TPT January 2025

HANDLING, BUNDLING, PACKAGING & LOGISTICS

Bird’s eye view of MAC’s 105ft, ultrasonic and eddy current equipped NDT system with automated materials handling at RGM’s Illinois plant

Efficient and accurate automated handling system to prevent back-ups or jams

current test, a demagnetiser removes existing magnetic fields in the bars that might counteract the fields induced by the eddy current probes during the test. For detection of internal flaws, the Echomac ® FD-6 eight channel ultrasonic electronics and 100mm rotary were selected. Ultrasonic transducer test signals can penetrate the entire bar, allowing a 100 per cent volumetric inspection to detect core internal flaws, such as cracks, voids and inclusions, as well as some surface flaws. The rotary head mechanism spins the transducer elements and water couplant at speeds up to 2,400rpm around the bar as it is fed through the test. The transducers are housed in holders that facilitate set up for different sized materials. Special attention was paid to the design of the automated handling system to prevent back-ups or jams, while promoting efficiency and accuracy. A conductor PLC with HMI touch screen controls all operations including rotary testers, triple guides, the bench, conveyors, sorting, marking and alarms.

As Andrew Strzalkowski, the founder and president of RGM, said: “We’ve always believed in working with suppliers at the earliest stage possible. The best results come when very specific needs are expressed and exchanged during the initial stages of design consultation.” Now installed by MAC, the large system, which is more than 100ft long, can test rods and bars ranging from 12" to 42" (3.66 to 12.80m) long and 0.75" to 3.5" (19.05 to 88.9mm) diameter at speeds up to 150 fpm (45.72mpm). One of the earliest decisions made was to select an eddy current rotary probe tester. MAC’s 350 Rotomac ® used in this installation, is considered an industry choice for detecting longitudinal, seam-type defects, including cracks, pits, and laps. Operating at 150’ per minute this rotary can detect defects as short as 0.4" to 0.5" and, depending on material quality, defects smaller than 0.004" deep. At RGM, the current mill operation for uninterrupted testing flow is 120fpm, typically set up on 0.10" depth notches. To optimise the accuracy of the eddy

ROUND Ground Metal (RGM ® ), a premier producer of close-tolerance, high-quality round rod and bar, and Magnetic Analysis Corporation (MAC ® ), have joined forces to create a fully automated system that enables efficient, high quality testing of stock for use in industries such as aerospace, heavy equipment, energy and medicine. RGM and MAC designed a system incorporating both eddy current and ultrasonic technologies to test cold finished carbon steel, alloy and stainless rod and bars. The system includes MAC Rotomac ® and Echomac ® test rotaries that detect surface defects and internal flaws

28

www.read-tpt.com

JANUARY 2025