Polysius
Find the crack
while it is still just a crack.
Key figures strip
- Non-destructive
- The component stays intact and in place
- No cleaning
- Prior cleaning of the tooth gearing is not necessary
- No contamination
- Of the lubricants by testing media
- Design experts
- Assess the measurement results
- Preventive
- Before the crack becomes a failure
The Difference
| What crack testing normally costs you | What this test costs you |
| The tooth gearing has to be cleaned and degreased before anybody can test it; testing media end up in the lubricant, so the oil is compromised; which means an oil change, or a decision to live with it; which means the test only happens when the machine is open anyway; which means it happens rarely, and often too late | Prior cleaning of the tooth gearing is not necessary; no contamination of the lubricants by testing media; so no oil change is triggered by the inspection itself; so the test does not have to wait for a major intervention; so it can be done preventively, which is the entire point |
What We Test
Non-destructive testing allows us to inspect the structural material properties of mill end walls, supporting rollers, tyres, pinions and similar plant components.
| Welded and structural | Weld joints · mill end walls · maintenance holes · stressed plates |
| Running and rotating | Supporting rollers · tyres · crusher and hammer mill shafts · cast components |
| Driving and meshing | Pinions · tooth gearing · girth gears · similar stressed drive components |
What We Look For
Every other measurement service in this portfolio examines geometry. This one looks past the geometry at the metal itself.
Reliably detected, in weld joints, tooth gearing, shafts, plates and cast components — the failure mode that gives least warning
Discontinuities in the material that are not yet cracks but are where cracks will start
Material that is not uniform where it should be — the kind of defect a casting can be born with
Not what the certificate said when the part was delivered, but what the material is like now, after years under stress
One Component, Three Questions
Take a supporting roller. It can fail in three different ways, and each one is found by a different service.
| Service | The question | What it examines |
| polscan® | Is it in the right place? | Geometry — dimensions of tyres and supporting rollers, axis deviation, axial runout, measured optoelectronically while the kiln runs |
| polgrind® | Is its surface sound? | Surface condition — grooves, unevenness, roughness, loss of concentricity, corrected by mobile machining |
| NDT | Is the metal sound? | Material — a crack below the surface, an irregularity in the forging, an inhomogeneity that no machining will remove because it is not on the surface at all |
Assessment by Design Experts
Finding an indication is the easy part. Any qualified testing company can tell you there is something in the material. The question that follows decides what you do next: does it matter?
- 1 — The test finds an indication
- A crack, an irregularity, an inhomogeneity, at a certain location and of a certain extent
- 2 — Our design experts assess the results
- The people who calculate these components decide what the finding means for this component, in this position, under this load
- 3 — You get a decision, not a data set
- Whether it can stay in service, whether it needs watching, or whether it has to come out at the next shutdown
The Six Field & Measurement Services
| Service | Examines | Typical objects |
| NDT | The material itself — cracks, irregularities, inhomogeneity, current properties | Weld joints, mill end walls, maintenance holes, supporting rollers, tyres, pinions, tooth gearing, crusher and hammer mill shafts, stressed plates, cast components |
| polscan® | The geometry of the rotary kiln, measured during operation | Kiln axis, shell deformation, eccentricity, ovality, tyre and roller dimensions |
| poldrive | The drive system and how it meshes | Girth gear and pinion, contact pattern, load distribution, bearings, oil |
| polgrind® | Running surfaces — and corrects them | Kiln tyres and supporting rollers, mill slide rings |
| PlantScan 3D | The three-dimensional shape of anything | Buildings, process systems, terrain, HPGR roll bodies, gyratory crusher elements |
| Drone Inspection | Visible condition of what is hard to reach | Towers, stacks, roofs, conveyor routes, quarry and terrain |
Your Added Value
Preventive checking of weld joints, end walls and maintenance holes
Preventive crack testing on crushers and hammer mill shafts, on stressed plates, tooth gearing, tyres and on cast components
Prior cleaning of the tooth gearing is not necessary
No contamination of the lubricants by testing media
Assessment of the measurement results by our design experts
Testing current material properties and detecting cracks and inhomogeneity — with extremely high precision.