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Operating instructions FOERSTER MAGNATEST D 3.623 Single piece testing 2.0
Operating instructions MAGNATEST D 3.623 Software version 2.0 SGP
Copyright 2004 Institut Dr. Foerster Institut Dr. Foerster GmbH & Co KG retains ownership of all property rights to all information provided in this document. The documents shall support only operation and service of the delivered units. All (direct and indirect) duplication and disclosure to unauthorized third parties is strictly prohibited. So far software is supplied or installed on the system, it is subject to copyright laws. It may be used only for operating the related system in the manner described in the sales documentation or in the User Manual. Any use over and above this is expressively prohibited. Violations of this clause shall entail liability to pay compensation for damages and may also result in prosecution under criminal law. Microsoft and Windows are registered trademarks or trademarks of the Microsoft Corporation in the USA and / or other countries. 30.03.2007
TABLE OF CONTENTS 1 Basic Safety Information
1
1.1
1
Warnings And Symbols
1.2 Safety In Magnetic Fields 1.2.1 Field Effect On People And Physical aids 1.2.2 Whole Body Exposure 1.2.3 Exposure Of Limbs And Information During Work 1.2.4 Field Effect On Magnetic Data Carriers And Watches
1 1 2 2 3
1.3
Principle; Usage To The Intended Purpose
3
1.4
Declaration Of Compliance
4
2 General Information
5
2.1
Intended Application Of The Device
5
2.2
Physical Fundamentals Of Magnet Inductive Test
5
3 Commissioning
6
3.1
Installation (Desktop Device)
6
3.2
Connections
7
3.3 Control Elements Of MAGNATEST D 3.623 3.3.1 Elements Of The User Interface
9 11
3.4
Switching On
13
3.5
Switching Off (Standby)
13
3.6 General Procedure 3.6.1 Preparation of the test device 3.6.2 Calibration 3.6.3 Testing
14 14 14 15
4 Software Description
16
4.1
17
Remote Function
4.2 Series Operation 4.2.1 Generating A Test Order
18 20
4.3 Laboratory Operation 4.3.1 Password Protection 4.3.2 Start Image Laboratory Operation Mode
23 23 25
4.4
27
The Test Definition
4.5 Configuration Of Test Parameters 4.5.1 Representation Of The Spectrum Of The Received Signal 4.5.2 Show All Parameter Settings
31 37 38
4.6 Calibration 4.6.1 Definition Of Reference Part
41 52
4.7 Testing 53 4.7.1 Recalibration
58
4.8 Documentation 4.8.1 Tabular Representation Of Individual Values 4.8.2 Test Classes Of Individual Values 4.8.3 Frequency Distribution Of Sorting Classes
60 63 66 68
4.9
71
Administration
4.9.1 4.9.2 4.9.2.1 4.9.2.2 4.9.3 4.9.3.1 4.9.4 4.9.4.1
Input- / Output Module Configuration Of The Sorting Definition Of Sorting Classes Configuration Of Output Bits Configuration Of Trigger Mode Automatic Threshold Setting Maintenance General Parameter
73 76 77 77 79 84 86 89
4.10 Internal Help Function 4.10.1 Navigation In The Help System 4.10.2 Navigation In The Table Of Contents 4.10.3 Navigation In The Index
98 98 99 100
4.11
Print Function
101
5 Language Selection
103
5.1
Introduction
103
5.2
Installing A Different Language Version Of Windows
104
5.3
Selecting A Different Language For MAGNAWIN
104
6 Maintenance And Service 6.1
Maintenance Schedule
6.2
Cleaning 106
6.3
Calibration
7 Multiplexer
106 106 106
107
7.1
Intended Application Of The Device
107
7.2
Front Side Of Multiplexer
107
7.3
Rear Side Of Multiplexer
108
7.4
Installation
109
8 Technical Data
110
8.1
Dimensions And Weight
110
8.2
General Technical Information
110
8.3
Connections / Peripherals
111
8.4
Technical Data Of The Multiplexer
112
Basic Safety Information
1
BASIC SAFETY INFORMATION
1.1
WARNINGS AND SYMBOLS
The following designations and/or signs are used in these operating instructions in order to give particularly important information: Hint
Note
Danger
1.2
1.2.1
particular information about the economic use of the device. particular information about requirements and/or prohibitions regarding avoidance of damage.
information and/or requirements and prohibitions regarding avoidance of personal injuries or extensive damage to property.
SAFETY IN MAGNETIC FIELDS
FIELD EFFECT ON PEOPLE AND PHYSICAL AIDS At present there are no binding standard values for people with pacemakers. All corresponding standards were withdrawn. In individual cases measurements at the workplace are necessary, taking account of the individual situation (type of pacemaker and implantation method). The operator is responsible for the correct attachment of the warning sign "No entry for people with pacemakers"!
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Basic Safety Information
The operator must ensure that national standards and health and safety at work regulations1 are complied with (e. g. marking working areas, instructing employees in safety, preparing operating instructions).
1.2.2
WHOLE BODY EXPOSURE
Because of the low dispersion of the magnetic field in the usual working position there is no whole body exposure even with the maximum magnetising current. For this reason there is no requirement for access rules to the working rooms. Exception: wearers of pacemakers must be made aware of the possibility of danger through magnetic fields by means of appropriate signs.
1.2.3
EXPOSURE OF LIMBS AND INFORMATION DURING WORK
1. Do not place hands in the coil when it is in operation! 2. When the coil is in operation, keep the following safety clearances: • 4.5 cm with 8 hours' exposure per working day • 2 cm with 2 hours' exposure per working day This information is based on the most unfavourable combination of coils in each case with corresponding appliance settings (frequency, coil current). The necessary safety clearances are therefore usually smaller in practice. In the event that test parts are not fed automatically, you must use an object carrier made of non-conductive, non-magnetic material for feeding the test device.
1
In Germany the employers' liability insurance association regulations for health and safety at work BGV B11 (VBG 25) apply; "Accident Prevention Regulations Electromagnetic Fields" dated 1 June 2001. All information on this page refers to these regulations.
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Basic Safety Information
1.2.4
FIELD EFFECT ON MAGNETIC DATA CARRIERS AND WATCHES Because of the functional fields of the coils, proximity to magnetic data carriers (cheque cards, etc.) can lead to loss of stored data. Wearing watches near the coils can cause malfunctions and even to these watches stopping.
1.3
PRINCIPLE; USAGE TO THE INTENDED PURPOSE
- The machine/plant has been built according to the state of the art and to the recognized regulations concerning safety engineering. Nevertheless, its use may cause risks for life and limb of the user or third parties and/or impairments of the machine and of other material assets. - Use the machine/plant only in technically perfect condition as well as to the intended purpose with an awareness of safety and dangers under observation of the operating instructions! Particularly defects that could impair safety should be removed at once! - By no means circumvent or shut down the existing safety facilities and covers. - The machine/plant is exclusively designed for material/structural tests of metallic components. Another usage or a usage going beyond that usage is regarded as non-intended usage. The manufacturer/supplier is not liable for defects resulting there from. The risk will be borne by the user alone. A usage to the intended purpose also includes the observance of the operating instructions and the compliance with inspection and maintenance instructions.
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Basic Safety Information
1.4
DECLARATION OF COMPLIANCE
DECLARATION of CONFORMITY
We declare in our own responsibility, that this product complies with the requirements of following European Directives and corresponding Standards: • European Directive 73/23/EEC: Safety of electrical apparatus • European Standard EN 61010 • European Directive 89/336/EEC: Electromagnetic Compatibility • European Standard EN 61326-1
January 28, 2004 INSTITUT DR. FOERSTER Division CT – Component Testing
Dr.-Ing. Jürgen Nehring
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General Information
2
GENERAL INFORMATION
2.1
INTENDED APPLICATION OF THE DEVICE
The FOERSTER MAGNATEST D 3.623 is a test device for sorting metallic individual parts according to their physical properties, permeability and electric conductivity (magnet inductive test). In general, these sizes correspond with alloy composition and/or structure. The unit is able to sort distinguishable materials into up to 6 groups. Owing to the 19" enclosure size, the test device can be operated as desk device and also as a built-in device in a cabinet.
2.2
PHYSICAL FUNDAMENTALS OF MAGNET INDUCTIVE TEST
For performing the test, the individual parts are brought into a magnetic alternating field, which is created in a continuous-flow coil. Because of the (relative) permeability and the electric conductivity of the sample there is an influence on the magnetic field, which leads to a voltage in a second winding of the coil. This is evaluated regarding its amplitude and phase and the result is compared with group limits established in a calibrating process. Distinguishable with this procedure are: -
different metallic materials
-
same metals with different alloy compositions (C, Mo, Cr, Mn, Ni ...) and/or different crystalline structures, in particular hardened / non-hardened, ferrite / perlite contents, different cast conditions, ageing conditions, etc.
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Commissioning
3
COMMISSIONING
3.1
INSTALLATION (DESKTOP DEVICE)
Normally the MAGNATEST D 3.623 is integrated in a 19”- equipment cabinet. It also can be used as desktop device. Then it is equipped with a cover handle. In this case pay attention to the following items: -
Install the test device on an even plane.
-
Installation with cover handle such that the front forms a right angle with the viewer's point of view. In this way, the display on the TFT monitor can be seen at best quality.
-
Position the coil at least at a distance of 50 cm from the test device.
-
Protect the test coil by means of a plastic adapter against wear. This will simultaneously lead to a reproducible positioning of the test parts.
-
Keep the specified ambient conditions (temperature, humidity).
-
The place of installation should be free from strong magnetic alternating fields since the test could be affected by them.
-
Do not cover the lateral air exits and the air filter at the rear side of the device.
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Commissioning
3.2
CONNECTIONS Mains switch Mains fuse and voltage selector Printer socket Socket external monitor Opto-I/O
Mains connection socket Socket external keyboard Socket coil cable Air filter
Figure 1: Connections of MAGNATEST D 3.623
Elements at the rear side: Mains switch
This switch generally should remain in position I. Switching on and off the MAGNATEST D 3.623 is performed with the ON/OFF switch at the front side. Should a defect prevent the test device from being switched off with the front side switch, switch it off with the mains switch at the rear side.
Mains connection socket
Socket for mains cable.
Mains fuse and voltage selector
In the fuse holder are two miniature fuses 5 X 20 mm, T 3.15 A at power voltage 230 V or T 6.3 A at power voltage 115 V. Prior to opening the fuse holder by all means disconnect the device from the supply! The adjusted mains voltage is visible in an inspection window in the fuse holder. Voltage changing 115 / 230 V AC is performed by turning the basic switch by 180°.
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Commissioning
Opto IO
As a standard, the MAGNATEST D 3.623 is equipped with an optocoupler card. Optionally, a second I/O card can be built in. For the connector pin assignment refer to “Input- / Output Module” on page 73.
Test coil
Connector for the test coil. For connecting, use the connecting cable with order no. 3.625.11-9911.
External keyboard
For entering alphanumerical characters, e. g. for giving names for test orders, connect an external keyboard. Every commercial keyboard with a PS/2 plug may be used.
Printer
Connector for a parallel printer. The printer must be installable under Microsoft Windows XP.
External monitor
This connector can be used for the connection of an external monitor or a multimedia projector (VGA, 640 X 480 points).
USB socket
The USB socket serves to connect an external mouse ore a mass storage. Alternatively, you can use the sockets on the front side.
Air filter
In order to safeguard a sufficient cooling of the test device, clean and/or exchange the air filter from time to time. (see section “Cleaning” on page 106) Fehler! Keine gültige Verknüpfung.
You find hints for the installation of a multiplexer from page 107!
First, connect the test coil via coil cable with the connector at the rear side. By switching on the MAGNATEST D without a test coil or disconnecting a test coil while the system is running electronic components can be damaged! If necessary, further peripherals can be connected, for example an external keyboard, a mouse, a printer or a foot switch. An external keyboard is necessary if names or other entries in text fields should be edited. Otherwise, the system uses standard entries. Then establish the power supply. 8
MAGNATEST D 3.623 Version SGP 2.0
Commissioning
3.3
CONTROL ELEMENTS OF MAGNATEST D 3.623 HELP Cursor keys PRINT Rocker switches
ON / OFF TAB ENTER ESCAPE Disk tray
Figure 2: Front side of MAGNATEST D 3.623
ON/OFF (on/off switch)
The device is switched on and off with the ON/OFF switch. When switching the device off, it is first shutdown in a controlled manner and then the power supply unit is switched off. This procedure may take some time. It is important to disconnect the device from the supply system only after it has switched off completely. Should switching off not be possible because of a failure, the device has to be switched off with the mains switch at the rear side of the device.
