Manual Magnatest D 2.0 SGP en R11

8/22/2019 Manual Magnatest D 2.0 SGP en R11

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Operating instructions

FOERSTER MAGNATEST D 3.623

Single piece testing 2.0


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Operating instructionsMAGNATEST 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 onlyoperation 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 copyrightlaws. It may be used only for operating the related system in the mannerdescribed in the sales documentation or in the User Manual. Any use over andabove this is expressively prohibited. Violations of this clause shall entail liability topay compensation for damages and may also result in prosecution under criminallaw.

Microsoft and Windows are registered trademarks or trademarks of theMicrosoft Corporation in the USA and / or other countries.

30.03.2007


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TABLE OF CONTENTS

1 Basic Safety Information 1

1.1 Warnings And Symbols 1

1.2 Safety In Magnetic Fields 1

1.2.1

Field Effect On People And Physical aids 1

1.2.2 Whole Body Exposure 21.2.3 Exposure Of Limbs And Information During Work 21.2.4 Field Effect On Magnetic Data Carriers And Watches 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 93.3.1 Elements Of The User Interface 11

3.4 Switching On 13

3.5 Switching Off (Standby) 13

3.6 General Procedure 14

3.6.1

Preparation of the test device 143.6.2 Calibration 14

3.6.3 Testing 15

4 Software Description 16

4.1 Remote Function 17

4.2 Series Operation 184.2.1 Generating A Test Order 20

4.3 Laboratory Operation 234.3.1 Password Protection 23

4.3.2

Start Image Laboratory Operation Mode 25

4.4 The Test Definition 27

4.5 Configuration Of Test Parameters 314.5.1 Representation Of The Spectrum Of The Received Signal 374.5.2 Show All Parameter Settings 38

4.6 Calibration 414.6.1 Definition Of Reference Part 52

4.7 Testing 534.7.1 Recalibration 58

4.8 Documentation 604.8.1 Tabular Representation Of Individual Values 63

4.8.2

Test Classes Of Individual Values 66

4.8.3 Frequency Distribution Of Sorting Classes 68

4.9 Administration 71


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4.9.1 Input- / Output Module 734.9.2 Configuration Of The Sorting 764.9.2.1 Definition Of Sorting Classes 774.9.2.2 Configuration Of Output Bits 774.9.3 Configuration Of Trigger Mode 794.9.3.1 Automatic Threshold Setting 844.9.4 Maintenance 86

4.9.4.1

General Parameter 89

4.10 Internal Help Function 984.10.1 Navigation In The Help System 984.10.2 Navigation In The Table Of Contents 994.10.3 Navigation In The Index 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 106

6.1 Maintenance Schedule 106

6.2 Cleaning 106

6.3 Calibration 106

7 Multiplexer 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


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Basic Safety Information

1 BASIC SAFETY INFORMATION

1.1 WARNINGS AND SYMBOLS

The following designations and/or signs are used in these operating instructionsin order to give particularly important information:

Hintparticular information about the economic use of the device.

Note

particular information about requirements and/or prohibitions

regarding avoidance of damage.

Danger

information and/or requirements and prohibitions regardingavoidance of personal injuries or extensive damage to property.

1.2 SAFETY IN MAGNETIC FIELDS

1.2.1 FIELD EFFECT ON PEOPLE AND PHYSICAL AIDS

At present there are no binding standard values for people with

pacemakers. All corresponding standards were withdrawn. Inindividual 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 correctattachment of the warning sign "No entry for people withpacemakers"!

1 MAGNATEST D 3.623Version SGP 2.0


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The operator must ensure that national standards and health andsafety at work regulations1 are complied with (e. g. marking workingareas, instructing employees in safety, preparing operatinginstructions).

1.2.2 WHOLE BODY EXPOSURE

Because of the low dispersion of the magnetic field in the usual working positionthere 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 ofdanger through magnetic fields by means of appropriate signs.

1.2.3 EXPOSURE OF LIMBS AND INFORMATION DURINGWORK

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 unfavourablecombination of coils in each case with correspondingappliance 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 objectcarrier 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 workBGV B11 (VBG 25) apply; "Accident Prevention Regulations Electromagnetic Fields" dated 1 June2001. All information on this page refers to these regulations.



