GearScan 3 Surface Burn Analyzer for Gear Teeth by Stresstech Oy
| Brand | Stresstech Oy |
|---|---|
| Origin | Finland |
| Manufacturer Type | Authorized Distributor |
| Origin Category | Imported |
| Model | GearScan 3 |
| Pricing | Upon Request |
Overview
The GearScan 3 Surface Burn Analyzer is a non-destructive, electromagnetic induction-based inspection system engineered specifically for the detection and characterization of grinding-induced thermal damage on gear tooth surfaces. Developed by Stresstech Oy—a Finnish leader in residual stress and surface integrity measurement—the GearScan 3 applies the principle of eddy current perturbation to identify microstructural alterations caused by excessive heat during precision grinding operations. Unlike optical or metallographic methods, it requires no surface preparation, chemical etching, or sample sectioning, enabling rapid in-process or post-process evaluation directly on production-line gears. The system detects subsurface white-layer formation, overtempered zones, and localized martensite decomposition—key indicators of grinding burn that compromise fatigue life, contact strength, and noise performance in transmission and powertrain components.
Key Features
- Patented multi-frequency eddy current array sensor optimized for curved gear flank geometry and varying module sizes
- Real-time, high-resolution spatial mapping (up to 0.1 mm lateral resolution) of thermal damage severity across full tooth profiles
- Integrated reference calibration using certified NIST-traceable burn standards for quantitative severity grading (Class A–D per ISO 14104)
- Ruggedized industrial enclosure rated IP54, compatible with shop-floor environments including coolant mist, vibration, and temperature fluctuations (10–40 °C)
- Modular probe design supporting straight, helical, bevel, and internal gears—adjustable stand-off distance (0.5–3.0 mm) with automatic lift-off compensation
- Built-in motorized scanning carriage (optional) for automated, repeatable traversals along tooth length and profile
Sample Compatibility & Compliance
The GearScan 3 accommodates ferromagnetic gear materials including case-hardened 18CrNiMo7-6, 20MnCr5, and AISI 4320 steels, as well as powder metallurgy (PM) and carburized alloys with hardness ranges from 55 to 65 HRC. It complies with international standards governing surface integrity assessment: ISO 14104 (non-destructive testing of grinding burn), ASTM E3092 (standard guide for electromagnetic testing of gears), and VDI 2544 Blatt 2 (German guideline for gear quality assurance). Data acquisition and reporting support GLP/GMP traceability requirements, including user authentication, electronic signatures, and audit-ready PDF/CSV export with timestamped metadata.
Software & Data Management
Controlled via Stresstech’s proprietary GearScan Studio software (Windows 10/11, 64-bit), the system provides intuitive workflow-driven operation—from probe alignment and calibration to scan setup, real-time visualization, and report generation. The software implements automated defect classification using adaptive threshold algorithms trained on validated burn datasets. All raw signal data (amplitude, phase, impedance locus) are stored in HDF5 format for long-term archival and third-party analysis. For regulated environments, optional FDA 21 CFR Part 11 compliance modules enable role-based access control, electronic record integrity checks, and full audit trail logging—including operator actions, parameter changes, and calibration events.
Applications
- Final quality gate inspection of automotive transmission gears (manual, DCT, EV reduction units)
- Process validation and optimization of CNC gear grinding parameters (wheel speed, feed rate, coolant flow)
- Root cause analysis of premature gear failure in wind turbine gearboxes and aerospace actuators
- Supplier qualification audits requiring objective, quantitative burn assessment per OEM specifications (e.g., ZF, GKN, Bosch)
- Research and development of new grinding wheel formulations and hybrid machining strategies (grinding + laser-assisted processing)
FAQ
Does GearScan 3 require coupling media or surface coating?
No—operation is fully dry and non-contact; no couplant, paint, or conductive spray is needed.
Can it detect burn beneath coatings such as phosphate or black oxide?
Yes, provided coating thickness remains below 15 µm; thicker coatings attenuate signal penetration and require empirical verification.
Is certification available for ISO/IEC 17025 accredited laboratories?
Stresstech provides factory calibration certificates traceable to SI units; end-user accreditation requires local scope validation per ISO/IEC 17025 clause 6.5.
What training and technical support options are offered?
Stresstech delivers on-site installation commissioning, operator certification workshops, and remote diagnostics via secure VPN; annual service contracts include firmware updates and recalibration.
How does GearScan 3 differ from conventional Barkhausen noise analyzers?
Unlike single-point Barkhausen systems, GearScan 3 employs multi-frequency eddy current imaging—delivering superior spatial resolution, immunity to magnetic permeability drift, and direct correlation to microhardness gradients observed in cross-sections.