Rocker switches S1-S10
Depending on the displayed icons, the rocker switches perform different operating functions. The respective function is found in the description of the software operation. If necessary the side to press is indicated with the symbols “” (= right) in the manual. In particular for the entry of parameters where numerical values are to be incremented or decremented or existing values are to be selected, the right or the left side of the rocker is to be actuated accordingly.
PRINT
In some windows the print key performs a hardcopy on the standard printer. 9
MAGNATEST D 3.623 Version SGP 2.0
Commissioning
HELP
By pressing the Help key, a window is opened on the monitor with help for the respective situation (context sensitive).
ENTER
The Enter key is to be used for the confirmation of windows that include OK / abort - button. The abort function is performed via the escape key. Besides the function that actually has the focus is performed (see TAB).
CURSOR
The Cursor keys move: a) the blue marking bar in configuration windows between lines or columns of a table b) the visible segment of the calibrating / test window.
TAB
With the TAB key the focus (visible by a rectangle on the icon) is shifted to the icon below the actual one.
Icon with focus
Icon without focus
At the bottom of the screen the function of the marked icon is displayed. ESCAPE
In windows that include the OK / abort - button, the escape key performs the abort function. It also closes most of the windows.
Front door
By turning the handle to the left, the door of the disk tray can be unlocked. Behind the cover is a 4X USB hub.
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MAGNATEST D 3.623 Version SGP 2.0
Commissioning
3.3.1
ELEMENTS OF THE USER INTERFACE 1
2
3
5
4
6
7
Figure 3: Start image
(1) Headline
In the headline an information about the version number of the actual software as well as the name of the actual test definition and the number of the test order is displayed. The color of the headline changes depending on the application running in the foreground (headline is blue) or in the background (headline is gray). If the program is not running in the foreground, it cannot be operated by function keys (S1 ... S10) on the right side. For switching you need a mouse or a keyboard (ALT-TAB).
(2) Operation field
In this field the icons are located. Depending on the displayed window they are changing. A rocker switch is belonging to each icon on its right (S1 … S10).
(3) Status line
The status line shows the actual mode of the test device. Mainly the mode distinguishes between the lab operation and the series operation. It is further separated in modes for the calibration, testing, documentation and so on.
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MAGNATEST D 3.623 Version SGP 2.0
Commissioning
(4) Operation help
This window shows the function that is performed with the left side of the rocker switch that actually has the focus. The according icon in this case is marked with a frame. The focus is moved to the next icon with the TAB key.
(5) Operation help
This window shows the function that is performed with the right side of the rocker switch that actually has the focus (ref. to key on page 10).
(6) Date
This field shows the actual date (date of the system clock).
( 7) Time
This field shows the actual time (time of the system clock).
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MAGNATEST D 3.623 Version SGP 2.0
Commissioning
3.4
SWITCHING ON
After establishing all connections, the test device can be switched on with the ON/OFF switch at the front side. At the rear side there is a mains switch in the range of the mains connector. This must be in position I! Operating system and MAGNATEST D 3.623 software are automatically started. In case of being connected to a network the name of the user and the password must be entered when starting up. Therefore an external keyboard must be connected. Prior to any tests, the test device should "warm up" for about half an hour in order to avoid an influence of testing results caused by temperature. This is particularly important, if the device was transported from a cold into a warm environment or vice versa! The test device is ready for operation as soon as the start image is displayed.
3.5
SWITCHING OFF (STANDBY)
Switching off the device is performed with the ON/OFF key at the front side. The key will cause the test program to end. All data will be automatically stored. Afterwards, the device will switch to standby operation. It is not necessary to turn off the MAGNATEST D with the switch on the rear side. The actual test order remains active und can be continued at the next starting.
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Commissioning
3.6
3.6.1
GENERAL PROCEDURE
PREPARATION OF THE TEST DEVICE
Desk devices are to place and to connect according to the hints on page 6. At the selection of the test coil, it is to observe that the gap between the test sample and the coil is as small as possible (high fill factor). For fixing the sample in the test coil and to guaranty the reproducibility of the positioning, the usage of a plastic adapter (non ferromagnetic metal is also possible) is recommendable. After this, the test device is to switch on. When the start screen is visible the device is ready for further operation. To set up the test device perform the following steps: -
switch to laboratory operation mode (ref. to “Laboratory Operation” on page 23)
-
select a test definition or generate a new one (ref. to “The Test Definition” on page 27)
-
adjust the test parameter (ref. to “Configuration Of Test Parameters” on page 31)
-
adjust the parameter for sorting and triggering (ref. to “Configuration Of The Sorting” on page 76 and “Configuration Of Trigger Mode” on page 79)
3.6.2
CALIBRATION
Calibration is the definition of the sorting areas. It is done with defined good samples. The calibration samples must be in the same condition as the parts under test. This is to verify by means of appropriate test procedures. You can do the calibration in series or laboratory mode. You find the differences between both modes in the paragraph “Calibration” on page 41. In the calibration window all icons are marked with a yellow stripe at the right edge to prevent confusion with the test window (green edge). First calibrate the samples for the first test class (A). The actual test class is displayed at the left edge of the screen. For calibration every piece must be put in the coil one by one in a well defined position. Tolerances in the position lead to a considerable reduction of the separation potential.
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MAGNATEST D 3.623 Version SGP 2.0
Commissioning
Trigger the test device, depending on the configuration, with the S1 key (manual trigger), from external by a port of the optocoupler input or by the internal trigger mode. During the test, a green control lamp (symbol) is activated on the screen, which means that the system is busy. As soon as the lamp is off, the test sample can be changed. The last test value is displayed blinking. Calibration parts are sorted appropriate to the setting of the parameter “sorting behaviour” (see page 95). If wanted, the process can be continued with further test classes. Test classes can only be generated in the laboratory operation mode. It is possible to generate the test classes without picking up calibration values and to continue the calibration later on in series mode. Do not generate more test classes than necessary, because the manual adaptation of the field can be large-scaled. The number of tolerance fields results in the number of parameter sets multiplied by the number of test classes. By this you get six tolerance field when testing with three frequencies and two test classes. Calibration of the test class must be continued at least until a tolerance field is created around the calibration values (minimum 5, maximum 30 samples, see “sum of cal. parts” at page 93) As long as the calibration is incomplete switching into test mode is not possible. Before finishing calibration, the size and the shape of the tolerance fields can be adapted with the corresponding functions (see the parameter “test class type” and “test class size” on page 94). Size and shape of the tolerance areas should be selected in the way that no overlapping with other areas happens. The gap between the groups especially to NOK groups should be big enough. Press the ESCAPE key to finish the calibration mode (see also parameter “autochange to test mode” on page 93).
3.6.3
TESTING
The testing mode serves to sort out parts that fail to meet the requirement. Depending on the number of test classes sorting happens as A = OK / R = NOK or in different classes A, B, C, … R. The handling of the test samples in the test mode is identical with the one in the calibration mode. Additional sorting is performed after the test. The result is displayed at the left edge of the screen and, if corresponding settings are made, parallel an optocoupler output is set.
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MAGNATEST D 3.623 Version SGP 2.0
Software Description
4
SOFTWARE DESCRIPTION
Generation of test order
ok cancel
Calibration mode
new value deleting of last / all values select value reference part / add; change test class change evaluation mode size of tolerance field info actual status change view manual zoom automatic zoom
Test mode
new value delete previous value recalibration mode / test mode info actual status change view manual zoom automatic zoom
Documentation
Password
Table of single values
first / last page previous / next page selection of parameter set
Table of sorting classes
first / last page previous / next page selection of parameter set
Histogram
first / last page previous / next page show histogram delete test order print protocol
Export to ASCII
first / last page previous / next page add definition copy definition delete definition enable / disable channel
Change to series operation
Selection of test definition
add set delete set frequency adaptation evaluation of higher harmonics coil current attenuation coil matching / ADC adaptation sensitivity channel selection spectrum show parameter settings new value deleting of last / all values select value reference part / change test class change evaluation size of tolerance field info actual status change view manual zoom automatic. zoom new value delete previous value recalibration mode / test mode info actual status change view manual zoom automatic zoom
Parameter setting
Calibration mode
Test mode
Configuration of sorting
Administration
Configuration of trigger mode
test class -> sorting class sorting class -> output bit selection of parameter set set trigger mode /cross hairs set input bit set edge type set trigger level demag. level repair data bank delete all test definitions delete all test orders info hard-/software info general parameter reset all data banks
Maintenance
MAGNATEST D Release 2.0
Change to laboratory operation
The operation of the MAGNATEST D 3.623 is performed on two levels.
Figure 4: Software structure of the MAGNATEST D 3.623
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MAGNATEST D 3.623 Version SGP 2.0
Software Description
On the level of series operation, the operator can create a new test order based on an existing test definition, calibrate the device with sample parts (establish the sorting limits), and perform a series test. On this level no settings can be changed. On the next higher level of laboratory operation, additional configuration steps can be performed. After switching on the device is always in series level. How to work with an existing test definition is described under the point ”Generating A Test Order” on page 20. If no test definition exists, first of all it has to be defined in laboratory operation. How to do this is described in chapter “add a new definition” on page 28 of this manual.
4.1
REMOTE FUNCTION
For special applications the MAGNATEST D can be remote controlled via interface e. g. by a PC. You find a list with detailed descriptions of the instructions in the document “Remote control instruction MAGANATEST D” with the order number 1880160 / 3.632 SW1.0 UA6C/EN.
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MAGNATEST D 3.623 Version SGP 2.0
Series Operation
4.2
Software Description
SERIES OPERATION
After starting up the system is always in the "series operation" mode1. This is used for the recording and documentation of test results based on a device setting determined in the test definition, but there is no possibility to change any settings. Generate a test order for starting the calibration or testing mode. or S2 are used for restarting an already started test The keys S1 order after an interruption as long as the last generated test order has not yet been closed. A closed test order cannot be reopened for a continuation of testing!
Figure 5: Start image of series operation
Description of the icons: S1
testing
testing
By pressing the key the testing mode in series operation mode after an interruption is restarted. In the testing mode the parts are sorted and stored for later documentation purposes. You find further information about this function under the point “Testing” on page 53.
1
The behavior can be changed by the parameter “Starting module” (see on page 97).
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MAGNATEST D 3.623 Version SGP 2.0
Series Operation
S2
Software Description
calibration
calibration
With this key the calibration in series operation mode after an interruption is started. With this a calibration can be edited or completed. You find further information about this function under the point “Calibration” on page 41. S4
new test order
new test order
This function creates a new test order based on an existing test definition (see “Generating A Test Order” on page 20). For this a stored test definition is to select from a table. If it already contains a calibration, the testing mode starts automatically when closing the window, else the program continues with the calibration. S5
documentation
documentation
By pressing the key a window with functions for documenting test data is opened. A further description of this functions can be found in the chapter “Documentation” at page 60. S8
laboratory mode
laboratory mode
The function changes from series operation level into the laboratory operation level. The laboratory mode operation contains all functions for setting up the test device. The settings are stored as so-called test definitions. In case the password protection is active, the password is requested at the switching.
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MAGNATEST D 3.623 Version SGP 2.0
Series Operation
4.2.1
Software Description
GENERATING A TEST ORDER
Prior to entering into calibrating or measuring function, always activate a test . From there you directly change definition in the selection field with key S4 to the calibrating or testing mode. Select a test definition with the keys CURSOR ▲▼ (blue marking).
