DuraPro 1000 :: Hardness testing modules for automated systems

Hardness testing modules
for automated systems.

Four different modul types.

Universal hardness testing module with surface preparation.

Detailed documentation for planning purposes

Can be used in new or existing systems/lines/plants

Ports for data link-ups

Details

Achievements

Accessories

Technical data

Applications

Hardness testing modul

Test portal for the determination of hardness on forged steel in HBW 10/3000
Single test points are defined by means of a laser pointer
Milling of test area via end mill cutter
Monitoring of test height by light barrier
Measurement data is transmitted to Windows-based software

Automation with DuraPro Modules

We are cooperating successfully with various automation partners concerning any kind of automation.
Constructions as per customer request

DuraPro 1000.

Universal hardness testing module with surface preparation.

Brinell
acc. to EN ISO 6506, ASTM E-10
10/250	10/500	10/1000	10/5000
10/3000	HBT (not acc. to standards)

Rockwell
acc. to EN ISO 6508, ASTM E-18
HRC	HRG	HRK	HRP
HRV

DuraPro 1000 is a hardness testing module with a high definition 1/2” camera for fully automatic, standardised image analysis of optical testing methods. For hardness testing on unprocessed raw items the test unit is equipped with a milling unit to ensure the test surface can be prepared optimally. Load application is done via the tried and tested closed control loop method facilitating a larger test load range.

Areas of use

This module can be applied for a wide range of purposes as it uses both optical and depth gauging methods. The integrated milling unit means there is no need for any further manual treatment of test pieces prior to testing

Control unit and gauging electronics

DuraPro 1000 uses a Siemens control system for the entire milling and testing cycle. Gauging is conducted using standard G3 electronics and can also be driven by the Siemens SPS. The entire controls, LCD touch screen display for hardness testing, the Siemens operating panel and the operating buttons for the milling unit are contained in a compact control unit.

Installation and clamping

Fully automatic image analysis

Automatic image analysis facilitates excellent repetitive precision. Various surface settings can be saved along with the load and degree of enlargement. This ensures substances are always tested under the same conditions. To ensure the indents are displayed as well as possible and for setting purposes the DuraPro 1000 has an 8.4“ touchscreen panel that can be operated in the following languages: DE/EN/IT/SP/FR.

Meaningful statistics

All test results can be displayed as bar graphs or line charts with tolerance limits overlaid. Statistical considerations and result ranges are included as standard. Test reports and diagrams can be printed out via a USB interface.

Operating and controlling the milling unit

A Siemens SPS control unit is responsible for the automatic milling and testing cycle for the DuraPro1000. The Siemens OP77A control unit is used to set all necessary milling parameters and is labelled in the following languages DE/EN/IT/FR/SP. The control cabinet also includes buttons for functions such as start/stop cycle, laser pointer on, etc.

Data export

All hardness testing data can be transported with the optional export tool as .csv- or .txt via the Ethernet interface, facilitating continuous, unbroken data administration.

Communication with plant/line controls

The Siemens controls can communicate with other control systems via Profibus facilitating simple integration into systems and machines. There are hardware inputs and outputs available for the connection of an emergency off button.

Efficient surface preparation

Suitable for various test pieces

The Durapro1000 enables tests to be carried out on a wide range of items. The fully automated test point preparation allows untreated materials to be subjected to hardness testing. The integrated grinding unit helps to determine the best possible surface conditions for hardness testing.

Positioning via laser pointer

In order to position a test point on a subject without immense effort the DuraPro 1000 is equipped with a laser pointer. This enables a test point to be accurately manoeuvred to from a remote position because the laser point can be very clearly seen on a test piece.

Setting the grinding depth

Grinding depth can be varied and set between 0 and 6 mm by the operator. The surface is checked with a test head before the grinding process is initiated to ensure the required grinding depth is achieved.

Get the Flash Player to see this player.

Additional options available:

Automatic chip suction during the grinding process
Heating/cooling for all electrics to raise the working temperature range from -10 °C to 50 °C
Software for the automatic calculation of the average of three test points and the production of an average value for the Ethernet interface

A selection of references

DuraPro 1000 is integrated into a large portal for Brinell hardness testing on shafts, rings, blocks, plates etc. including surface preparation and automatic suction of chips and bits.

Over 50 years of experience.

In the hardness testing segment.

Nowadays many new production plants and existing machines are developed and upgraded with modular components. As the hardness testing section of EMCO Maier GmbH was founded in 1954 EMCO-TEST can offer decades of experience in this field. Their entire know-how has been packed into the DuraPro series hardness testing modules to be able to provide modular machine components for a wide range of hardness testing applications. An EMCO-TEST hardness testing module always consists of a testing unit and control unit with connecting leads.

Hardness testing modules with know-how.

Premium technology in modular units.

		Expand existing systems This testing module is ideal for the task of expanding on existing systems. Hence expense can be spared as there is no need to acquire special machinery, plants or lines.
		Integration into new systems The testing module can also be integrated into new plants, systems and production lines. This enables hardness testing to be added directly to the flow of production as early as the planning phase. Work pieces do not need to be removed from the production process and 100% of the pieces can be tested.

		Customised Hardness Testers Logical interfaces and exact assembly instructions facilitate the construction of custom-built hardness testing systems, tailored to the exact needs of each user. The only precondition is the existence of a device capable of accommodating and moving the testing module according to the technical information provided.
		Universal application Whether expanding and upgrading an existing plant, integrating hardness testers into a new production line or setting up a hardness tester as a stand-alone solution, the modular construction of the DuraPro series means it can be used in any situation.

Detailed documentation for planning purposes.

Construction drawings, assembly plans etc.

Documentation for planning purposes

To give users and plant constructors as much support as possible we provide plenty of detailed documentation for our DuraPro series products as early as the planning phases for plants, lines and machines etc. As well as technical data for installation and drilling plans we also provide complete DXF files in 2D und 3D for each individual hardness testing module allowing testing modules to be added to, and positioned in construction drawings simply and easily. All documents needed for planning and construction can be downloaded.

Documentation for operation

On receiving a hardness testing device the customer also receives detailed documentation on each individual DuraPro product. This includes assembly and installation instructions, and operating instructions, to ensure the module is installed and used correctly. These instructions are produced in five languages: DE/EN/IT/FR/SP.

Download Documentation DuraPro 1000

All the main features at a glance.

For end users and plant builders.

Use

Planning

	100% checks possible during manufacture
	Savings made due to upgradability of existing plants
	Low maintenance
	Simple operation
	Various languages
	Ports for data link-ups

	Logical interfaces
	Space saving construction
	Durable and can be used in heavy machine building
	Exact assembly instructions
	Flexible integration
	Downloadable DXF files for plant construction
	Communication with other control systems
	Can be used in new systems/lines/plants
	Can be used in existing systems/lines/plants
	Can be used as a stand-alone solution

Hardness testing module DuraPro 1000

Test unit M5CP30 incl. Milling unit for surface preparation
control unit with LCD-touch screen display and
Siemens OP77A operator panel for milling parameter input
test methods Brinell/Rockwell (acc. to standards)
loads 60 - 3000 kgf
incl. standard nose cone K06, length 140mm,
support dia. 23 mm, drilling 13,5 mm
connection cable package, length 10m

Attention: A suction unit is required
Either option F10, or an equivalent suction unit by customer

Select your requested accessories! |