Case Study - Cone Bearing Hardness TestChallenge Some customers have experienced manufacturing problems within their heat treating process that result in soft cones (inner rings). These “soft” parts managed to make their way through the manufacturing and quality control processes, and then end up being installed in their respective assemblies. The reason these components make it through the QA process is that these companies take unnecessary risks when relying on the outdated and inconsistent destructive batch testing method. Soft cones (a relatively inexpensive component) can cause premature bearing assembly failures. These failures are caused by hardened rollers traveling at high speeds, under great loads and elevated temperatures, wearing into the softer material of the untested defective cone bearing race. The end result can be expensive recalls or warranty repairs for manufacturers or become an unnecessary repair for the end customer. In some cases, these can be a costly item to replace or depending on the application as well as create the potential for catastrophic failure if they are an integral part of a high dollar assembly.
The Solution/Setup To solve this problem, our customers decided to implement one of our Eddy Current test solutions. In each case the customers also decided to have a turnkey system provide, to inspect 100% of the cone bearing product “in-line”. One system was designed to be a high speed fully automated unit, installed prior to final grind capable of testing up to 100 parts per minute. The other system was developed for off-line testing, but could be integrated into a production line, if required, testing at approximately 60 parts per minute. With both types of systems there was no need to stop the part in order to take a test, as the Criterion/Zetec eddy current systems can accommodate high production part rates by testing each bearing dynamically. This can dramatically increase production through put compared to other eddy current systems on the market who need to stop each part in order to test. Interested companies can address their cone bearing test by:
The fast and capable industrial I/O built into the eddy current instruments have the outputs necessary to enable the use of sorting gates, paint markers, engraving devices, directly or through PLC communications. Instruments Can be used with the MIZ®-23, MIZ- 27 CT or the InSite HT. Other Uses Testing of symmetrical components for correct alloy or in some cases, product size (geometry changes). |