Figure 6: Selection of a test definition
When selecting a line, further data of the marked test definition are indicated on the right of the selection field. Besides you can expand or reduce each line with the keys WX. Confirm the selected test definition with ENTER. Afterwards, the program will automatically change to the: a)
Test operation, if a complete basis calibration exists. (ref. to “Testing” on page 53)
b) Calibrating mode, if no or an incomplete basis calibration exists. A calibration is complete only if each test class contains at least 5 values. (ref. to “Calibration” on page 41)
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MAGNATEST D 3.623 Version SGP 2.0
Series Operation
Software Description
If the calibration mode or testing mode is started without having an active test order, the following error message appears:
Figure 7: Hint, that now test order is existing
You find a function for deleting of test orders in the documentation function (ref. to “Frequency Distribution Of Sorting Classes” on page 68)! Fields of the test order generation function: definition name
The field displays the name of the currently marked test definition.
material
The field shows the entry of the field "Material" as it has been indicated in the test definition.
# sets
The field shows the number of adjusted parameter sets. When using the manual or the external trigger method in series testing mode, a maximum of 24 parameters sets can be processed. When using the internal trigger as well as the cross hair displaying mode the test definition may only contain one parameter set.
# test classes
The field shows the number of the existing test classes. Adding a test class is only possible in laboratory operation.
coil type
Shows the coil type the test definition was created for. Following coil types are known by the MAGANATEST D 3.623: •
NF PROBE
•
NF SHORT COIL
•
NF COIL 21
MAGNATEST D 3.623 Version SGP 2.0
Series Operation
Software Description
•
HF COIL
•
HF PROBE
•
UNKNOWN Connection of a HF-probe or a booster might damage the connected sensor!
order name
The "test order" number (number of the batch to be tested next; five-digit string of figures) is dynamically generated when marking a test definition. No sequence of batches may be derived from it. If required enter any name for the test order. It is stored as text. Internally the test order is handled by a serial number that cannot be edited by the user.
test start
Shows date and time when marking a test definition.
operator
If an external keyboard is connected, the name of the tester can be entered into this field. Therefore move the cursor with the TAB key to the input field.
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MAGNATEST D 3.623 Version SGP 2.0
Laboratory Operation
4.3
Software Description
LABORATORY OPERATION
The laboratory operation is the level on which all settings of the test device are done. By pressing the S8 key the operation level changes from series- to laboratory operation (see “Series Operation” at page 18).
Figure 8: Message when ending the actual test order
4.3.1
PASSWORD PROTECTION
Switching from series to laboratory operation mode can be protected from tampering by a password. If the protection is active, a window for entering the password appears.
Figure 9: Window for entering the password
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MAGNATEST D 3.623 Version SGP 2.0
Laboratory Operation
Software Description
The password is a combination of numbers with 1 – 5 digits. They have to be entered with the function keys S1 – S10. Afterwards the window must be closed with ESCAPE. If the password was correct, the starting image of the laboratory mode appears. If the combination was wrong, the series operation mode remains active. Switching between the series and laboratory mode than is enabled for the next five minutes without entering the password again. After this time it must be entered again for changing the mode. The user has to configure the password in the maintenance window (see “password” on page 95). You find the window for setting up the password on the following way:
Figure 10: Path to the configuration of the password
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MAGNATEST D 3.623 Version SGP 2.0
Laboratory Operation
4.3.2
Software Description
START IMAGE LABORATORY OPERATION MODE
After changing in the laboratory operation mode, the start image of the laboratory operation mode appears. From here, other functions like the adjustment of the test parameters are called.
Figure 11: Start image of the laboratory operation
Function keys of the start image of the laboratory operation: S1
calibration
calibration
The calibration in laboratory operation is stored in the actual test definition and is used for all test orders based on it. S2
testing
testing
The testing mode in opposite to the one in series mode doesn’t save test data and doesn’t make entries in the statistical analysis. S3
setup
setup
In the window the test parameter set-up you define the parameter sets. A parameter set consists of the adjustable parameters frequency, evaluation of high harmonics and the attenuation of the coil current (reduction of the coil current) 25
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Laboratory Operation
Software Description
Due to those parameters the quality of separating different material conditions is controlled. All adjustments are stored in the actual test definition. You find the description of the test parameters under the item “Configuration Of Test Parameters” on page 31. S4
test definitions
test definitions
In the window a test definition can be selected, created or deleted. You find further information about test definitions on page 27. S8
series mode
series mode
This function changes from laboratory operation to series operation. S9
administration
administration
The administration window contains functions for example for the adaptation of the test device to automatically running processes and the data bank administration (see from page 71).
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The Test Definition
4.4
Software Description
THE TEST DEFINITION
A test definition is always the basis for each test order. It contains all settings for testing. Among testing parameters also settings for the in- and outputs for the communication with control devices e. g. PLCs. Also the calibration can be stored in it. All test orders that base upon a definition that already includes a calibration start in testing mode. With key S4
the view of the existing test definitions is displayed.
Figure 12: List of existing test definitions
Operation functions: ▲▼
previous line
next line
Select a test definition by marking it with the blue bar. Therefore serve among the keys CURSOR ▲▼ the keys S1 and S2 for changing the pages. When closing the window the marked test definition becomes the actual one. All later made settings are stored in it. The name of the actual test definition is displayed in the headline of the windows.
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The Test Definition
S1
Software Description
first page
last page
Jump to the first respectively last page of the table S2
previous page
next page
Jump to the previous respectively next page of the table S3
add a new definition
add a new definition
The function opens a window for the input of data for the generation of a new test definition and adds it at the end of the table displayed in Figure 13 as new line with the corresponding line number (column „no.”).
Figure 13: Window for setting up a new test definition
The new test definition contains one standard parameter set (frequency 32 Hz; attenuation 6 dB; harmonic 1) as well as the actual settings for the triggering and sorting. So the columns “# sets” and “# test class” of new test definitions always contain a 1. The number of parameter sets is defined at the configuration of the test parameters (see „Configuration Of Test Parameters” on page 31), the one of the test classes at the calibration in the laboratory mode (see „Calibration“ on page 41). The test definition automatically gets a preset name. This is made up of the designation "test def." and a serial number (e. g. "test def. -6"). If an external keyboard is connected, the standard name may be changed, as well as all following fields that are exclusively used for the later documentation may be completed. Change between the fields with TAB. 28
MAGNATEST D 3.623 Version SGP 2.0
The Test Definition
Software Description
The window includes the following fields: definition name
The test description is stored under the entered name. Any character sequence may be used as a name for the test description (max. 15 characters).
The contents of the following fields have no influence on the test. category
material
criterion
description
S4
This field can be used by the user in order to group the test definitions according to own criteria. Here, the name of the material to be tested can be entered. In this field you can enter the kind of test, e. g. confusion test or hardness control. This field can be used to enter further descriptive information. copy test definition
copy test definition
The copying function copies the marked test definition completely. The new one contains the test parameter, the configuration of the I/O-setting, and if existing, the calibration. The operation is identical with the creation of a test definition. S6
deletes the active definition
deletes the active definition
In order to delete an existing test definition, first it has to be marked. In order to delete the test definition, you have to press key S6 will be a query.
. Then, there
Figure 14: Query before the deletion of a test definition
It has to be confirmed with ENTER or to be aborted with ESCAPE. The entry of the deleted test definition is deleted from the table and the numbering of the first column (no.) is updated. 29
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The Test Definition
S8
Software Description
delete channel
add channels
The enabling / obstruction of multiplexer channels prevents the usage of outputs without connected coils. Only enabled channels can be selected later at the configuration of the test parameters. The number of enabled multiplexer channels stands in the column “used channels”. When no multiplexer is connected, the changing of the number of used channels is without function. ESC
closes the window
At the closing the marked test definition becomes the actual one. The program returns to the starting image.
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The Test Definition
4.5
Software Description
CONFIGURATION OF TEST PARAMETERS
In order to adjust the test parameters, the system must be in laboratory operation and the test definition to be adjusted must be active (see on page 23 “Laboratory Operation”). Open the respective window with key S3
for adjusting the test parameters.
Figure 15: Window for editing the test parameters
Operation functions: ▲▼
previous line
next line
Select a line by marking it with the blue bar. Therefore serve the keys CURSOR ▲▼. S1
new parameter set
new parameter set
Adds a new parameter set (line) to the table. This will copy the parameter set where the blue bar is. Afterwards, the table is sorted anew. This happens dynamically when changing settings. By this the marking stays on the selected parameter set. The first sorting criterion is the test frequency (higher frequency at the top), the second the adjustment of the higher harmonic (lesser value at the top). 31
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Software Description
The test device will deal with the parameter sets with different test frequency or attenuation one after the other. Adding such parameter sets extends the time per tested part. Sets with the same setting of frequency and attenuation are combined. Up to 24 parameter sets per test definition can be created and used. Each line gets a serial number in the column “set no.” It is automatically updated by the adding or deleting of parameter sets. After the attempts to determine suited parameters and to reduce the test time all parameters that do not permit a separation should be deleted. For the use of the internal trigger function as well as the cross hair display mode the test definition only may contain one single parameter set!
S2
delete parameter set
delete parameter set
Removes the parameter set which is highlighted with the blue bar out of the table. This may lead to the fact that possible entries below the deleted parameter set move upwards and get a new number in the first column. S3
decrease frequency
increase frequency
Function for adjusting the test frequency in [Hz]. The test frequency belongs to the parameter that mainly influences the test result. The adjustable frequency range depends on the transfer properties of the respective connected coil. The coil type is automatically recognized during switching on. For NF-coils the value can be adjusted in the range between 2 and 1024 Hz and if a HF-coil is connected between 2 and 12288 Hz. The recognized coil type is shown in the headline of the window. The frequency area of the test coil is stated on its type plate. LF frequencies [Hz]: 2, 4, 8,16, 32, 64, 128, 256, 512, 1024 (LF short coil 2048) HF frequencies [Hz]: 2, 4, 8,16, 32, 64, 128, 256, 512, 1024, 2048, 4096, 8192, 12288 The test speed is corresponding with the number and height of the selected frequencies. The time prolongs by the reduction of the test frequency and by an increasing number of parameter sets. The adjusted frequency is displayed in the column “frequency [Hz]”. Right key
Changes to the next higher frequency. 32
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The Test Definition
Software Description
Left key
Changes to the next lower frequency. S4
decrease harmonics
increase harmonics
This parameter adjusts the number of the high harmonic to be evaluated. The actual value is represented in the column “harmonic”. Value 1 means that the fundamental oscillation is evaluated. The evaluation of higher harmonics can only be used when testing ferromagnetic parts since other materials do not create higher harmonics. If a part with the appropriate properties is inside the coil, the test signal with a frequency of up to 2048 Hz may be evaluated up to the 11th harmonic. The excitation of higher harmonics can be (ref. to “Representation Of The checked with the function "Spectrum" Spectrum Of The Received Signal” on page 37). Right key
The value of the parameter is increased. Left key
The value of the parameter is decreased. S5
decrease attenuation
increase attenuation
The coil current influences the strength of the magnetic field in the test coil. It can be reduced in steps of 1 dB beginning at 0 dB. The actual setting is displayed in the column “attenuation [dB]”. The upper adjustment level is depending on the coil type. The quality of the test, especially when testing ferromagnetic parts, is depending besides the frequency on the attenuation! Right key
Increasing the value of the parameter reduces the coil current (lower magnetic field excitation). Left key
Reducing the value of the parameter increases the coil current (higher magnetic field excitation).
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The Test Definition
S6
Software Description
coil matching
ADC adaptation
A coil matching or ADC adaptation deletes all data and settings of the calibration! Right key
ADC matching performs a level control of the receiving amplifier for all parameter sets (parameter “sensitivity”).
For the process put a test part in the coil and confirm the inquiry with ENTER. Left key
After changing test parameter (frequency, harmonic, attenuation), a so-called coil matching is performed automatically when closing the actual window. Pressing can also start the same function. If it is performed with the key, the S6 program remains in the window of the test parameter setting. For this purpose, a test part has to be in the coil.
The displayed query has to be confirmed by pressing the ENTER key. The process can take up to a few minutes depending on the height and number of frequencies. In the mean time the busy symbol appears on the screen. First, the coil current is adapted to the test coil considering the frequency. Next, the number of presignals and the demagnetisation are optimised. At last the receiving amplifier is balanced.
