NDT test facilities

MT test facilities

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 voltage	3 x 400 V 50 Hz
Control voltage	230 V 50 Hz
Power consumption	1.5 kVA
Drive power of hydraulic unit	1,500 W
Intensity UV illumination (at a distance of 400 mm)	approx. 3,800 µW/cm²
Roller diameter	150 mm
Roller speed (steppless adjustable)	0 min^-1 - 50 min^-1
Test table dimensions	1,500 mm x 1,000 mm x 1,000 mm
Height worktop	590 mm
Weight	approx. 300 kg
*Test part:*
Dimensions (on roller guide)	L = 250 mm - 1,000 mm ∅ = 100 mm - 650 mm
Weight	max. 1,000 kg

Item number :139.900.051

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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

Version:

HELLMAG Universal 500 AC

⋅

HELLMAG Universal 700 AC

⋅

HELLMAG Universal 1000 AC

Item number :139.900.330

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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 Demagnetisation
Dimensions	4,500 mm x 2,500 mm x 3,000 mm
Weight	approx. 2,000 kg

Item number :139.900.000

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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 connection	3 x 400 V / 50 Hz / 250 A
Power consumption	max. 70 kVA
Duty cycle	100 %
Control voltage	24 V DC
Magnetisation coil	ZER-O-MAT coil
Magnetisation	max. 12,000 Aw
Length test section	600 mm
Test object diameter	∅ 170 mm - 400 mm
Operation	Control panel and foot switch
Dimensions (WxLxH)	5,000 mm x 2,500 mm x 3,000 mm
Weight	approx. 2,500 kg

Item number :100.000.999

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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 connection	3 x 400 V / 50 Hz / 32 kVA
Power consumption	max. 8 kVA
Duty cycle	60 %
Control voltage	24 V DC
Magnetic coil	5-turn trapezoidal coil
Rotary drive	0.4 kVA with frequency converter control
RPM control	stepless
Magnetising current	max. 1,100 A, stepless
Max. load capacity	800 kg
Operation	Control panel and foot switch
Dimensions	2,000 mm x 2,000 mm x 1,600 mm
Weight	approx. 400 kg

OPTIONAL

Darkening cabin and UV illumination
Extension for UT testing (EMAT)

Item number :131.050.030

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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

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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:

Pre-cleaning
Washing
Drying → at up to 100 °C
Cooling → up to 40 °C
Application of the penetrant
Washing
Emulsifying
Re-washing
Drying → at 60 °C
Application of the developer
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 ...

HELLING GmbH

NDT test facilities

MT test facilities

Prüftisch 051-100 - Test equipment for magnetic particle testing

HELLMAG Universal crack detection bench

HELLMAG Vario 2500 AC crack detection bench

ZER-O-MAT® magnetisation system

ROD-A-FLUX wheelset testing facility

ROD-A-MAT MT wheelset testing facility

PT test facilities

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