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1.2.4 FIELD EFFECT ON MAGNETIC DATA CARRIERS ANDWATCHES

Because of the functional fields of the coils, proximity to magneticdata 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 therecognized regulations concerning safety engineering. Nevertheless, its usemay 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 theintended purpose with an awareness of safety and dangers under observationof 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 ofmetallic components. Another usage or a usage going beyond that usage isregarded 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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1.4 DECLARATION OF COMPLIANCE

DECLARATION of CONFORMITY

We declare in our own responsibility, that this product complies with therequirements 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. FOERSTERDivision CT Component Testing

Dr.-Ing. Jrgen 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 metallicindividual parts according to their physical properties, permeability and electric

conductivity (magnet inductive test). In general, these sizes correspond with alloycomposition 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 deviceand 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 samplethere 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 comparedwith 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/ordifferent 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. Italso 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 seenat 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

Opto-I/O

Printer socket

Socket external monitor

Mains connection socketSocket external keyboard

Air filter

Socket coil cable

Mains switchMains fuse and voltage selector

Figure 1: Connections of MAGNATEST D 3.623

Elements at the rear side:

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.

Mains switch

Should a defect prevent the test device from beingswitched off with the front side switch, switch it off with

the mains switch at the rear side.

Socket for mains cable.Mains connection socket

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 powervoltage 115 V.

Mains fuse and voltageselector

Prior to opening the fuse holder by allmeans disconnect the device from the

supply!

The adjusted mains voltage is visible in an inspectionwindow in the fuse holder. Voltage changing 115 / 230

V AC is performed by turning the basic switch by 180.


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Commissioning


As a standard, the MAGNATEST D 3.623 is equippedwith an optocoupler card. Optionally, a second I/O cardcan be built in. For the connector pin assignment referto Input- / Output Module on page 73.

Opto IO

Connector for the test coil. For connecting, use the

connecting cable with order no. 3.625.11-9911.Test coil

For entering alphanumerical characters, e. g. for givingnames for test orders, connect an external keyboard.Every commercial keyboard with a PS/2 plug may be

used.

External keyboard

Connector for a parallel printer. The printer must be

installable under Microsoft Windows XP.

Printer

This connector can be used for the connection of anexternal monitor or a multimedia projector (VGA, 640 X

480 points).

External monitor

The USB socket serves to connect an external mouseore a mass storage. Alternatively, you can use the

sockets on the front side.

USB socket

In order to safeguard a sufficient cooling of the testdevice, clean and/or exchange the air filter from time totime. (see section Cleaningon page 106)

Air filter

Fehler! Keine

gltige

Verknpfung.

You find hints for the installation of amultiplexer from page 107!

First, connect the test coil via coil cable with the connector at the rear side.

By switching on the MAGNATEST Dwithout a test coil or disconnecting atest coil while the system is runningelectronic 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 ifnames or other entries in text fields should be edited. Otherwise, the system uses

standard entries. Then establish the power supply.


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Commissioning


3.3 CONTROL ELEMENTS OF MAGNATEST D 3.623

ON / OFF

TAB

ESCAPE

Disk tray

ENTER

Rocker switches

PRINT

HELP

Cursor keys

Figure 2: Front side of MAGNATEST D 3.623

The device is switched on and off with the ON/OFFswitch. When switching the device off, it is firstshutdown in a controlled manner and then the power

supply unit is switched off. This procedure may takesome time. It is important to disconnect the device fromthe supply system only after it has switched off

completely.

ON/OFF(on/off switch)

Should switching off not be possible because of afailure, the device has to be switched off with the mains

switch at the rear side of the device.

Depending on the displayed icons, the rocker switchesperform different operating functions. The respective

function is found in the description of the softwareoperation.

Rocker switches S1-S10

If necessary the side to press is indicated with thesymbols (= right) in the manual.

In particular for the entry of parameters wherenumerical values are to be incremented ordecremented or existing values are to be selected, theright or the left side of the rocker is to be actuatedaccordingly.

In some windows the print key performs a hardcopy onthe standard printer.

PRINT


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Commissioning


By pressing the Help key, a window is opened on themonitor with help for the respective situation (contextsensitive).

HELP

The Enter key is to be used for the confirmation ofwindows that include OK / abort - button. The abort

function is performed via the escape key. Besides thefunction that actually has the focus is performed (seeTAB).

ENTER

The Cursor keys move:CURSOR

a) the blue marking bar in configuration windows

between lines or columns of a table

b) the visible segment of the calibrating / test window.

With the TAB key the focus (visible by a rectangle onthe icon) is shifted to the icon below the actual one.

TAB

Icon with focus Icon without focus

At the bottom of the screen the function of the markedicon is displayed.