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The Test Definition
S7
Software Description
decrease sensitivity
increase sensitivity
The adjustment of this parameter is done automatically at the coil matching process or the ADC adaptation! The setting of the sensitivity adjusts the voltage of the test coil to the measuring area of the A/D-converter. The actual setting is displayed in the column “sensitivity [dB]”. This parameter allows the manual adjustment of the signal voltage if the automatic setting leads to an too low or too high amplification of the receiving signal. Changing the setting leads to the deletion of the possibly existing calibration! The voltage at the receiving side of the coil is depending on multitude factors. It rises due to increasing of the coil current and is depending on the sensor type and the magnetic and electrical properties of the test samples. For being measured correctly, it is matched by a voltage divider and an amplifier to the dynamic range of the AD-converter. Too high voltage leads to the overflow of the converter, too low voltage to the deterioration of the measurement. The actual modulation percentage can be seen in the function „harmonic“ as percent of the fundamental harmonic. It should be in a range between 65 - 85%. Key right
Increases the sensitivity, the signal amplitude is enlarged. An overflow of the AD-converter leads to an error message! Key left
Reduces the sensitivity, the signal amplitude is reduced. S8
channel dec
channel inc
This parameter sets the test channel of the multiplexer, which is used for executing the parameter set.
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The Test Definition
Software Description
Setting a channel only takes effect if a multiplexer is connected! You can only select channels that are enabled in the test definition (see on page 30 “add channels”). The channel number is displayed in the column “channel”. S9
show harmonics
show harmonics
With this function, the representation of the signal spectrum of the currently marked parameter set is activated in a new window. The display of the higher harmonics is limited to 2 kHz (see “Representation Of The Spectrum Of The Received Signal” on page 37). S10
show all parameter settings
show all parameter settings
The function opens a window that displays detailed information of the parameter sets. You find more details under the point “Show All Parameter Settings” at page 38. ESC
closes the window
Close the parameter set-up window with ESCAPE. If the set up has been changed a coil matching is processed automatically (see on page 34, “coil matching”).
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The Test Definition
4.5.1
Software Description
REPRESENTATION OF THE SPECTRUM OF THE RECEIVED SIGNAL Only ferromagnetic higher harmonics!
parts
generate
So for the process a corresponding test part must be in the test coil. When testing ferromagnetic parts there may be an excitation of frequencies in the test coil that are not included in the exciting test signal. These frequencies are called higher harmonic. They increasingly occur when using high field strengths. Higher harmonics sometimes possess a high separation potential and can then be very useful for the test procedure. However, this has to be checked from application to application. In order to evaluate whether the received signal of the currently marked parameter set includes higher harmonics or not, use the function "Spectrum". It is called with key S9 . Then the view window (which is empty first) for the spectral representation of the test signal appears. At the upper edge of the window the number of the active parameter set as well as the appropriate frequency are indicated. In a first step, perform a coil matching with key S2 . For this purpose, there must be a ferromagnetic test part in the coil since otherwise no higher harmonics can be created! Afterwards trigger a test measurement with S1 .
Figure 16: Spectral representation of a test signal
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MAGNATEST D 3.623 Version SGP 2.0
The Test Definition
Software Description
Now, the signal spectrum is displayed in the current window. The bar above f1 displays the level of the base wave, the bars above f3 … f11 the level of the high harmonics. Higher harmonics > 1% of display height can be used for the test. Functions Of the Spectral Representation ESC
closes the window
Close the window with ESCAPE. The program will skip into the representation of the parameter sets. S1
take measurement
take measurement
The function takes a measurement and displays the spectrum of the signal. S2
coil matching
coil matching
This function performs a coil matching (see on page 34, “coil matching”).
4.5.2
SHOW ALL PARAMETER SETTINGS
The information window shows details of the parameter settings.
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The Test Definition
Software Description
Figure 17: Window showing all parameters of all settings.
The software sets most of the parameters automatically. Operation functions
▲▼
vertical selection
vertical selection
Use the CURSOR keys ▲▼ to select a set or a parameter. ►◄
spread out parameter set
shrink parameter set
Spread out the viewing of a parameter set with the CURSOR key ► and fold it up with the CURSOR key ◄. S1
decrease pre-signals
increase pre-signals
Presignals are measurements without mentioning the results to set ferromagnetic test samples in a defined magnetic condition. By this the test results become stabile and reliable. Increasing the number of pre-signals prolongs the test duration depending on the test frequency. Additional to the adjustable parameters explained before, the window shows following parameters: presignals
see above 39
MAGNATEST D 3.623 Version SGP 2.0
The Test Definition
Software Description
averaging
Due to averaging the test results become more stable and the signal/noise ratio becomes better. coil current
This value shows the maximum coil current (at 0 dB attenuation) as per mil of the maximum current of the device (2 ampere). The actual current results from the indicated value divided by 1000, divided by the factor of the parameter “attenuation” multiplied by 2 A. Example: indicated value: 250 attenuation: 6 dB = 2 250 / 1000 / 2 * 2 A = 0.25 A
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Calibration
4.6
Software Description
CALIBRATION
Calibration is the definition of the thresholds by calculating the dispersion and the position of the values of the test samples in good condition. The calibration function is available in the laboratory operation mode as well as in the series operation mode. Opening an existing calibration deletes all test data. For calibration between 5 and 30 calibration samples per test class have to be tested. If several test classes have been established, these must be clearly distinguishable from each other. The higher the distance of groups towards each other in relation to the own size, the better is the ability of sorting and the safety of test. The calibration window is closed with ESCAPE. The switching from the calibration to the testing mode, depending on the configuration of the software, also can perform automatically! The software changes to the start image. When in laboratory operation mode a test class without calibration values exists, the system asks for deleting it.
Figure 18: Inquiry, if the empty test class should be deleted
When confirming with ENTER the test class mentioned at the end of the message is deleted. With the ESCAPE key the message is deleted, the test class keeps remaining. The main differences in operation of the calibration function between the laboratory mode and the series mode are: Laboratory mode 1. Start the calibration with S1. 2. The calibration is stored in the test definition and is taken as basis for each test order based on this test definition. It is also possible to make settings in the calibration (test classes, size of test class, evaluation type) without picking 41
MAGNATEST D 3.623 Version SGP 2.0
Calibration
Software Description
up calibration data. These settings are taken as default settings in the calibration in the series mode. 3. All adjustable parameters are enabled. Series mode 1. If there is no or an incomplete calibration stored in the test definition, the calibration mode is starting when creating a test order. A calibration is complete when at least five test values are picked up for each test class. 2. The generation of a new test class is blocked. Only the test classes generated in the laboratory mode are available. 3. For adding values a calibration can be opened in series operation mode with S2. 4. A new calibration has to be done for each test order (compare on page 41 Series mode, item 2.). 5. If you reopen the calibration after picking up test data, the last 50 test values are displayed as “0”. The better orientation makes the adaptation of the test class easier (see below).
Figure 19: Display at changing calibration
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MAGNATEST D 3.623 Version SGP 2.0
Calibration
Software Description
If calibration is to be performed in series operation and if more than one test class is to be used, the test classes B, C, etc. are to be generated as empty classes in the laboratory mode!
When entering the calibration window for changing an already existing calibration all stored test data are deleted! Up to four parameter sets are displayed parallel on the screen.
Figure 20: Calibration window (laboratory operation)
Elements of the calibration window: 1
Number of the parameter set that is displayed in the current window Calibration values of up to four parameter sets can be displayed simultaneously
(1)
Channel number 43
MAGNATEST D 3.623 Version SGP 2.0
Calibration
Software Description
The channel number displays the number of the multiplexer channel stored in the parameter list (see on page 35, “channel dec / inc”). 128 Hz
Current adjustment of the test frequency The display of the parameters belonging to the window presents a better view and a help for a later selection of useful parameter sets.
f1
Number of the evaluated harmonic
2 dB
Setting of the attenuation
XX :1
Factor for enlarging the represented cut-out of the measuring plane. The zoom factor informs you about the size of the visible cut-out in relation to the complete test range. The higher the indicated factor, the smaller the cut-out of the measuring plane.
A
active test class The MAGNATEST D 3.623 can distinguish up to six test classes.
x=nnnn y=mmmm
x/y values of the last calibration value The current test values are only displayed in the single view mode. Owing to the resolution of the analog-to-digitalconverter of 14 Bit, the value range in x- and y-direction is ± 8192 points (comparison size without physical unit).
#V/W
Amount of current calibration values in the actual test class / number of the actually selected calibration value. Up to thirty calibration values per test class can be recorded. The tolerance field (sorting limit) is calculated after reaching five calibration values and displayed. busy lamp The lamp is on for the duration of the test.
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Calibration
Software Description
Icons of the calibration window: S1
take measurement
take measurement
Triggers the recording of a calibration value (manual trigger function). Execution is made irrespective of the direction of the rocker switch. Further trigger methods can be found in the chapter “Configuration Of Trigger Mode” on page 79.
S2
delete all values of current test class
delete last value
This function serves to delete calibration data of the current test class (see function S4 “previous test class” on page 46). In order to delete a selected value see function S3 “select previous part” below. Right key
Deletes all values of the current test class (A, B, C, ...) but not the test class itself. After pressing the key, a query appears:
With the key ENTER the query is confirmed and all calibration values of the current test class are deleted. With ESCAPE the query is deleted, the calibration values are remaining. Left key
Deletes the last value of the current test class (A, B, C, ...) or the one selected with S3. S3
select previous part
select next part
Makes it possible to select a calibration value in order to delete it with the key . The selected value appears blinking. The number of the selected < S2 part is displayed at the left side of the display behind the number of parts of the actual test class. Right key
Marks the next value resp. after the last one the first again. Left key
Marks the previous value resp. the last after the first again. 45
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Calibration
S4
Software Description
previous test class
next test class
Switches between test classes resp. generates a new one (only in laboratory mode!). The classes A to F can be generated for sorting. Class Y serves to store a reference part for later recalibration. The current test class (A, B, ... F or Y) is displayed on the left side of the monitor. Right key
The function changes to the next higher test class (e. g. A B). If the selected test class does not exist yet, a query will appear as to whether it is to be generated.
Confirm the inquiry with ENTER. The new test class automatically gets the next free letter of the alphabet. The program will change into the new test class. As a maximum, six test classes (A - F) can be generated for sorting. Different test classes must be clearly distinguished. The bigger the distance is between the groups related to their own size, the better is the separation and the test security. Left key
The next lower test class is selected (e. g. C S5
B or A
previous class type
Y). next class type
Another evaluation form is allocated to the current test class. The parameter set to change therefore must exclusively be shown else an error message appears (see on page 50 “visualization screen”).
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Calibration
Software Description
Four evaluation forms are available: Circle
A circular tolerance field is drawn around the calibration values. The centre of the circle lies in the centre of gravity of the calibration values. The diameter is determined by the value being furthest away from the centre of gravity. The sorting limit is set to the triple distance of this value from the centre of gravity or to the value set with S6. Ellipse
An elliptical tolerance field is drawn around the calibration values. The calculation of the ellipse is performed on the basis of a two-dimensional normal distribution. For the field size no fixed probability is taken as a basis (no fixed sigma value); instead, the size of scattering is taken as the basis as in case of the evaluation form circle. Box regression
This evaluation form consists of the evaluation form rectangle the limits of which are restricted by two parallel regression lines along the main distribution axis of calibration values. The calculation of size is performed as following described for the rectangle. This tolerance form is distinguished by its close adaptation to the calibration value distribution. Rectangle
A rectangular tolerance field is put around the calibration values. The size, the position and the rotation are manually adjustable at the evaluation kind. The centre of the rectangle lies in the centre of gravity of the calibration values. The threshold in x and y direction is calculated by the calibration values been farthest away from the centre. As default it is laid on the triple distance of the minimum size. After selecting the evaluation method „rectangle“ with the key S6 can be switched in an operation mode for editing the size, the position and the orientation.
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Calibration
Software Description
Figure 21: Adaptation of the tolerance field
In the menu for the adaptation of the evaluation form rectangle recording of calibration values is not possible! After a manual adaptation the tolerance field is not recalculated! By this calibration values also can lie outside the tolerance field. By changing the test class type or a new manual adaptation they can be included in the tolerance field. Symbol
Key
Explanation
S1
Function for editing the width of the tolerance field.
S2
Function for editing the height of tolerance field.
S3
Function for the horizontal shifting of the tolerance field.
S4
Function for the vertical shifting of the tolerance field.
S5
Function for editing the orientation of the tolerance field by max. ± 45°.
