MAGWERKS

Our Commitment

With manufacturers under pressure from increased competition, reduced budgets, capital constraints, and the need to maximize throughput, it is more important than ever to ensure that when capital dollars are spent they return the highest long-term value for your company’s stakeholders and shareholders.

Magwerks machines are designed from top to bottom to be the most robust, accurate, and dependable magnetic particle inspection machines available. Since we began production in 1994 we have continuously incorporated improvements and added features to our machines that truly set us apart from any other brand of MPI machine available.

As we continuously improve our equipment, we are very careful to ensure that all improvements and new features we develop are backward compatible with our earlier machines whenever possible.

Magwerks' only business is magnetic particle inspection equipment and supplies and we take our business very seriously. We are privately owned and not a division of a large multi-national corporation that arbitrarily decides when equipment is obsolete and to cease support.

Magwerks is the only manufacturer of MPI equipment that maintains support for all of the equipment it has manufactured. We have been in business since 1993 and we will never stop supporting your new machine or the other machines we have sold.

If your expectation is that your equipment should be supported by the manufacturer for 5, 10, or more years from now, Magwerks is the only company that will meet your expectation. Your Magwerks machine will never be “obsolete”.

The following information and images highlight and compare some of the features and benefits of Magwerks magnetic particle inspection equipment.

Magwerks Chassis Electrical

Look inside a Magwerks machine and you will quickly see the craftsmanship of construction we are known for. These machines are custom built by craftspeople in the United States who still care.

Magwerks MPI machine features:

• Full PLC machine control
• All components are circuit-breaker protected
• Closed loop current control
• Solid-state switching
• All wiring is track-mounted and numbered
• AC phase and voltage sensing safety
• Built-in LED panel lighting

Magwerks Power Transformers

Magwerks transformers are typically twice the size of transformers commonly used in the MPI equipment industry.

The image compares a Magwerks transformer with a competitor's transformer. Both transformers shown are from 6,000 amp rated machines, and the Magwerks design clearly uses a much larger, more robust transformer. The power transformer is the last place to be cutting corners on for this type of equipment.

Magwerks transformers feature:

• A proprietary design with increased size and mass to provide improved heat dissipation and current-carrying capability
• A premium core using only 100% genuine silicon-oriented grain steel
• Solid pure copper windings — no cheap alloys or recycled materials
• A 13.5 volt boosted output to balance resistive losses (18 volt transformers are also available)

Switching SCR Stack

Modern MPI equipment uses silicon controlled rectifier (SCR) stacks for switching. Gone are the old troublesome magnetic contactors that were used for high current switching. The key to dependable operation and long life for these critical devices is the ability to dissipate the high amount of heat they generate during operation.

The image compares the Magwerks SCR stack with a competitor's SCR stack. Both stacks shown are from machines with the same capacity rating.

Smaller heat sinks mean a higher operating temperature, which shortens the life of any electronic component, especially a large SCR.

Magwerks heat sinks are 66% larger than the competitor's typical heat sink, and our buss work is 100% solid copper with a minimum cross section of 500,000 square mils for our 6,000 amp machine. This is definitely no place to be stingy with materials cost.

Magwerks “SCR Diagnostic Interface” — An Exclusive

Included as standard equipment on Magwerks machines is the exclusive Magwerks SCR Diagnostic Interface.

This SCR interface allows a technician or operator to quickly see which SCRs are operating and if the SCRs are wired and operating correctly. No other manufacturer's equipment has this capability.

Before the development of the Magwerks SCR Diagnostic Interface, finding a failed SCR could have taken a trained technician hours. Now any electrician can identify the problem almost instantly, saving hours of diagnostic time and money. The Magwerks SCR Interface also has the additional benefit of warning the technician if an SCR has been installed improperly during replacement.

Machine Protection

Beginning with 2012 production, Magwerks added even more internal safety features to all of our MPI machines.

The first image shows the Magwerks TVS Block (Transient Voltage Suppressor). This control is manufactured by Magwerks exclusively for our equipment and features a specialized diode that can react to an over-voltage condition in one picosecond (0.000 000 000 001 seconds).

The addition of this Magwerks-exclusive device has saved several of our customers from costly repairs caused by over-voltage spikes, such as lightning strikes that typical surge suppressors cannot stop.

The second image shows our Voltage Monitoring Device (VMD). All Magwerks MPI equipment comes standard with a VMD. This safety device protects the machine and your investment from improper electrical connections, under-voltage, over-voltage, phase imbalance, phase loss, and prolonged voltage drops.

Our VMD operates continuously, monitoring the incoming power and automatically shutting down the machine if the incoming power is not within proper operational specifications. This is another device that is standard on Magwerks equipment that has saved numerous customers around the world from costly damage caused by improper voltage input, unstable electrical power from the local provider, or issues with the power distribution system in the plant.

Heavy Duty Main Power Contactor

Standard on Magwerks wet horizontal and stationary power pack equipment is a built-in heavy duty main power contactor. This allows the machine's main power to be turned on and off at the operator console.

Older equipment, and even newly manufactured competitors' equipment, often does not come with a power contactor that can be switched on and off at the operator's console. Without this feature, the only way to turn the power off on a competitor's machine is at a main disconnect.

Magwerks was the first to offer a master power contactor and has now expanded on this feature to include a programmable auto-shutoff feature for additional power savings.

Plug-and-Play Pneumatics

On Magwerks equipment with pneumatic devices, we supply as standard equipment an installed air pressure regulator with gauge, an oil/water separator, and a lubricator. Also included is an air shutoff slide valve already attached.