In windows that include the OK / abort - button, theescape key performs the abort function. It also closes

most of the windows.

ESCAPE

By turning the handle to the left, the door of the disktray can be unlocked. Behind the cover is a 4X USBhub.

Front door


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Commissioning


3.3.1 ELEMENTS OF THE USER INTERFACE

3 4

1

5 6 7

2

Figure 3: Start image

In the headline an information about the versionnumber of the actual software as well as the name ofthe actual test definition and the number of the testorder is displayed. The color of the headline changesdepending on the application running in the foreground(headline is blue) or in the background (headline isgray). If the program is not running in the foreground, it

cannot be operated by function keys (S1 ... S10) on theright side. For switching you need a mouse or a

keyboard (ALT-TAB).

(1) Headline

In this field the icons are located. Depending on thedisplayed window they are changing. A rocker switch is

belonging to each icon on its right (S1 S10).

(2) Operation field

The status line shows the actual mode of the testdevice. Mainly the mode distinguishes between the laboperation and the series operation. It is furtherseparated in modes for the calibration, testing,

documentation and so on.

(3) Status line


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Commissioning


This window shows the function that is performed withthe left side of the rocker switch that actually has thefocus. The according icon in this case is marked with aframe. The focus is moved to the next icon with theTAB key.

(4) Operation help

This window shows the function that is performed withthe right side of the rocker switch that actually has thefocus (ref. to key on page 10).

(5) Operation help

This field shows the actual date (date of the system

clock).(6) Date

This field shows the actual time (time of the system

clock).

( 7) Time


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Commissioning


3.4 SWITCHING ON

After establishing all connections, the test device can be switched on with theON/OFF switch at the front side.

At the rear side there is a mains switchin the range of the mains connector.

This must be in position I!

Operating system and MAGNATEST D 3.623 software are automatically started. Incase of being connected to a network the name of the user and the passwordmust be entered when starting up. Therefore an external keyboard must beconnected.

Prior to any tests, the test device should"warm up" for about half an hour inorder to avoid an influence of testingresults caused by temperature. This isparticularly important, if the device wastransported from a cold into a warmenvironment 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 GENERAL PROCEDURE

3.6.1 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 testsample 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 thepositioning, 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 Definitionon page 27)

- adjust the test parameter (ref. to Configuration Of Test Parameters onpage 31)

- adjust the parameter for sorting and triggering (ref. to Configuration OfThe Sortingon page 76 and Configuration Of Trigger Modeon page 79)

3.6.2 CALIBRATION

Calibration is the definition of the sorting areas. It is done with defined goodsamples. The calibration samples must be in the same condition as the partsunder test. This is to verify by means of appropriate test procedures.

You can do the calibration in series or laboratory mode. You find the differencesbetween both modes in the paragraph Calibration on page 41.

In the calibration window all icons are marked with a yellow stripe at the rightedge to prevent confusion with the test window (green edge).

First calibrate the samples for the first test class (A). The actual test class isdisplayed at the left edge of the screen. For calibration every piece must be put inthe 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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Commissioning


Trigger the test device, depending on the configuration, with the S1 key (manualtrigger), from external by a port of the optocoupler input or by the internal triggermode. 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 isdisplayed blinking.

Calibration parts are sorted appropriate to the setting of the parameter sortingbehaviour (see page 95).

If wanted, the process can be continued with further test classes. Test classes canonly be generated in the laboratory operation mode. It is possible to generate thetest classes without picking up calibration values and to continue the calibrationlater 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 oftolerance 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 threefrequencies and two test classes.

Calibration of the test class must be continued at least until a tolerance field iscreated around the calibration values (minimum 5, maximum 30 samples, seesum of cal. parts at page 93) As long as the calibration is incomplete switchinginto test mode is not possible.

Before finishing calibration, the size and the shape of the tolerance fields can beadapted with the corresponding functions (see the parameter test class typeand test class sizeon page 94).

Size and shape of the tolerance areas should be selected in the way that nooverlapping with other areas happens. The gap between the groups especially toNOK groups should be big enough.

Press the ESCAPE key to finish the calibration mode (see also parameter auto-change to test modeon 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 = NOKor in different classes A, B, C, R.

The handling of the test samples in the test mode is identical with the one in thecalibration mode.

Additional sorting is performed after the test. The result is displayed at the leftedge of the screen and, if corresponding settings are made, parallel an

optocoupler output is set.


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Software Description

4 SOFTWARE DESCRIPTION


The operation of the MAGNATEST D 3.623 is performed on two levels.