ESCAPE
With the ESCAPE key the operation returns to the calibration mode. 48
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Calibration
S6
Software Description
decrement test class size
increment test class size
The default value for the size of the tolerance field is 3.0. This function can only be used in single view mode. If the evaluation method „rectangle“ is set, the operation and displaying of the window is like shown at the description of this function above! Right key
Enlarges the current tolerance field step by step by 0.5 up to a maximum enlargement factor 25. Left key
Reduces the current tolerance field step by step. The smallest adjustable size of the tolerance field is 1.0 (size where the tolerance field just encloses all values). S7
show info
show info
Pressing this key will open an info window in the foreground. The info window cannot be opened, if several parameter sets are displayed simultaneously. It always refers to the current test class. Press S8
changes the view on the parameter sets.
Figure 22: Information window of the calibration mode
Besides the number of the current parameter set, the current test class, the size of the tolerance field and the number of calibration values the info window displays statistical information about the calibration values. 49
MAGNATEST D 3.623 Version SGP 2.0
Calibration
Software Description
Close the window is with ESCAPE. S8
previous visualization screen
next visualization screen
Shift function between the individual representations of parameter sets and view windows where up to four parameter sets are displayed in one window.
The functions "Class type", "Test class size" and “Show info” can only be executed in individual display of the parameter set to be changed. A trial to edit these functions in the overview generates the following error message:
The operation of the functions "manual / automatic zoom" always refers to all visible view windows. S9
zoom out
zoom in
The function "manual zoom" enlarges or reduces the visible area of the calibration level. The measure for the current zoom adjustment is shown at the upper edge of the respective parameter window. The zoom covers the range from 1:1 to 2048:1. The changing happens by factor 2. The higher the adjusted zoom factor, the smaller the visible cut-out of the calibration level. After execution of manual zoom the window is not automatically scaled anymore (the window is frozen). This means that calibration values that lie outside the visible area may not be displayed. 50
MAGNATEST D 3.623 Version SGP 2.0
Calibration
Software Description
Should the area of the calibration level to be enlarged move out of the window during enlargement, the display cut-out may be moved with the cursor keys. S10
rescale
rescale
The function "automatic zoom" scales all visible parameter windows to a size that all existing calibration values are displayed. After adding new values, scaling is automatically calculated anew. Automatic zoom will thaw the windows that have been frozen with the manual zoom.
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Calibration
4.6.1
Software Description
DEFINITION OF REFERENCE PART
Influenced by the environment, for example changes of temperature during series testing drifting of the values may happen. Due to warming or cooling the conductivity of the components of the test device as well as the testing parts is influenced. As a result the loss can increase, because a rising number of good parts are falling outside close to the threshold. By using a reference part the shift of the test values in test mode can be compensated. Record the reference part as following: -
Select test class Y with < S4
-
Put reference part in test coil
-
Press S1 to pick up a value (Y)
-
Switch back to the standard test class with S4 >
Figure 23: Definition of reference part Y
Test the reference part in the recalibration mode to correction the drift (ref. to “Recalibration” at page 58). Automatic test systems sort the reference part as bad part.
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Testing
4.7
Software Description
TESTING
In the testing mode all icons have a green strip at their right side! The testing function is available in the laboratory mode as well as in the series mode. The operation in both modes is identical but the following points: Laboratory mode -
Pressing S2
starts testing.
-
The test data are neither stored nor used for documentation.
Series mode -
If a basis calibration was performed in the test definition, the test mode will automatically start when generating a test order.
-
Testing mode can also be started from the start image (series operation) with key S1 . If no valid calibration is available for the current test order, a respective error message will be displayed.
(ref. to “Generating A Test Order” at page 20) -
The last 5000 test values are stored in the data bank and they are available for further documentation.
-
For each test order a protocol can be printed. A function for printing a protocol is located in the documentation window for the selection of a test order for displaying the histogram (see “Frequency Distribution Of Sorting Classes” on page 68).
For testing each part must be positioned in the test coil in the same way as in the calibration mode. If no other adjustments were made trigger the test with the S1 key. During the test the green control lamp on the left side at the bottom of the screen is switched on. It means that the device is busy. The test is finished when the symbol is disappeared, then the sample can be changed. The sorting result is displayed on the screen and, if corresponding configurations of the sorting outputs were made, the output for the sorting gate is set.
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Testing
Software Description
The test levels of maximal four parameter sets are represented in an automatically scaled manner. Switching to further sets is done with S8 . The number of the actual test order is displayed behind the name of the test definition in the headline and in the info window. The number of the test order is automatically incremented. It is generated unique and not depending on the test definition. Close the test window with ESCAPE. The actual test order can be continued with the corresponding key after an interruption as long as it is active. The test order finishes when another one is created or the software changes into the laboratory operation mode.
Figure 24: Test window
Elements of the test window: 1.
Number of the parameter set that is displayed in the current window Calibration values of up to four parameter sets can be displayed simultaneously.
(1)
channel number The channel number displays the number of the multiplexer channel stored in the parameter list (see on page 35 “channel”).
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Software Description
Current adjustment of the test parameter
128Hz - f1 - 2dB
The header line of every represented parameter set shows the actual setting of the parameters "frequency", "evaluated harmonic" and “attenuation”. Factor for enlarging the represented cut-out of the measuring plane.
64:1
The zoom factor informs you about the size of the visible cut-out in relation to the complete test range. The higher the indicated factor, the smaller the cut-out of the measuring plane. Sorting result of the last test part
A
Besides the unique allocation of a part in a class A - F a test value in different parameter sets may also fall into different classes. In this case, it is evaluated with X. This means that the part cannot uniquely be allocated to one class. If one part is not inside one of the tolerance fields for at least one parameter set, it is sorted in class R (reject). x/y values of the last test value. The analog values are only displayed, if one individual test class is represented on the monitor.
x = nnnn y = mmmm
Display for an over steering of the test device. If voltage overflow at the receiving side occurs, the indication is set for five seconds. In this case the sample is sorted as bad. The busy lamp is on for the duration of the test. Icons of the testing mode: S1
take measurement
take measurement
Triggers a test value recording (manual trigger function). Performance is executed irrespectively of the direction of the rocker switch. The last established value is represented flashing. As a maximum, 200 test values are displayed. S2
delete last measurement
delete last measurement
Deletes the last value. 55
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Testing
S3
Software Description
recalibration
testing
If no reference part was stored in the calibration changing to recalibration is not possible! For further information see “Definition Of Reference Part” at page 52. Left key
Changes in the recalibration mode (ref. to “Recalibration” on page 58). The sorting indication left above shows Y. Right key
Changes from the recalibration mode back into the testing mode. The sorting indication by this is deleted. S7
show info
show info
Press this key and an info window will be opened in the foreground.
Besides the name of the test definition and the test order, the date and time of test start, the number of defined parameter sets and the number of tested parts it also represents information about the distribution of test values in the sorting classes. The window is closed with ESCAPE. S8
next visualization screen
previous visualization screen
Switching function between the individual representations of parameter sets and the overview windows where up to four parameter sets per window are displayed. 56
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Software Description
The operation of functions "manual / automatic zoom" always refers to every view windows!
S9
zoom out
zoom in
The function "manual zoom" enlarges or reduces the visible area of the testing level. The measure for the current zoom adjustment is shown at the upper edge of the respective parameter window. The higher the adjusted zoom factor, the smaller the visible cut-out of the testing level. After execution of manual zoom the window is not automatically scaled. This means that test values that lie outside the visible area may not be displayed. Should the area of the testing level to be enlarged move out of the window during enlargement, the display cut-out may be moved with the cursor keys. S10
rescale
rescale
The function "automatic zoom" scales all visible parameter windows to a size that all values are displayed. After adding new values, scaling is automatically calculated anew. Automatic zoom will thaw the windows that have been frozen with the manual zoom.
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4.7.1
Software Description
RECALIBRATION
During testing drifts can happen by variation of the ambient temperature. Due to this the results approach to threshold and they are going more and more to lie outside. The recalibration function serves to correct this drift. The calculation of the correcting factor is done by comparing the value of the reference piece in the recalibration mode with the one picked up in the reference mode (see to “Definition Of Reference Part” on page 52). The trend correction happens by adding the correction factor to the test values. In the test window the recalibration mode must be activated with < S3 . The sorting indication in this mode shows Y. For recalibration the same sample that was used as reference part has to be tested.
Figure 25: Testing the reference part
The result is displayed as Y. With the cursor keys h fg d it can be shifted on the screen. In automatic test systems the part is sorted as R (bad part). . The program returns to the
The mode is finished by pressing S3 > standard testing mode.
All following values are shifted by the calculated correction value (difference between the position of the reference part and the one of the recalibration part). 58
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Software Description
To make sure that bad parts are still rejected after the recalibration some bad parts should be tested!
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Documentation
4.8
Software Description
DOCUMENTATION
You can open the documentation level on the start page of the series mode with key S5 . From here different kinds of reports can be selected.
Figure 26: Selection of documentation function
The window offers three evaluation types:
ESC
Close window
The window is closed and the program changes in the starting image of the series mode. S1
test results in tabular form
test results in tabular form
Tabular representation of individual values of last test (ref. to “Tabular Representation Of Individual Values” on page 63)
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S2
Software Description
test classes in tabular form
test classes in tabular form
Tabular representation of test classes of last test (ref. to “Test Classes Of Individual Values” on page 66) S3
histogram
histogram
Graphical representation of test class distribution (histogram) (ref. to “Frequency Distribution Of Sorting Classes” on page 68) S10
write test data to ASCII file
write test data to ASCII file
The function exports the data of the last test order into a text file in ASCII standard. From there the data can be processed with another software, e. g. with data visualization tools or spreadsheet software. The text file consists of several columns separated by spaces. There number is determined by the number of used parameter sets. The first column is the number of the data (ten figures). Then the columns with the X / Y data (four figures plus sign) follow. At last the test classes are listed numeric coded. The codes have following meanings: 1 – A, 2 – B, … 6 – F, 7 – X, 8 – R.
Figure 27: Example for exported test data
The text file is always written in the folder C:\Projects\Data. Its name consists of the name of the test definition, the test order number and the actual test order 61
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Software Description
number (it differs if the test order number internally is incremented due to editing of the calibration).
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4.8.1
Software Description
TABULAR REPRESENTATION OF INDIVIDUAL VALUES
With this function, the last 5000 test values (X / Y values) of the last test order can be shown in tabular representation. The representation always shows the values of one parameter set. If necessary the test results of further parameter sets can be displayed with S3 .
selected parameter set no. of displayed test order no. of parameter sets
Figure 28: Tabular representation of individual values
Columns of the table: no.
Serial number of test result
date
Date when the value was recorded
time
Time of test
X
X-portion of test value
Y
Y-portion of test value 63
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result
Test class of the selected parameter set.
evaluate
Total sorting result. In case of the use of several parameter sets, the total result is formed as follows: a) The classification of all parameter sets is equal the sorting result corresponds to the result of the parameter sets. b) The classification of the parameter sets is different, however, all values are within a tolerance field or the result of one test class is in the intersection of two test classes. E. g. the test result of parameter set 1 is A, the one of 2 is B the sorting result is X. c) In at least one of the parameter sets the result is not within any of the tolerance fields the sorting result is R.
Operation functions: ESC
Close window
The program will skip to a higher level into the window of documentation overview. S1
first page
last page
Right key
Jump to the last page of the table Left key
Jump to the first page of the table S2
previous page
next page
Right key
Jump to next page Left key
Jump to previous page
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S3
Software Description
previous parameter set
next parameter set
Right key
Selection of next parameter set Left key
Selection of previous parameter set
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4.8.2
Software Description
TEST CLASSES OF INDIVIDUAL VALUES
The window shows the table with the test classes of the single values for all test sets (Set 1 – Set n).
Figure 29: Test class of every test value in the overview
The columns of the table: no.
Serial number of test result
date
Date when the value was recorded
time
Time of test
S1, S2 ...
These columns show the test class in dependence with the parameter sets.
?
Category of total result The information is identical with „evaluate“ in the window of the individual values.
