E (replaced by SAE AMS 2644)

European technical regulations regarding occupational health, operational safety and ergonomics are complied with.

If you would like to discuss your specification with us, please send us your inquiry by E-mail!

We would also be happy to guide you through our NDT exhibition in Hamburg and advise you on your testing problem! More information ...

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