Home » Products » PAUT Testing » STPS-PAUT Testing System

Phased Array Inspection
of Bars

High testing speed with
short change-over times
Leaflet   Technical Data

Phased Array Inspection of Bars

The ECHOGRAPH-STPS bar inspection system features a high testing speed of up to 2 m/s and simultaneous and simple adjustment of the probe carriers, resulting in short change-over times. Optional accessories include a light barrier for the generation of test enable signals, a coupling agent filter system (KMA4) and a marking device (FME) for true-to-position flaw location and/or go/no-go marking.

 Inspection technique

The detection of internal flaws is carried out with straight beam shots, whereas surface-near flaws are detected with angle beam shots. The ultrasound is coupled via guided water jets (squirters) and permits test conditions comparable to immersion testing with short untested ends. The contact-free coupling ensures little probe wear, also in case of black bar testing.

The image shows a CIVA simulated insonification with 8 and 17 shots.

CIVA 8 shots CIVA 17 shots

 Probes with protective guiding skids

CAD image of STPS-PAUT mechanics

Five phased array probes, which are equally spaced (72°) around the bar circumference, are employed for flaw detection. The probes generate sector scans with up to 20 shots and, in total, up to 120 parallel test channels are active. The sound fields of the five phased array probes provide multiple overlapping with 100% coverage of the complete cross section. The probe carriers are mechanically protected by guiding skids, which are also responsible for stable coupling and testing conditions by guiding the probe carriers along the bar surface. Unavoidable mechanical bar tolerances are compensated for by the spring-loaded suspension of the probe carriers.
 System layout

The testing mechanics is mounted on a height adjustable test table. A horizontal support (sliding device) is mounted onto the test table and is used to move the test mechanics between test position (in-line) and calibration position (off-line). In off-line position, calibration and service work can be carried out without interfering with the ongoing production. Feeding of specimens is carried out by centric roller drivers (triple rollers are advisable, double rollers also possible). Normally, after testing, automated sorting of the tested bars (go and no-go sorting) is applied. The required mechanical conveyors are usually supplied by the customer to ensure smooth integration into the manufacturing process line.

Layout STPS
 Evaluation electronics and ECHOVIEW Data Management Software


Evaluation of the ultrasonic signals is carried out with parallel phased array electronics, which is specially designed for automatic systems. Various flaw gates, amplitude thresholds, programmable time-corrected gain TCG (DAC) and multiple evaluation parameters are available. The electronics is mounted in a shielded and fully air-conditioned electronic cabinet (ELNS). A movable operating panel (BAG) that may be relocated next to the test mechanics is fitted with a 24”-monitor used for setting of the test parameters and for visual data display (i. a. for the indication of A-scans during calibration). Remote access of the electronics is provided by the diagnosis module.


The KARL DEUTSCH software package ECHOVIEW is designed for an industrial PC with a RAID managed HD system for highest data safety under Windows© 10. It documents, stores and processes the test parameters, test reports and results, and optionally supports communication with a remote host computer.

 For trials in dynamic mode: Test system in our applications lab

The KARL DEUTSCH laboratory for ultrasonic testing systems provides a roller conveyor and allows for trials in dynamic mode with realistic testing speeds – also on material provided by customers. Several reference bars of varying diameters are available. They contain artificial defects, which were produced and certified by the BAM Institute for Material Research and Testing in Berlin, Germany.
 Watch it on video

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 Technical data
 Round Bars
steel, hot rolled or cold drawn, aluminium extruded or cast, copper, brass, etc.
 Diameter range (D) 16 to 130 mm (standard), option: from 8 mm up to 150 mm, various system set-ups are available
 Length min. 2.5
 Ovality max. 2% of D
 Straightness deviation max. 2 mm/m
 Surface condition black, bright, drawn or cast
 Temperature max. 60 °C
 Bar ends machined, no burr
 Sensitivity min. FBH 0.7 under static conditions (dependent on diameter, surface condition, straightness)

Current Dates

07 - 10 May 2019
33rd Control, Stuttgart

27 - 29 May 2019
DACH Annual Meeting, Friedrichshafen

14 - 17 October 2019
28th testXpo, Ulm

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