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Operation functions: ESC
Close window
The window is closed an the program returns to the starting page of the documentation function. S1
first page
last page
Right key
Jump to the last page of the table Left key
Jump to the first page of the table S2
previous page
next page
previous parameter set
next parameter set
Right key
Jump to next page Left key
Jump to previous page S3
A page displays at maximum eight parameter sets. Use this function to switch to the next / previous pages. Right key
Selection of next parameter set Left key
Selection of previous parameter set
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4.8.3
Software Description
FREQUENCY DISTRIBUTION OF SORTING CLASSES
First the software opens a list with the stored test orders.
Figure 30: Table of stored test orders
Icons of the window: ESC
Close window
The window is closed an the program returns to the starting page of the documentation function. ▲▼
previous line
next line
Use the cursor keys to select a line in the table. S1
first page
last page
Right key
Jump to the last page of the table Left key
Jump to the first page of the table 68
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S2
Software Description
previous page
next page
show histogram
show histogram
Right key
Jump to next page Left key
Jump to previous page S3
The function displays the histogram of the selected test order.
number of parts in the test class test order test definition
test class Figure 31: Frequency distribution of test classes of a batch
S4
delete test order
delete test order
This function deletes the selected test order. 69
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To prevent unintended deleting of the test order an inquiry is displayed.
Press ENTER to delete the test order or ESCAPE to interrupt the function. S5
print protocol
print protocol
This function prints a protocol with the most important data of the selected test order. The protocol is available in two versions. The long one supplementary contains the complete list of test parameters. The witching has to be made with the general parameter “Protocol compressed” (see on page 97).
Figure 32: Example of the test protocol (long version)
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4.9
Software Description
ADMINISTRATION
In the window “Administration” settings for the in- and outputs can be made and functions for the maintenance of the data banks can be started.
Figure 33: Window for selecting the inputs and outputs
Description of the icons: S1
modify sorting parameter settings
modify sorting parameter settings
Window for the configuration of sorting outputs for the control of a sorting gate (see on page 76 “Configuration Of The Sorting”)
S2
modify host parameter settings
modify host parameter settings
Window for the configuration of the measurement triggering (see on page 79 “Configuration Of Trigger Mode”)
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S10
Software Description
maintenance
maintenance
The function opens a window containing maintenance functions for the data base. They are not used for standard operation purposes. The maintenance menu should only be operated by skilled operators resp. FOERSTER service staff, because wrong operation may cause the irrevocable deletion of data!
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4.9.1
Software Description
INPUT- / OUTPUT MODULE
The MAGNATEST D has 8 in- and outputs1 for connections e. g. to a mechanical device. Connections are carried out with the 37-pin Sub-D connector at the rear side of the MAGNATEST D (ref. to Figure 1 at page 7). Via this, signals can be exchanged in a potential-free manner with external control units (programmable controller, initiator, sorting switch). This is particularly important when the MAGNATEST D 3.623 is incorporated in automatic processing facilities. For the use of the input and output signals an external power supply unit DC 24V has to be used. The settings of the IOs are stored in the active test definition and can be changed any time. Changes become active immediately. Changing the setting of the I/O parameters only takes effect on the active, not on already existing test definitions! At the same time it is a presetting for new test definitions. 20
37
1 2
19
Figure 34: Numbering of the 37-pin D-Sub connector
1
The in- and outputs can be extended by the installation a second opto-I/O-card.
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Pin assignment of the connector: PIN number
Assignment
PIN number
Assignment
1
1st opto input +
20
1st opto input -
2
2nd opto input +
21
2nd opto input -
3
3rd opto input +
22
3rd opto input -
4
4th opto input +
23
4th opto input -
5
5th opto input +
24
5th opto input -
6
6th opto input +
25
6th opto input -
7
7th opto input +
26
7th opto input -
8
8th opto input +
27
8th opto input -
9
1st opto output +
28
Vin1
10
2nd opto output +
29
SGND
11
3rd opto output +
30
SGND
12
4th opto output +
31
SGND
13
5th opto output +
32
Vin2
14
6th opto output +
33
SGND
15
7th opto output +
34
SGND
16
8th opto output +
35
GND 5V
17
1st timer input +
36
1st timer input -
18
2nd timer input +
37
2nd timer input -
19
supply voltage +5V; Imax = 1.6A
Table 1: Pin assignment 37-pin Sub-D connector
Note to Table 1: •
Vin1: Power supply of the 1st opto output group (output 1 ... 4)
•
Vin2: Power supply of the 2nd opto output group (output 5 ... 8)
•
SGND: Minus connection of the external 24 V power supply of the opto output group. All SGND pins are connected among each other.
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•
GND 5 V: Minus connection of the internal 5 V supply. The voltage can be used for driving a foot switch without separate power supply. Please take care of the maximum current of 1.6 A.
•
“1st opto output +” corresponds to output bit 1
•
“1st opto input +” in common with “1st opto input -” correspond to input bit 1
•
The timer inputs are actually not used. In case of controlling the multiplexers by the optoI/O-interface the used opto output group must not be supplied with 24 V externally at pin 28 (Vin1) respectively pin 32 (Vin2), because this will lead to a total damage of the analogue part of the test device!
Input
Output internaly Magnatest D
internaly Magnatest D
Vin1 resp. Vin2
PLC, foot switch …
-
24 V DC ext. power supply
+
24 V DC ext. power supplyl
opto input +
+ -
opto output
laod
opto input -
SGND
Figure 35: Wiring pattern for connecting the opto ports
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4.9.2
Software Description
CONFIGURATION OF THE SORTING
Outputs serves to integrate the test device in an automatic test procedure e. g. to control a sorting unit via PLC after testing. With key S1 a window with a table is opened where the test class definition is configured. There a test class (A, B, C, ...) is assigned to a sorting class (1 ... 8).
Figure 36: Configuration of sorting classes
Icons of the configuration window: S1
test class assignment
test class assignment
Switches to the display shown in Figure 36 where the sorting classes are assigned. S2
output bit assignment
output bit assignment
Switches to the display shown in Figure 37 where the out put bits are assigned. S5
decrease active value
increase active value
This function increases / decreases the setting value of the selected field. Select a field with the CURSOR keys WX. 76
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Software Description
Left key
Decreases the number of the selected sorting class. Right key
Increases the number of the selected sorting class.
4.9.2.1
DEFINITION OF SORTING CLASSES
In the first step the sorting classes are defined in the window test class assignment (ref. to Figure 36: Configuration of sorting classes). The field marked blue is positioned to the test class to be adjusted with the keys CURSOR ►◄. With key S5 the sorting class is adjusted. The sorting class is an intermediate step for the configuration of the sorting. It serves to combine different test classes. Test classes of the same sorting class are sorted through the same gate.
4.9.2.2
CONFIGURATION OF OUTPUT BITS
Then the configuration of the outputs has to be performed. The respective . window has to be opened with key S2
Figure 37: Allocation of sorting classes to the outputs (bit 1 - bit 8)
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Software Description
In the table you set the link between the sorting class and the out put bit affected by it. For this purpose, the sorting class / bit number has to be marked with the blue cursor using the keys CURSOR ▲▼ and ►◄. The field has to be enabled / . The fields marked with a cross are enabled. The disabled with key S5 referring bits are set when the respective sorting class is activated in the testing mode. Bit numbers shown in red are already used for other functions, for example to set an error output and can’t be used for sorting any more. Further parameters that are using outputs can be found in the list of the “General Parameter”. You find the descriptions of these parameters on page 89. The bits marked in the table with X are activated when the corresponding sorting class is set. The output signal of the sorting class “collect” is always activated, irrespective of the sorting result. From external facilities, it may be evaluated as “test completed”. With key S1 you change to the window for the sorting class definition. With ESCAPE you return to the start page of the laboratory mode.
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4.9.3
Software Description
CONFIGURATION OF TRIGGER MODE
The configuration of the trigger input is used to control the kind of measuring release for example by a programmable controller, foot switch or initiator.
Figure 38: Adjusting the measuring release
Multiple used inputs are marked with an exclamation mark behind the bit number! Functions of the window: ▲▼
previous line
next line
Use the cursor keys to select a line in the table. S5
increase the value
decrease the value
The function increases / decreases the setting of the selected parameter or selects another entry from a list.
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S6
Software Description
calculate trigger level
calculate trigger level
The function opens a page for the automatically setting of the internal trigger by means of test samples. closes the window
ESC
All settings are stored when leaving the window with ESCAPE. List of Parameters: trigger mode
This item indicates the type of triggering the test. manual (default)
Testing is started by pressing the key S1. internal
On the basis of the coil voltage, the test system detects when a test part is inserted into the coil and then will automatically trigger a test. The internal trigger function can only be used when the active test definition only contains one single parameter set (see “new parameter set” on page 31). When more than one parameter set has already been defined in the table, the following error text is displayed:
In this case first of all the setting „manual“ is to select before closing this window. In the test definition all parameter set except one are to delete. Thereafter the internal trigger function can be selected. When the trigger function „internal“ is set, the test system asks for emptying the coil to determine the voltage vector of the empty coil every time the calibration or test window is entered.
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Software Description
If the process is done with material in the coil, the trigger function will not work properly. The process then has to be done again by closing and opening the calibration or test window again. The internal trigger can only be applied with frequencies up to 4 kHz! Above this disturbances can appear.
The conveyance speed and the test frequency must be matched. If the speed is too high, the quality of the test can drastically reduce.
Check the reliability after the preparation by means of some samples to make sure that no untested parts can pass the test coil. In case of doubt the sorting gate must be adjusted in a way that untested parts are sorted as bad. external
An external signal, e. g. from PLC, triggers the testing (see on page 82 “input bit”). Alternatively, measuring can still be triggered with key S1. cross hairs
If this item is activated the test and calibration windows show cross hairs (orange “+”) that permanent dynamically indicates the actual test value, as long as it is in the visible section of the window. In case of an empty coil or a too small scaling of the measuring plane the cross hair can stay out of the visible section.
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Software Description
The cross hairs function can only be used when the active test definition contains only one parameter set. It cannot be combined with the external or internal trigger mode. input bit
For the use of the external triggering you have to indicate which port the signal transmitter is connected with. The value can be adjusted between 1 to 8 (1st to 8th opto input). The signal level of the input should be DC 24V. Voltage is to be supplied via an external power supply unit. Multiple used input bits are signed with an exclamation mark! For the triggering methods manual and internal this setting is irrelevant.
edge type
This parameter indicates the signal edge where the test is started.
The positive signal edge is used as a trigger.
The negative signal edge is used as a trigger. Only one test per pulse is performed. trigger level
in a The value can be adjusted with the key S5 range between 1 and 9999. For the basic setting the 82
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Software Description
assistant for adjusting the trigger level should be used. Refer to the point „Automatic Threshold Setting” on page 84“. demag. level
This function serves to demagnetize the test piece after the test (see also service parameter “predemag.” on page 92). 0
The demagnetization is turned off. This can cause residual magnetization of the tested part. By turning off the demagnetization, the test duration can be reduced considerable. For testing non-ferromagnetic parts like aluminium or austenitic steel, you can turn off the function without any disadvantage. 1–4
In the steps 1- 4 the demagnetisation is performed with different thoroughness. The higher the setting of the parameter is set, the longer gets the time for the demagnetisation. The demagnetisation stops when a new trigger signal is set.
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4.9.3.1
Software Description
AUTOMATIC THRESHOLD SETTING
The function “auto threshold setting“ performs a sequential controlled setting of the threshold for the internal trigger. This function has no meaning if using other trigger modes. Make sure that the table of test parameters contains only one set! First set the trigger mode on internal (ref. to “trigger mode“ on page 80). Next press S6
to start the assistant for the setting of the trigger level.
Then a request to empty the test coil appears.
Figure 39: Hint to empty the test coil
In the next step the voltage of the coil with test sample is measured. For this also a corresponding message appears:
Figure 40: Hint to pass samples through the test coil
The measurement can be performed with one or more samples. We recommend using more samples to take changes of the positioning and passing speed into account. Press ENTER to stop the process after picking up the wished number of samples. Then the calculated threshold is displayed as a graphic.
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Software Description
trigger level voltage of empty coil max. voltage of test coil with sample Figure 41: Displaying of the trigger level
The lower blue area displays the voltage of the empty coil, the yellow one the difference between the empty coil and the coil with sample. The trigger level is automatically put 30% above the voltage of the empty coil. Close the window with ESCAPE. You can manually adjust the trigger threshold, e. g. after the always necessary function check, with the item “trigger level”. If the check should show that no suitable setting for a save triggering can be found choose another kind of triggering.