Calibration mode

new value

deleting of last / all valuesselect value

reference part / add; change test class

change evaluation mode

size of tolerance field

info actual status

change viewmanual zoom

automatic zoom

Test mode

new value

delete previous value

recalibration mode / test mode

info actual status

change viewmanual zoom

automatic zoom

Generation of test orderok

cancel

first / last page

previous / next page

add definitioncopy definition

delete definition

enable / disable channel

Selection of test definition

Administration

Configuration of sorting

test class -> sorting class

sorting class -> output bit

selection of parameter set

Maintenance

repair data bank

delete all test definitionsdelete all test orders

info hard-/software infogeneral parameter

reset all data banks

Calibration mode

new value

deleting of last / all values

select value

reference part / change test classchange evaluation

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

Configuration of trigger mode

set trigger mode /cross hairs

set input bit

set edge type

set trigger level

demag. level

MAGNATESTDRelease2.0

Documentation

Table of single values

Table of sorting classes

Histogram

Export to ASCII

first / last page



first / last page



first / last page


show histogram

delete test order

print protocol

add setdelete set

frequency adaptation

evaluation of higher harmonics

coil current attenuationcoil matching / ADC adaptation

sensitivitychannel selection

spectrum

show parameter settings

Parameter setting

Password

Changeto

labo

ratoryoperation

Changetoseriesoperation

Figure 4: Software structure of the MAGNATEST D 3.623


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Software Description


On the level of series operation, the operator can create a new test order basedon an existing test definition, calibrate the device with sample parts (establish thesorting limits), and perform a series test. On this level no settings can bechanged.

On the next higher level of laboratory operation, additional configuration stepscan be performed.

After switching on the device is always in series level.

How to work with an existing test definition is described under the pointGenerating 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 thismanual.

4.1 REMOTE FUNCTION

For special applications the MAGNATEST D can be remote controlled viainterface e. g. by a PC.

You find a list with detailed descriptions of the instructions in the documentRemote control instruction MAGANATEST D with the order number 1880160/ 3.632 SW1.0 UA6C/EN.


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Series Operation Software Description


4.2 SERIES OPERATION

After starting up the system is always in the "series operation" mode1

. This is usedfor the recording and documentation of test results based on a device settingdetermined in the test definition, but there is no possibility to change any settings.

Generate a test order for starting the calibration or testing mode.

The keys S1 or S2 are used for restarting an already started testorder after an interruption as long as the last generated test order has not yetbeen 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 aninterruption is restarted. In the testing mode the parts are sorted and stored forlater documentation purposes.

You find further information about this function under the point Testing onpage 53.

1The behavior can be changed by the parameter Starting module (see on page 97).


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S2 calibration calibration

With this key the calibration in series operation mode after an interruption isstarted. With this a calibration can be edited or completed.

You find further information about this function under the point Calibration onpage 41.

S4 new test order new test order

This function creates a new test order based on an existing test definition (seeGenerating A Test Order on page 20). For this a stored test definition is to selectfrom 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 Documen-

tation at page 60.

S8 laboratory mode laboratory mode

The function changes from series operation level into the laboratory operationlevel. 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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4.2.1 GENERATING A TEST ORDER

Prior to entering into calibrating or measuring function, always activate a test

definition in the selection field with key S4 . From there you directly change

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 onthe right of the selection field. Besides you can expand or reduce each line withthe keysWX.

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 Testingon page 53)

b) Calibrating mode, if no or an incomplete basis calibration exists. A calibrationis complete only if each test class contains at least 5 values.(ref. to Calibrationon page 41)


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If the calibration mode or testing mode is started without having an active testorder, the following error message appears:

Figure 7: Hint, that now test order is existing

You find a function for deleting of testorders in the documentation function(ref. to Frequency Distribution Of

Sorting Classeson page 68)!

Fields of the test order generation function:

The field displays the name of the currently marked test

definition.definition name

The field shows the entry of the field "Material" as it hasbeen indicated in the test definition.

material

The field shows the number of adjusted parameter

sets.# sets

When using the manual or the external trigger

method in series testing mode, a maximum of 24parameters sets can be processed.

When using the internal trigger as well as the crosshair displaying mode the test definition may only

contain one parameter set.

The field shows the number of the existing test classes.Adding a test class is only possible in laboratoryoperation.

