The new requirements of the automotive sector for security parts are more and more strict: TQM Itaca has developed a new workstation for checking hardness, presence of free cementite and nodularity in nodular cast iron (ST 3010 ES). Simplifying the inspection operations means reduced cycle-times that are compatible with 100% in-line inspection – average time for each complete cycle: 4 seconds.
Besides the separation of rejects, it manages the process control in real time, with the relative signalling of instability situations (fully configurable statistical alarms) and evaluation of the production process in line with the guidelines of automotive sector manufacturers.

THE CHECKS
The adopted technologies guarantee extreme speed and optimum results.
· WEIGHT CONTROL by means of a load cell.
· NODULARITY CONTROL by means of sonic resonance, which enables global evaluation of the part and highlights eventual macro-defects.
· CONTROL OF HARDNESS AND FREE CEMENTITE by means of induced currents - known as "eddy" or "Foucault" currents.

THE MARKING
The system consists in the marking of good pieces only: the marking can be made with marking machines (impact, ink-jet, etc).

THE WORKSTATION
The ST 3010 ES workstation can be managed by a single operator who, after visual examination, places the parts on the conveyor belt for the automatic cycle. The complete cycle consists in:

· Visual examination of the part made by the operator
· Loading in position
· Weighing of the part
· Sonic resonance control (nodularity test)
· Eddy current control (hardness and cementite presence)
· Separation of rejects
· Marking of good parts

The single stations (weighing, sonic control, eddy current) work automatically. After the controls, the good part is marked and proceeds on the line, while the reject is transferred to the reject collecting container. The electronics for the management of the workstation are on board the machine. All the movements and the relative safety checks are managed by a single PLC, with evident advantages for programming and type change.

CONFIGURATION OF THE SYSTEMS

A standard product with different configurations in order to satisfy the needs of each customer.
The lay-out of the measuring station is defined according to the available space in the production line. All the dimensions and the positioning of the single components are definable in relation with the needs of the customer.

ST 3010 ES

Single bench, with electrical cabinet and wiring, probes and coil holders, weighing station, marking station, unloading device for good parts / rejects and user interface.

ST 3020 ES

Single bench, tooled as the ST 3010 ES, but is factory prepared for the integration of a second bench - ST 3005 ES - in order to control 2 production lines at the same time. The electronics of the bench ST 3020 ES allow simultaneous and independent control of 2 channels for each inspection (weight, EC, SC); so it is possible to analyse different parts on the 2 stations maintaining the 4 second cycle time and full functionality on both lines.

ST 3005 ES

Addditional single bench, which can be used only if integrated with the bench ST 3020 ES; the 2 benches share the electronics for the instrument control. It is supplied complete with probes and coil holders, weighing station, marking station, unloading device for good parts / rejects and user interface.

PROCESS CONTROL

The measuring instruments send the test results to the Software Itastat 6, that processes the single measurements and gives the operator the global outcome of the test, guaranteeing the maximum ease of use.
An innovative algorithm enables correcting the results of the sonic control correlated to the effective weight of the part. That allows a higher accuracy in the Good/Reject separation, and hence a higher reliability of the control workstation.

The system has full Network functionality, with data saving in an SQL Database and the possibility, through the appropriate Software Italarm, to control the monitoring in real time of all the measuring workstations.