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4.9.4
Software Description
MAINTENANCE Only skilled operators or FOERSTER service staff should use the functions of the data bank maintenance, because wrong operation may lead to loss of data!
Figure 42: Window with the functions of the data bank maintenance
Icons of the data bank maintenance: S1
repair data bases
repair data bases
This function performs a repair of the Access data bank. Among others, it reduces the space of the data on the hard disk and speeds up the data access. After pressing the key a message appears. Confirm the message with ENTER to continue operation.
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Software Description
The data bank maintenance is automatically performed after 100 program starts.
S2
delete all test definitions
delete all test definitions
The function deletes all entries in the list of the test definition. The test orders keep remaining but they can’t be opened for continuing testing. The function can be used to delete all data e. g. if the application field of the test device changes because of shifting it to another department. Before deleting, a safety inquiry appears. It must be confirmed with ENTER to continue or cancelled by ESCAPE.
S3
delete all test orders
delete all test orders
The function deletes all test orders. This does not influence the serial numbers of new test orders. The test definitions are not deleted. Before deleting, a safety inquiry appears. It must be confirmed with ENTER to continue or cancelled by ESCAPE.
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S4
Software Description
display HW / SW versions
display HW / SW versions
The function lists the hardware and software versions of the components of the MAGNATEST D. In first line it serves as information for the service in case of a failure or update.
Figure 43: Example for the list of components
Close the window with the ESCAPE key.
S5
maintenance
maintenance
This function serves for the setting of general parameter for the installation. Further information are found under the point “General Parameter” at page 89.
S10
reset data bases
reset data bases
Due to resetting of the data banks all user data are deleted!
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4.9.4.1
Software Description
GENERAL PARAMETER
The general parameter serves to adapt the test device to the installation conditions. Select the parameters with ▲▼.
Figure 44: Example for the list of components
S5
decrease active value
increase active value
Function for incrementing / decrementing numbers or a selection of an option. It is suitable for small corrections (e. g. changing an entry from off to on). S6
enter value
enter value
While a selection of options or a slight change of numbers can be done best with function above, is this function best for entering multidigit numbers (e. g. remote port, password).
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Software Description
Figure 45: Window for the input of numbers
Enter the numbers with the keys S1 to S0. You can delete the last entry with the W key. For closing the window press ESCAPE and check the setting of the corresponding parameter. Installation parameter: speaker
off
The internal speaker is turned off. The confirmation signal of the trigger is mute. on (standard setting)
The internal speaker is turned on. program termination
cannot end program with ESCAPE (standard setting)
The testing program can’t be terminated with the ESCAPE key. Terminating is possible only with an external keyboard by pressing ALT+F4. can end program with ESCAPE
The program can be terminated by pressing the ESCAPE key in the starting screen of the series mode. By this, the Windows desktop appears.
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Software Description
shut down windows after ending program
The program can be terminated by pressing the ESCAPE key in the starting screen of the series mode. By this, the system turns off. remote access
For special applications the MAGNATEST D can be remote controlled. The commands can be transmitted by a network or serial interface. For special applications the MAGNATEST D can be remote controlled via interface e. g. by a PC. You find a list with detailed descriptions of the instructions in the document “Remote control instruction MAGANATEST D” with the order number 1880160 / 3.632 SW1.0 UA6C/EN. use TCP/IP (standard setting)
The network socket (Ethernet) is used. use serial port
The commands are transmitted via serial interface. remote port
The parameter “remote ports” sets the port address number (TCP/IP) or COM port number for transmitting the commands for remote control (ref. to remote access).
mux interfacing
The switching of the test channels of the multiplexer up to four channels is done via coil cable without further hardware adaptation. From five to eight channels the opto I/O interface is used. use coil cable
Switching the channels is done via coil cable. use IO card
Controlling the multiplexer happens bit coded via the second optocoupler card of the MAGNATEST D. error output bit
In case of an error or system message appearing on the screen an error output for the PLC can be set. The bit no of the output is set here. At the configuration of outputs in general see to it that there is no double usage!
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The error signal can be reset by the input set by the parameter “input bit”. bit no. = 0, the function is inactive bit no. > 0, the signal is active high bit no. < 0, the signal is active low (standard setting = 5) error acknowledge port
This input sets the error message back. (standard setting = 0)
sorting pulse time
As default sorting outputs are set until the next trigger signal is released. This parameter resets the sorting output after an adjustable time, without having a new trigger signal. Independent of this the sorting signal is reset by the next trigger. 0 (default)
Standard mode as described above. time in ms
A value unequal zero means the pulse duration in milliseconds. The value can be set in a range from 10 to 1000 in steps of ten. filter
This parameter switches the 50 Hz1 filter for the use in an environment with strong magnetic fields for example due to electrical machines. Note that the filter also reduces test signals in the range of the filter frequency (e. g. 16 Hz, f3). So changing the parameter setting can influence the test values. Therefore stored calibrations should be renewed. off (default)
The filter is switched off. on
The filter is switched on. predemag.
1
This function performs a demagnetization of the test part before testing. When activated it prolongs the test duration (see parameter “demag. level” on page 83).
60 Hz in countries with corresponding power-line frequency
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Software Description
off (default)
The function is switched off. on
The function is switched on. To be active, also the demagnetisation must be turned on and the test set must contain at least two frequencies with different attenuations. sum of cal. parts
After picking up the number of calibration parts set in this parameter the system the software automatically switches from the calibration to the testing mode. It can be set between 5 (minimal necessary to calculate a tolerance field) and 30 (maximum number of calibration parts). For the automatic switching the parameter “autochange to test mode” must be activated.
autochange to test mode
Switch to activate the automatic switching from the calibration mode to the testing mode after a defined number of test samples. off (default)
The automatic switching to the testing mode is turned off. The parameter “sum of cal. parts” is ignored. on
The function is in laboratory mode as well as in the series mode active. Switching is performed after the set number of calibration parts is reached. with trendcorrection
The trend correction function automatically recognizes and corrects a drift of the test data. This function can be used alternative to the trend correction using the reference part and recalibration method. no (default)
The automatic trend correction is off. yes
The trend correction function is active. trend correction factor
This parameter adjusts the sluggishness of the trend correction function. It can be set between 0 and 300. The higher the value is the slower is the reaction of the trend correction. The best setting must be found by own experiences depending of the individual circumstances. 93
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(standard setting = 50) test class type
The calibration mode takes the setting of this parameter for the first calculation of the tolerance field. Independent of this the tolerance field can be adapted manually (see “previous / next class type” at page 46). ellipse
The standard class type is the ellipse. circle (default)
The standard class type is the circle. rectangle
The standard class type is the rectangle. boxregression
The standard class type is the box regression. test class size
The test class size is a factor by this the minimal size of the tolerance field is enlarged. The minimal size of a tolerance field just includes all calibration values (test class size = 1). The value can be set in a range from 1 to 25 in steps of one. (Default value = 3)
opto output port for calibration mode
This parameter sets the output bit that is set when the system is in the calibration mode. By this a line control can mention, that only calibration parts may be supplied to the test device. As long as the system is in calibration mode the sorting is done according to the setting of the parameter “sorting behaviour” (see page 95). bit no. = 0, the function is inactive bit no. > 0, the signal is active high bit no. < 0, the signal is active low (Default setting = 0)
opto output port for test mode
This parameter sets the output bit that is set when the system is in the testing mode. By this a line control can mention, that testing parts may be supplied to the test device. bit no. = 0, the function is inactive bit no. > 0, the signal is active high bit no. < 0, the signal is active low 94
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(Default setting = 0) password
Switching in the laboratory mode can be protected against unauthorised operation. By this only entitled personal in the company can change parameter settings. Without the password only the series mode can be used. 0 (default)
The password function is disabled. Changing from series operation mode to laboratory operation mode is possible without entering the password. numeric code
With S5 the numeric code for the password is to set. It has to be entered at the switching from series to laboratory mode. sorting behaviour
This parameter controls the sorting behavior for calibration parts, considering the sorting configuration. This means, that corresponding sorting outputs must be configured (ref. to “Configuration Of The Sorting” on page 76). off (default)
Calibration parts are not sorted. sort to R
All calibration parts are sorted as bad (class R). sort to A, B, C …
Calibration parts are sorted as good, corresponding to their test class (A, B, C, etc.). amplitude reserve
The sensitivity of the measuring input automatically is controlled in a way that the voltage is optimal adapted to the dynamic of the AD-converter. In applications with high straggling or where the input voltage is higher than at the coil matching, e. g. due to fast movement of the test parts, a voltage overdrive of the receiving amplifier can occur. With the parameter “amplitude reserve” the automatically adjusted amplification can be manually reduced. The parameter can be set between 0 and 6 dB. (standard setting = 2) 95
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print to file
Software Description
no (default)
All printouts are sent to the system printer. yes
The print function creates a JPG-file instead of an printout on the system printer. The file gets the name PICXX.JPG (XX is a serial number from 1 to 99). It is stored in the folder “c:\projects\data\pictures”. use outlier test
yes
When leaving the calibration mode the outlier test checks the homogeneity of the test classes, by searching for data that are very far away from the centre point of the other values. By this value by value is taken out of the group and for the rest a virtual circular tolerance field of the size 5.0 is calculated and checked, if the insulated value is lying inside or outside the tolerance field. If the value is lying outside it is an outlier. As soon as an outlier is detected the outlier test stops.
X
X X X
X X
X
X
Case 1: no outlier detected
X X X
Case 2: no outlier detected
X X X X X
Case 3: no outlier detected
Case 4: outlier detected check finished
Figure 46: Procedure of outlier test
The referring sample then is deleted from all parameter sets. To get at least 5 calibration samples anyway, the minimum number of calibration parts is 6 when the outlier test is active. no (default setting)
The outlier test is off. 96
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Starting module
Software Description
This function allows the automatic continuation of a test order when switching on. Series mode (default setting)
After switching on the starting image of the series mode is displayed. The test device waits for an action of the user. Calibration
After switching on the calibration mode of the series mode is automatically started. If there is no active test order, a corresponding message is displayed. Testing
After switching on, the testing mode of the series mode is automatically started. If there is no active test order, a corresponding message is displayed. Protokoll compressed
The protocol can be generated in a long or short form. In the short version, the information about the coil type and the test parameters is excluded. Off
The protocol is printed in the detailed version. On
The protocol is printed in the abridged version.
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4.10 INTERNAL HELP FUNCTION The internal help function is activated by pressing the key HELP on the front side of the MAGNATEST D 3.623. From the start images of the series mode and the laboratory mode first the window with the help for the navigation in the help system appears.
Figure 47: Example for the display of the internal help system
4.10.1 NAVIGATION IN THE HELP SYSTEM Because the MAGNATEST D shall be operated without mouse and external keyboard, the functions for the navigation in the internal help system are assigned to the keys on the front side. These special functions are available only while the help is active. When closing the help window the functions of the key on the front side are corresponding to the icons again.
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The internal help function should not be activated during testing because it might slow down the speed of data evaluation!
Key
Description < S1
Jump back to last visited page
S1 >
Help to Help
< S2
Previous page
S2 >
Next page
< S3
Opens the "Contents" file card
S3 >
Opens the "Index" file card
< S4 > < S10 > TAB (Space) ENTER
Prints a screen shot on the printer Exit help Move focus to next item Opens a marked topic
CURSOR ▲
Scrolls up one line
CURSOR ▼
Scrolls down one line
CURSOR ►
Scrolls right
CURSOR ◄
Scrolls left
ESCAPE
Exit help
The help system of the MAGNATEST D is context sensitive. That means that the theme of the online help appearing on the screen is corresponding with the function that is performed. To get further information of the actual theme select the next page with S2 >. To select the previous page press < S2.
4.10.2 NAVIGATION IN THE TABLE OF CONTENTS •
Press HELP key to activate the online help. 99
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•
Press < S3 to get the table of contents.
•
Select the wanted theme by pressing CURSOR ▲▼.
•
Press ENTER to get the sub themes listed.
•
Select the wanted item by pressing CURSOR ▲▼.