# test classes

Shows the coil type the test definition was created for.Following coil types are known by theMAGANATEST D 3.623:

coil type

NF PROBE

NF SHORT COIL NF COIL


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HF COIL

HF PROBE

UNKNOWN

Connection of a HF-probe or a boostermight damage the connected sensor!

The "test order" number (number of the batch to be

tested next; five-digit string of figures) is dynamicallygenerated when marking a test definition. No sequenceof batches may be derived from it.

order name

If required enter any name for the test order. It is stored

as text. Internally the test order is handled by a serialnumber that cannot be edited by the user.

Shows date and time when marking a test definition.test start

If an external keyboard is connected, the name of thetester can be entered into this field. Therefore move the

cursor with the TAB key to the input field.

operator


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Laboratory Operation Software Description


4.3 LABORATORY OPERATION

The laboratory operation is the level on which all settings of the test device aredone.

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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The password is a combination of numbers with 1 5 digits. They have to beentered with the function keys S1 S10. Afterwards the window must be closedwith 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 nextfive minutes without entering the password again. After this time it must beentered again for changing the mode.

The user has to configure the password in the maintenance window (seepasswordon 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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4.3.2 START IMAGE LABORATORY OPERATION MODE

After changing in the laboratory operation mode, the start image of the laboratoryoperation 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 isused for all test orders based on it.

S2 testing testing

The testing mode in opposite to the one in series mode doesnt save test dataand doesnt 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 highharmonics and the attenuation of the coil current (reduction of the coil current)


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Due to those parameters the quality of separating different material conditions iscontrolled.

All adjustments are stored in the actual test definition. You find the description ofthe 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 ofthe test device to automatically running processes and the data bankadministration (see from page 71).


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The Test Definition Software Description


4.4 THE TEST DEFINITION

A test definition is always the basis for each test order. It contains all settings fortesting.

Among testing parameters also settings for the in- and outputs for thecommunication with control devices e. g. PLCs. Also the calibration can be storedin it. All test orders that base upon a definition that already includes a calibrationstart 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 thekeys CURSOR the keys S1 and S2 for changing the pages.

When closing the window the marked test definition becomes the actual one. Alllater made settings are stored in it. The name of the actual test definition isdisplayed in the headline of the windows.


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S1 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 testdefinition and adds it at the end of the table displayed in Figure 13 as new linewith 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 alwayscontain a 1.

The number of parameter sets is defined at the configuration of the testparameters (see Configuration Of Test Parameterson page 31), the one of the

test classes at the calibration in the laboratory mode (see Calibrationon page41).

The test definition automatically gets a preset name. This is made up of thedesignation "test def." and a serial number (e. g. "test def. -6").

If an external keyboard is connected, the standard name may be changed, as wellas all following fields that are exclusively used for the later documentation may be

completed.

Change between the fields with TAB.


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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.

This field can be used by the user in order to group the

test definitions according to own criteria.

category

Here, the name of the material to be tested can be

entered.

material

In this field you can enter the kind of test, e. g.confusion test or hardness control.

criterion

This field can be used to enter further descriptive

information.

description

S4 copy test definition copy test definition

The copying function copies the marked test definition completely. The new onecontains 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 . Then, there

will be a query.

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 thenumbering of the first column (no.) is updated.


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S8 delete channel add channels

The enabling / obstruction of multiplexer channels prevents the usage of outputswithout connected coils. Only enabled channels can be selected later at the

configuration of the test parameters. The number of enabled multiplexer channelsstands 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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4.5 CONFIGURATION OF TEST PARAMETERS

In order to adjust the test parameters, the system must be in laboratory operationand 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


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 setwhere the blue bar is. Afterwards, the table is sorted anew. This happensdynamically when changing settings. By this the marking stays on the selectedparameter 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 thetop).


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The test device will deal with the parameter sets with different test frequency orattenuation one after the other. Adding such parameter sets extends the time pertested part. Sets with the same setting of frequency and attenuation arecombined.

Up to 24 parameter sets per test definition can be created and used. Each linegets a serial number in the column set no. It is automatically updated by theadding or deleting of parameter sets.

After the attempts to determine suited parameters and to reduce the test time allparameters that do not permit a separation should be deleted.

For the use of the internal trigger

function as well as the cross hair displaymode 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 setmove 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 therespective 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 ifa HF-coil is connected between 2 and 12288 Hz. The recognized coil type isshown 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 selectedfrequencies. 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.


