How can increasing testing volumes in industrial quality assurance be handled efficiently without compromising precision and reproducibility?
The answer lies in automation. Robot-assisted systems are increasingly being used in testing laboratories to handle specimens and perform material tests in exact accordance with standard specifications – reliably, reproducibly, and free from subjective influences.
Automation increases productivity and reduces costs
Especially in metal and plastics processing, where large quantities of specimens have to be tested every day, companies are increasingly relying on automated testing systems. The result: higher machine utilization, lower personnel costs, and reduced testing costs – while at the same time increasing test quality and process reliability.
Tailor-made solutions from Hegewald & Peschke
Hegewald & Peschke offers tailor-made engineering solutions in the field of destructive materials testing based on universal testing machines and hardness testers. The core components of the automated testing systems are usually a universal testing machine and a precise handling system based on an industrial robot. The universal materials testing software LabMaster controls and monitors the entire testing process – from specimen recognition and recording to documentation of the results and export of the data to an ERP system or another quality assurance or process control program. An integrated remote diagnosis system also ensures high system availability at all times. Each automated testing system is individually adapted to the requirements of the respective customer – for example, in terms of the load level of the universal testing machine used, the choice of clamping devices, or the measuring equipment used for the specimens. Depending on requirements, the systems can be individually designed to the desired degree of automation.
Flexible degrees of automation for every testing environment
In fully automated testing systems, sample identification is carried out via a unique ID, while the test sequences are controlled centrally via the network. These systems can be integrated directly into the manufacturing process and enable a particularly high sample throughput. Since no qualified personnel are required for sample feeding or system operation, all testing processes run efficiently and independently.
In partially automated systems, the tester performs individual tasks, such as sample labeling or random checks. Processes such as sample measurement, labeling, or other test-specific work steps can be easily integrated into the automated sequence. Semi-automated test cells can also be easily integrated into existing laboratory structures, supporting routine tests and thus reducing the workload for test personnel. At the same time, they offer a high degree of flexibility and can be converted for different test tasks as required.
Modular design for maximum adaptability
The automated testing systems for tensile tests from Hegewald & Peschke consist of modular assemblies that can be individually combined according to customer requirements.
The first step is sample feeding and handling via an automated system with a sample supply, robot, and optional intermediate storage. The test cells are well integrated into the logistics of the testing laboratory thanks to shelving systems. Specimens can be easily and continuously replenished without having to pause the testing process. A specially developed module then takes over the identification, alignment, and measurement of the specimens to ensure that each specimen is correctly recognized and precisely positioned. Of course, scales or other components can also be integrated for structural steels, depending on the test requirements.
The sample testing itself is carried out on a universal testing machine, which is optimally equipped for the automated testing task with suitable grips and an extensometer. This combination enables precise and repeatable measurements of forces and strains in accordance with the relevant standard specifications. After the test is complete, the specimens are automatically disposed of – either sorted for later evaluation (manual elongation at fracture or follow-up checks) or unsorted. Scrap-related sorting into ferrous and non-ferrous metals is also possible.
All processes can be centrally monitored and controlled via an integrated touch panel with PLC control.
Future-proof quality assurance
Thanks to their modular design and scalable levels of automation, the testing systems can be flexibly adapted to different testing tasks and laboratory requirements – from semi-automated laboratory solutions to fully networked test cells in the manufacturing process. Hegewald & Peschke thus offers not only state-of-the-art testing technology, but also a future-oriented response to the growing demands for efficiency, traceability, and quality in industrial materials testing.
Further information on automated testing systems