•
Press ENTER to get the help displayed.
•
Press ESCAPE to close the online help a jump back to the standard operation.
4.10.3 NAVIGATION IN THE INDEX If no external keyboard is available, navigation in the index is done as described in the following: •
Press HELP key to activate the online help
•
Open the index pressing S3 >
•
Change to the entries with TAB (SPACE).
•
Select one entry using the cursor keys.
Confirm the selection with ENTER to get the theme displayed.
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4.11 PRINT FUNCTION To print the contents of the screen (Hardcopy) a printer must be installed under Windows XP . Following types of printers are preinstalled: •
Inkjet printer (color) Epson Stylus Color 640, (default printer)
•
Laser printer (black/white) Oki Page 10ex When using a monochrome printer it has to be considered, that some graphic information may be lost if the foreground and the background color lead to the same gray scale in the print out!
The preinstalled printer must be connected to the parallel printer port (Lpt1)! For using other interfaces e. g. USB the corresponding Windows settings have to be made. The changing of the default printer has to be done as follows: -
Connect an external keyboard to the MAGNATEST D
-
The windows start menu has to be activated with the windows key or by pressing [STRG + ESC].
-
The item Settings / Printers has to be selected.
-
With the keys [CURSOR UP/DOWN] the printer to be the default one has to be selected. The setting has to be confirmed by pressing [ENTER] .
-
With the key [ALT + F] the menu item File has to be activated and the item Set as default to be selected. Confirm the selection with [ENTER].
The installation of other printers than the preinstalled types has to be done by the service. If the operator should be willing to do this by himself he should consider the following points: -
The operator must have the necessary knowledge how to install a printer.
-
The printer drivers are usually supplied on a CD-ROM. By this for the installation a CD-ROM drive is necessary. All versions from 1.03 or later have a directory C:\WININST on their hard disk, containing all CAB-files of the windows installation CD. So all necessary drivers can be installed without a CD-Rom drive!
-
Windows at the end of the installation process asks for the original Windows CD. Therefore, also a CD-ROM drive is required. 101
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-
Software Description
For the installation an external keyboard and / or a mouse has to be connected. At devices for 19” installation perhaps long connecting cables have to be used.
The printing function is applicable with the PRINT key in the following windows: Laboratory mode
Series mode
•
Calibration
•
Testing
•
Parameter set up
•
Calibration
•
Testing
•
Tabular representation of individual value
•
Test classes of individual values
•
Frequency distribution of sorting classes
In the other windows the button is without function.
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Language Selection
5
LANGUAGE SELECTION
5.1
INTRODUCTION
The MAGNATEST D will be delivered by FOERSTER either in German or in English language version. In order to switch to another language version it is necessary to perform two steps: 1. Change the language of the Windows operating system. 2. Change the language of MAGNAWIN application software. The language selection for the Windows operating system must be done by overinstalling Windows XP1 over the existing Windows version. This will be done either by the FOERSTER representative/subsidiary or by the customer himself. The language selection for the MAGNAWIN application software is done by a separate program which is installed on the system, see program Language Selection on the Windows desktop. This program offers a number of predefined language versions (presently German, English, French, Italian, Russian; other languages will be added in the future). It includes an editor that allows the user to edit his own language version if not yet covered by the system. In general, it is not necessary to select the same language for both parts (Windows operating system and MAGNAWIN application software). E. g. it is possible to use an English version of Windows together with the French version of MAGNAWIN. For languages with non-european type of characters (e. g. the Russian version with Cyrillic characters) you have to install the respective Windows version in order to get the right characters displayed!
1
An additional copy of Windows XP in the desired language is necessary. Please observe the Microsoft license regulations.
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5.2
INSTALLING A DIFFERENT LANGUAGE VERSION OF WINDOWS
You will need an external CD-ROM drive as well as an external keyboard and mouse in order to install the new language version of Windows®. FOERSTER offers a Service-Kit including an external CD-ROM drive and the necessary software drivers. Please proceed as follows: 1. Shut down the MAGNATEST D and switch off the system. 2. Connect the CD-ROM drive, the external keyboard, and the mouse to the MAGNATEST D. 3. Switch on the system and wait until the MAGNAWIN software has completed its start-up procedure. Exit from MAGNAWIN by pressing Alt-F4 on the external keyboard. 4. Start the setup program of Windows by executing the command D:\SETUP.EXE from the start menu of Windows® (the drive letter D: may vary according to the installation of your CD-ROM drive). 5. Follow the instructions of the Windows Setup program.
5.3
SELECTING A DIFFERENT LANGUAGE FOR MAGNAWIN
You will need an external keyboard and a mouse in order to switch the language on the MAGNATEST D. Please proceed as follows: 1. Exit from MAGNAWIN by pressing Alt-F4 on the external keyboard. 2. Start the program Language Selection by double-clicking on its icon on the desktop. 3. If the software actually doesn’t know the system data bank, a corresponding inquiry appears (Please select data base …). In this case first click on the item Open database in the “File” menu. This will open a window for the selection of the data bank. The complete path to the data bank is: “c:\projects\data\magnatestd.mdb”. 4. Clicking on the “File” menu opens a window with options. The function “Select a language to transfer to Magnatest D” opens a window for the selection of the wanted language. Clicking on the OK button switches the language. This confirms a corresponding message.
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5. If your language is not yet existent on the system you can edit the field “Your Language” Then install this newly created language in the way that is described under point 4.. In that case please send the file C:\PROJECTS\DATA\ MAGNATESTD.MDB to us and we will install your language into the system as one of the standard languages. 6. Exit from the “Language Selection” program by Alt-F4 and re-start the MAGNAWIN software by double-clicking on MAGNATEST D icon on the desktop.
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6
MAINTENANCE AND SERVICE
6.1
MAINTENANCE SCHEDULE
By not having mechanical components inside, a periodically maintenance for the test device is not necessary.
6.2
CLEANING Before working on the system disconnect it from the mains supply!
Clean varnished parts as well as the sealed keyboard and the monitor only with commercial detergents like rinsing agent and a soft rag. Under no circumstances cold cleaner, petrol, alcohol or similar agents may be used! In the same way cleaning may not be done using splashes of water or jetting! In order to safeguard a sufficient cooling of the test device, check, clean and/or exchange the air filter depending on the environment conditions from time to time. The visual check can be done from outside through the cooling slots at the side. For disassembling loosen both screws of the right slot cover with a small screw driver and pull out the air filter element. They have the order number 032 750 6 (packing unit = 5 pieces). Assembling has to be done in reverse order.
6.3
CALIBRATION
Before shipment the test device was calibrated in accordance with the preconditions of the ISO-standard 9001. We recommend to calibrate devices in annual intervals at normal use and calibration standard every two years. Calibration is done by Institut Dr. Foerster or one of our authorised workshops.
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Multiplexer
7
MULTIPLEXER
The multiplexer is an add-on device, which is not supplied with the MAGNATEST D.
7.1
INTENDED APPLICATION OF THE DEVICE
The MAGNATEST D 3.623 multiplexer serves to connect multiple test coils at the MAGNATEST D. With the multiplexer following operation modes can be performed: -
Testing one part at different locations.
-
Automatic changing of the test coil at one testing line for adaptation of different geometries of the samples. The device switches the coil when selecting another test definition. Testing different parts e. g. from different lines, with separate sorting cannot be done, because for all test channels a common test result is set!
7.2
FRONT SIDE OF MULTIPLEXER
Figure 48: Front side of the multiplexer
The multiplexer is controlled by the MAGNATEST D. By this it has no operation buttons or switches but only indicator lamps. The blue LED signed POWER indicates the power supply of the device when the MAGANATEST D 3.623 is turned on. The green indicator lamps show which test channel is actually active.
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7.3
REAR SIDE OF MULTIPLEXER Connection MAGNATEST Connection coil 1 Connection coil 3
Connection coil 4 Connection coil 2 Connection Opto I/O 1 Connection Opto I/O 2 Figure 49: Connections at the rear side of the multiplexer
Explanation of the elements at the rear side: Connection MAGNATEST D (Input Coil)
Connect this socket with the coil connection socket of the MAGNATEST D. This connection supplies the voltage for the multiplexer. Also the test channels of multiplexers up to four channels are switched via this cable.
Connection coil (Coil 01 – Coil 04)
Up to four test coils can be connected to the multiplexer in the standard specification. Optional the expansion up to eight channels is possible. If you connect only one coil to the multiplexer you must use channel no. 1 (Coil 01). Use further channels without gaps in rising order. Never switch the MAGNATEST D on without having a test coil connected!
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Connection Opto I/O
If using the multiplexer with more than four test coils the control is done by the opto I/O interface. In this case connect one of the opto I/O sockets of the multiplexer with the second optocoupler of the MAGNATEST D. This is exclusively reserved for the multiplexer. When controlling the multiplexer by the opto I/O interface the output group used for it must not be supplied with external power via pin 28 (Vin1) respectively pin 32 (Vin2), because this will lead to a damage of the analog circuit of the test device!
7.4
INSTALLATION
First connect the coil connection socket of the MAGNATEST D with the socket INPUT COIL of the multiplexers with a coil cable. After this connect at least one test coil at the coil connection socket 1. You can connect further test coils if required. For the use of the multiplexer pay attention for the following parameter: -
“delete / add channels” see page 30
-
“channel dec / inc” see page 35
-
“mux interfacing” see page 91 The connection of a multiplexer via optocoupler must be done by Foerster service staff!
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Technical Data
8
TECHNICAL DATA
8.1
DIMENSIONS AND WEIGHT desktop device
Dimensions; width / depth / height [mm]
490 x 420 x 178
Weight
8.2
19" built-in
486 x 450 x 178 18 kg
GENERAL TECHNICAL INFORMATION
Connected loads
115 / 230 V 50 / 60 Hz alternating voltage, 110 W (standby about 0.8 W)
Temperature range
Operation:
0 - 50°C
Storage:
-25 - 70°C
Operation:
< 80%, not condensing
Storage:
< 95%, not condensing
Relative humidity Protection class
IP 54 (front side)
Processor
Intel Celeron® ≥ 1,5 GHz
Monitor
TFT display 640 x 480 pixels
Memory RAM / HD
256 MB / ≥ 60 GB
Operating system
Windows XP
Test frequencies [Hz]
2, 4, 8, 16, 32, 64, 128, 256, 512, 1024, 2048, 4096, 8192, 12288 plus evaluation of the harmonics
Test signal
Sequential processing of sine signals
Coil current
max. 2 A
AD converter
14 bit = ±8192 points 110
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Technical Data
Number of parameter sets
24 per test definition
Number of sorting classes
6
8.3
CONNECTIONS / PERIPHERALS
External keyboard
PS/2
External mouse
PS/2
External monitor
SUB-D HD, 15 pins
Printer connection
parallel interface / USB
Serial interface
rear side 1 X RS 232, 1 X USB front side 4 x USB
Network
Ethernet 100 Mbit/s
Coils
NF and HF circumferential MAGNATEST S 3.625
coils
of
Connection of a HF-probe or a booster may cause damage of the coils. Also probes are not usable!
Booster MAGNATEST S not usable Multiplexer MAGNATEST D
see “Technical Data Of The Multiplexer” on page 112
Signal control (I/Os)
Sub-D connector, 37 pins potential-free in/outputs via optocoupler, 8 inputs 5 - 24 V DC 8 outputs 5.8 - 58 V DC / 1.7 A external voltage supply
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8.4
TECHNICAL DATA OF THE MULTIPLEXER
Dimension width / depth / height [mm]
486 x 450 x 178
Weight [kg] Temperature Relative humidity
ca. 4,5 kg Operation:
0 – 50°C
Storage:
-25 - 70°C
Operation:
8 – 80%
Storage:
5 – 95%
Protection class
IP 54 (front side)
Number of test channels
two or four in standard specification / expandable up to eight
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Masthead
Masthead
Release: 2.0/11 Status: 03.07 Author: G. Rother Order number: 1676571
Institut Dr. Foerster GmbH & Co. KG - Niederlassung Dortmund Joseph-von-Fraunhofer-Straße 15 D-44227 Dortmund Tel.: (++49 231) 975049-0 Fax.: (++49 231) 975049-8 E-Mail:
[email protected]
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