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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 ofhigher harmonics can only be used when testing ferromagnetic parts since othermaterials 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 beevaluated up to the 11th harmonic. The excitation of higher harmonics can be

checked with the function "Spectrum" (ref. to Representation Of The

Spectrum Of The Received Signalon 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 canbe reduced in steps of 1 dB beginning at 0 dB. The actual setting is displayed inthe 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 magneticfield excitation).


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S6 coil matching ADC adaptation

A coil matching or ADC adaptationdeletes 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 coilmatching is performed automatically when closing the actual window. Pressing

S6 can also start the same function. If it is performed with the key, theprogram 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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S7 decrease sensitivity increase sensitivity

The adjustment of this parameter isdone automatically at the coil matchingprocess or the ADC adaptation!

The setting of the sensitivity adjusts the voltage of the test coil to the measuringarea 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 theautomatic setting leads to an too low or too high amplification of the receiving

signal.

Changing the setting leads to thedeletion of the possibly existingcalibration!

The voltage at the receiving side of the coil is depending on multitude factors. Itrises due to increasing of the coil current and is depending on the sensor typeand the magnetic and electrical properties of the test samples. For beingmeasured 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 thedeterioration of the measurement.

The actual modulation percentage can be seen in the function harmonic aspercent 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 toan 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 forexecuting the parameter set.


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Setting a channel only takes effect if amultiplexer is connected!

You can only select channels that are enabled in the test definition (see on page30 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 currentlymarked parameter set is activated in a new window. The display of the higherharmonics is limited to 2 kHz (see Representation Of The Spectrum Of TheReceived Signal on page 37).

S10 show all parameter settings show all parameter settings

The function opens a window that displays detailed information of the parametersets. You find more details under the point Show All Parameter Settings atpage 38.


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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4.5.1 REPRESENTATION OF THE SPECTRUM OF THERECEIVED SIGNAL

Only ferromagnetic parts generatehigher harmonics!

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 thetest coil that are not included in the exciting test signal. These frequencies arecalled 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 fromapplication to application.

In order to evaluate whether the received signal of the currently marked parameterset 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 thetest signal appears.

At the upper edge of the window the number of the active parameter set as wellas the appropriate frequency are indicated.

In a first step, perform a coil matching with key S2 . For this purpose, theremust 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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Now, the signal spectrum is displayed in the current window. The bar above f1displays the level of the base wave, the bars above f3 f11 the level of the highharmonics. Higher harmonics > 1% of display height can be used for the test.

Functions Of the Spectral Representation


Close the window with ESCAPE. The program will skip into the representation ofthe 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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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 keysto 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 upwith the CURSOR key.

S1 decrease pre-signals increase pre-signals

Presignals are measurements without mentioning the results to set ferromagnetictest samples in a defined magnetic condition. By this the test results becomestabile 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 showsfollowing parameters:

presignals

see above


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averaging

Due to averaging the test results become more stable and the signal/noise ratiobecomes 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 Software Description


4.6 CALIBRATION

Calibration is the definition of the thresholds by calculating the dispersion and theposition of the values of the test samples in good condition.

The calibration function is available in the laboratory operation mode as well as inthe series operation mode.

Opening an existing calibration deletes all test data.

For calibration between 5 and 30 calibration samples per test class have to betested. If several test classes have been established, these must be clearlydistinguishable from each other. The higher the distance of groups towards eachother 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 thetesting mode, depending on theconfiguration 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 messageis deleted. With the ESCAPE key the message is deleted, the test class keepsremaining.

The main differences in operation of the calibration function between thelaboratory 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 eachtest order based on this test definition. It is also possible to make settings inthe calibration (test classes, size of test class, evaluation type) without picking


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up calibration data. These settings are taken as default settings in thecalibration 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, thecalibration 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 generatedin 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 41Series mode, item 2.).

5. If you reopen the calibration after picking up test data, the last 50 test valuesare 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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If calibration is to be performed in seriesoperation 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 windowfor changing an already existingcalibration all stored test data aredeleted!

Up to four parameter sets are displayed parallel on the screen.

Figure 20: Calibration window (laboratory operation)

Elements of the calibration window:

Number of the parameter set that is displayed in thecurrent window

1

Calibration values of up to four parameter sets can bedisplayed simultaneously

Channel number(1)


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The channel number displays the number of themultiplexer channel stored in the parameter list (see onpage 35, channel dec / inc).

Current adjustment of the test frequency128 HzThe display of the parameters belonging to the windowpresents a better view and a help for a later selection of

useful parameter sets.

Number of the evaluated harmonicf1

Setting of the attenuation2 dB

Factor for enlarging the represented cut-out of themeasuring plane.