With Magwerks equipment, the first thing you will need to do for installation will not be finding and purchasing extra components just to properly hook up the machine.

Main Power Circuit Breaker (Mobile Power Pack Only)

Magwerks installs a built-in internal circuit breaker on all of our mobile power pack equipment.

This protects your employees as well as your investment, as it is not uncommon for employees to connect this type of equipment to a large power source that is not fused or protected by an appropriately sized circuit breaker.

This is another Magwerks exclusive.

Magwerks “Micro-Touch” Standard Color Touch Screen

The Magwerks color touch screen comes standard with virtual instrumentation and multiple dynamic ranges and includes the following features:

• Shot Preview: displays the current for the next mag shot, eliminating trial-and-error current knob adjustments
• Repeatability: typical repeatability within one to two counts of least significant digit (LSD), even at low-end amperage shots
• Ultra-Low Range Mode: standard with 1 amp resolution and typical useful low-end performance down to 10 amps
• Automatic Preview Calibration: automatic self-recalibration keeps your shot preview within one to two ammeter counts of the actual shot

Magwerks Virtual Metering

Another exclusive feature available on Magwerks MPI equipment is virtual metering.

The low range repeatability and accuracy of this metering is unmatched in the industry. Specially designed for use on small, super-critical aircraft components, this 4.5 digit current control has ±2 amp repeatability with an accuracy of 0.1%, far exceeding current government military specifications and upcoming new specifications.

This feature makes a Magwerks machine one of the most accurate machines on the market and an ideal choice for complex inspections on critical parts.

Carrier Bath Pumps

Magwerks carrier bath pumps are simply the best used by any MPI equipment manufacturer.

The key to keeping a magnetic particle inspection machine in proper working order is to have a pump that works day in and day out and that is as maintenance free as possible.

Magwerks exclusively uses custom-designed 1,750 RPM stainless steel pumps with an impeller and pump curve design that is application-specific for MPI machines.

Besides being very dependable, the Magwerks pump provides:

• Reduced wear on magnetic particle media
• Minimized vibration
• Reduced noise
• Minimized bath temperature rise from circulation
• Maximized pump life
• Open impeller design to reduce clogging
• All wetted parts in the circulation system made from stainless steel or brass, eliminating rust scale

Magwerks Heavy Duty Steel Headstocks and Tailstocks

Magwerks fabricates headstocks and tailstocks from 1/4" plate steel. There is no cast recycled aluminum here.

They are designed to take a daily beating and keep working.

They feature:

• Baked-on custom powder coating (no low-quality spray paint)
• A 2.5" pneumatic cylinder that is bearing-supported
• Pre-drilled and tapped holes for mounting roller rests or black light arms

Additionally, all Magwerks tailstocks have rack gear drives with ball-bearing guides to prevent the tailstock from sticking or jamming on the bed rails.

Pneumatic cylinders are available in both headstock and tailstock configurations.

Wet Horizontal Tank and Frame Features

Magwerks wet horizontal tanks and frames feature:

• All stainless steel tanks to prevent rust scale or paint chips in the carrier bath
• 11 and 14 gauge American-made steel used for all support components, built to withstand the rigors of daily production
• Sealed cabinets to keep dust, dirt, and contaminated air out of the machine
• Hinged doors that provide easy access to internal components, eliminating the need to remove panels or deal with loose hardware
• Large stainless steel hip bars — no hardware-store conduit on pot metal hinges

A Green Machine

Magwerks machines are available with an auto-shutoff feature for the magnetizing circuit to save energy.

The auto-shutoff is user-adjustable from 5 to 99 minutes of idle time. This feature can add significant operational savings over a year, as the power transformer of an MPI machine typically consumes between 1,000 watts and 4,600 watts (1.0 to 4.6 kW) when idling without performing mag or de-mag cycles.

This automatic shutoff feature can easily save a plant over 15,000 kWh annually in electrical consumption per machine.

Older equipment, and even many newly manufactured machines, do not come with a power contactor to easily turn the machine on and off at the operator's console. The only way to turn the power off on these machines is at the main electrical disconnect, which often means they are left powered on when not in use.

Magwerks was the first to offer the operator-panel-switched power contactor and has expanded on this feature to include an auto-shutoff function for even more electrical power savings.

Other Magwerks Magnetic Particle Inspection Machine Features

• Eye adaptation timer built into the operator control panel to help avoid audit failures on this requirement
• “Easy Off” hip bar with easy-release spring hinge pins for quick removal and front cabinet access
• Genuine rock maple hardwood grates standard, one of the hardest woods available; UV-stabilized UHMW plastic grates are available for water-based carrier applications
• Adjustable operator console that can be rotated and raised for ergonomic operator use
• Built-in permanent forklift slots under the machine to protect personnel and prevent machine damage during moves
• Four standard ways to operate the mag pulse: operator control panel, hip bar, foot pedal, or optional pendant
• Factory-installed 120 volt accessory outlets, eliminating the need for electricians to add outlets for inspection and task lighting or accessories
• Factory-installed needle adjustment air valves to regulate the speed of opening and closing of headstock pneumatics, reducing risks of operator injury, part damage, and excessive machine wear
• “Keyed” foot pedal outlet connections to prevent accidental connection to the wrong outlet

Conclusion

From our standard machines to customized, application-specific systems, Magwerks is the go-to manufacturer for MPI equipment.

When you compare our industry-leading standard features and the craftsmanship of construction of Magwerks magnetic particle inspection equipment, along with the options we have available, to other MPI equipment on the market, you will see that Magwerks offers one of the best value investments for your company.

Please contact us to discuss your magnetic particle inspection needs for equipment or supplies and let us know how we can earn your business today.