XX :1

The zoom factor informs you about the size of thevisible cut-out in relation to the complete test range.The higher the indicated factor, the smaller the cut-out

of the measuring plane.

active test classA

The MAGNATEST D 3.623 can distinguish up to six test

classes.

x/y values of the last calibration valuex=nnnn=mmmm

The current test values are only displayed in the single

view mode.

Owing to the resolution of the analog-to-digital-

converter of 14 Bit, the value range in x- and y-direction

is 8192 points (comparison size without physicalunit).

Amount of current calibration values in the actual testclass / number of the actually selected calibrationvalue.

#V/W

Up to thirty calibration values per test class can berecorded. 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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Icons of the calibration window:


Triggers the recording of a calibration value (manual trigger function). Executionis made irrespective of the direction of the rocker switch. Further trigger methodscan be found in the chapter Configuration Of Trigger Mode on page 79.

S2 delete last valuedelete all values of current

test class

This function serves to delete calibration data of the current test class (seefunction S4 previous test classon page 46). In order to delete a selected valuesee function S3 select previous partbelow.

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 thecurrent 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 withS3.

S3 select previous part select next part

Makes it possible to select a calibration value in order to delete it with the key< S2 . The selected value appears blinking. The number of the selectedpart 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.


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S4 previous test class next test class

Switches between test classes resp. generates a new one (only in laboratorymode!).

The classes A to F can be generated for sorting. Class Y serves to store areference 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 selectedtest class does not exist yet, a query will appear as to whether it is to begenerated.

Confirm the inquiry with ENTER.

The new test class automatically gets the next free letter of the alphabet. Theprogram 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 isbetween 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 B or A Y).

S5 previous class type next class type

Another evaluation form is allocated to the current test class. The parameter set tochange therefore must exclusively be shown else an error message appears (see

on page 50 visualization screen).


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Four evaluation forms are available:

Circle

A circular tolerance field is drawn around the calibration values. The centre of thecircle lies in the centre of gravity of the calibration values. The diameter isdetermined by the value being furthest away from the centre of gravity. Thesorting 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-dimensionalnormal distribution. For the field size no fixed probability is taken as a basis (nofixed sigma value); instead, the size of scattering is taken as the basis as in caseof 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 ofcalibration 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 valuedistribution.

Rectangle

A rectangular tolerance field is put around the calibration values. The size, theposition 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 beenfarthest 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 beswitched in an operation mode for editing the size, the position and theorientation.


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Figure 21: Adaptation of the tolerance field

In the menu for the adaptation of theevaluation 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 testclass type or a new manual adaptation they can be included in the tolerance field.

Symbol Key Explanation

S1Function for editing the width of the tolerance

field.

S2 Function for editing the height of tolerancefield.

S3Function for the horizontal shifting of thetolerance field.

S4Function for the vertical shifting of the tolerancefield.

S5Function for editing the orientation of the

tolerance field by max. 45.

ESCAPEWith the ESCAPE key the operation returns tothe calibration mode.


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S6 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 beused in single view mode.

If the evaluation method rectangle isset, the operation and displaying of thewindow 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 maximumenlargement 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 windowcannot be opened, if several parameter sets are displayed simultaneously. Italways 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 ofthe tolerance field and the number of calibration values the info window displaysstatistical information about the calibration values.


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Close the window is with ESCAPE.

S8 previous visualization screen next visualization screen

Shift function between the individual representations of parameter sets and viewwindows where up to four parameter sets are displayed in one window.

The functions "Class type", "Test class size" and Show info can only be executedin individual display of the parameter set to be changed.

A trial to edit these functions in the overview generates the following errormessage:

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 calibrationlevel. The measure for the current zoom adjustment is shown at the upper edge ofthe 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 thecalibration 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 thevisible area may not be displayed.


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Should the area of the calibration level to be enlarged move out of the windowduring 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 thatall existing calibration values are displayed. After adding new values, scaling isautomatically calculated anew.

Automatic zoom will thaw the windows that have been frozen with the manualzoom.


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4.6.1 DEFINITION OF REFERENCE PART

Influenced by the environment, for example changes of temperature during seriestesting 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 isinfluenced.

As a result the loss can increase, because a rising number of good parts arefalling outside close to the threshold. By using a reference part the shift of the testvalues 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 Software Description


4.7 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 seriesmode. 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 willautomatically 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 testorder 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 thecalibration mode. If no other adjustments were made trigger the test with the S1key. During the test the green control lamp on the left side at the bottom of thescreen is switched on. It means that the device is busy. The test is finished whenthe symbol is disappeared, then the sample can be changed.

The sorting result is displayed on the screen and, if corresponding configurationsof the sorting outputs were made, the output for the sorting gate is set.


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The test levels of maximal four parameter sets are represented in an automaticallyscaled manner. Switching to further sets is done with S8 .

The number of the actual test order is displayed behind the name of the testdefinition 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 testdefinition.

Close the test window with ESCAPE.

The actual test order can be continued with the corresponding key after aninterruption as long as it is active. The test order finishes when another one iscreated or the software changes into the laboratory operation mode.

Figure 24: Test window

Elements of the test window:

Number of the parameter set that is displayed in the

current window1.

Calibration values of up to four parameter sets can be

displayed simultaneously.

channel number(1)

The channel number displays the number of the

multiplexer channel stored in the parameter list (see onpage 35 channel).


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Current adjustment of the test parameter128Hz - f1 - 2dB

The header line of every represented parameter setshows 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 thevisible cut-out in relation to the complete test range.

The higher the indicated factor, the smaller the cut-outof the measuring plane.

Sorting result of the last test partA

Besides the unique allocation of a part in a class A - F atest value in different parameter sets may also fall intodifferent classes. In this case, it is evaluated with X.This means that the part cannot uniquely be allocatedto one class. If one part is not inside one of thetolerance 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 areonly displayed, if one individual test class is

represented on the monitor.

x = nnnny = mmmm

Display for an over steering of the test device.

If voltage overflow at the receiving side occurs, theindication is set for five seconds. In this case thesample is sorted as bad.

The busy lamp is on for the duration of the test.

Icons of the testing mode:


Triggers a test value recording (manual trigger function). Performance is executedirrespectively of the direction of the rocker switch. The last established value isrepresented flashing. As a maximum, 200 test values are displayed.

S2 delete last measurement delete last measurement

Deletes the last value.


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S3 recalibration testing

If no reference part was stored in the

calibration changing to recalibration isnot possible!

For further information see DefinitionOf 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 sortingindication 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 teststart, the number of defined parameter sets and the number of tested parts it alsorepresents 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 andthe overview windows where up to four parameter sets per window are displayed.


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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 testinglevel. 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. Thismeans 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 thatall 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 RECALIBRATION

During testing drifts can happen by variation of the ambient temperature. Due tothis 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 thereference piece in the recalibration mode with the one picked up in the referencemode (see to Definition Of Reference Part on page 52). The trend correctionhappens 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 hfgd it can be shifted onthe screen.

In automatic test systems the part is sorted as R (bad part).

The mode is finished by pressing S3 > . The program returns to the

standard testing mode.All following values are shifted by the calculated correction value (differencebetween the position of the reference part and the one of the recalibration part).


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To make sure that bad parts are still rejected after the recalibration some badparts should be tested!


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Documentation Software Description


4.8 DOCUMENTATION

You can open the documentation level on the start page of the series mode withkey 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 Valueson page 63)


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S2 test classes in tabular form test classes in tabular form

Tabular representation of test classes of last test (ref. to Test Classes OfIndividual Valueson page 66)

S3 histogram histogram

Graphical representation of test class distribution (histogram)

(ref. to Frequency Distribution Of Sorting Classeson 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 ASCIIstandard. From there the data can be processed with another software, e. g. withdata visualization tools or spreadsheet software.

The text file consists of several columns separated by spaces. There number isdetermined 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 plussign) follow. At last the test classes are listed numeric coded. The codes havefollowing 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 ofthe name of the test definition, the test order number and the actual test order


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number (it differs if the test order number internally is incremented due to editingof the calibration).


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4.8.1 TABULAR REPRESENTATION OF INDIVIDUAL VALUES

With this function, the last 5000 test values (X / Y values) of the last test order canbe 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 parameter sets

no. of displayed test order

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


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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 orthe result of one test class is in the intersection of

two test classes. E. g. the test result of parameterset 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 notwithin any of the tolerance fields the sorting

result is R.


ESC Close window

The program will skip to a higher level into the window of documentationoverview.


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 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 TEST CLASSES OF INDIVIDUAL VALUES

The window shows the table with the test classes of the single values for all testsets (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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ESC Close window

The window is closed an the program returns to the starting page of the

documentation function.


Right key

Jump to the last page of the table

Left key

Documents

Manual Magnatest D 2.0 SGP en R11