A Flexible Solution for Long-Product Inspection

Are you seeing inconsistent test results with your long-product inspection process? In many cases, the issue is not the inspection of technology itself, but how the material moves through the test. Your inspection is only as good as the way it is handled.

Long-products must be lifted, aligned, driven, and supported correctly throughout inspection. When handling systems cannot adapt to different product sizes or changing test setups, inspection efficiency suffers.

A well-designed drive table helps remove much of this variability by creating a stable, repeatable testing condition. With controlled material movement in place, inspection results remain consistent for every test.

Why Long-Product Inspection Struggles Without a Quality Drive Table

In long-product inspection, material handling plays a direct role in both inspection accuracy and production efficiency. When material is not properly aligned and supported through the test process, then inspection results become harder to control and trust. The following challenges are common when a dedicated drive table is not in place.

• Inconsistent Speed Control: Without a stable and repeatable drive speed, inspection results can vary. This makes it more difficult to correlate inspection data with physical indications on the material. A consistent speed is also needed to accurately trigger the test start and stop points based on position.
• Unstable Material Positioning:  If the material is not centered through the sensor system, inspection results can vary. This makes the results harder to trust and often requires adjustments to the inspection setup to compensate for mechanical issues rather than true material conditions.
• Longer Setup and Changeover Times: When handling systems cannot easily adjust to different product sizes or test configurations, setup changes take longer than necessary. This reduces available inspection, involves more operator involvement, and limits overall throughput.
• Mechanically Induced Inspection Variability: Poorly designed drive systems can introduce shock and vibration into the material, creating false indications in inspection results. Excessive drive-roller force can also damage the material, further compromising inspection accuracy and product quality.

Inspection should strengthen your production process, not compete with it. A properly designed drive table helps stabilize testing conditions, reduce variability, and keep inspection aligned with production demands. The FOERSTER FlexDrive is a modular, production-ready drive table designed to deliver consistent material handling and repeatable inspection across a wide range of long-product applications.

How the FOERSTER FlexDrive Stabilizes Long-Product Inspection

FOERSTER is known for advanced automation and fully integrated inspection systems. At the same time, some production environments may benefit from a different approach. The FlexDrive combines all our expertise and knowledge into a dependable solution that provides controlled material handling while remaining flexible, serviceable, and easy to operate.

The FlexDrive is designed specifically for long-product inspection, where consistent material movement is critical. The base structure features two driver pillars equipped with bottom V-rolls and top pneumatic pinch rollers. This configuration delivers smooth, even drive force and avoids the shock and variation commonly associated with spring-based systems or poorly designed clamp roller assemblies. A soft drop pneumatic mechanism further reduces noise and helps maintain stable inspection conditions.

At the center of the system is a lift and shift table where the inspection takes place. The vertical lift function accommodates a wide range of material diameters. The horizontal shift function allows easy access for maintenance and sensor system adjustments. It also allows production to run in bypass mode when testing is paused. The result is an inspection process that can adapt quickly to changing requirements without disrupting material flow.

Engineered for System Compatibility and Serviceability

The FlexDrive integrates seamlessly with FOERSTER test equipment, including the DEFECTOMAT, CIRCOGRAPH, MAGNATEST, and CIRCOFLUX product families. It is adaptable to a variety of different sensor system sizes and configurations, making it a versatile handling solution for facilities that test different products or use multiple inspection methods on the same line.

Serviceability is important to the lifecycle of any product. The FlexDrive uses mechanical and pneumatic components rather than hydraulics, simplifying maintenance and reducing long-term complexity. Bearing rails and assemblies include grease fittings for routine service, and wear components are easily accessible and replaceable using readily available parts in the United States.

A Modular Platform That Grows with Your Operation

The modular design of the FlexDrive allows the system to grow with your needs. It can be configured for in-line or offline operation and positioned after upstream processes such as straightening or polishing as a final inspection step before shipping. There is also the possibility to extend the drive table if you need to add a demagnetizing unit or run an additional test.

By incorporating the FlexDrive into your inspection process, you create more stable testing conditions, reduce variability, and improve repeatability across production runs.

Is a Drive Table the Right Fit for Your Inspection Process?

The FlexDrive provides a practical way to increase production throughput while maintaining inspection quality. It will fit into your operation, helping your material handling support your inspection efforts rather than limiting them.

Use the checklist as a starting point to assess how your material handling affects inspection performance and production flow.

• Are setup changes or changeovers slowing inspection throughput?
  Repeated manual adjustments or sensor reconfiguration can indicate the need for more controlled and adaptable material handling.
• Does low-quality handling introduce variability into inspection results?
  If inspection outcomes vary from part to part or shift to shift, stabilizing material movement and induced mechanical variability can improve repeatability and confidence in results.
• Are maintenance and serviceability affecting uptime?
  Systems with accessible components and straightforward maintenance can reduce downtime and help control long-term operating costs.
• Do you need a solution that can scale over time?
  A modular drive table offers the flexibility to be built to your specifications and an affordable price point.

If you answered yes to several of these questions, a drive table may be a strong fit for your inspection process. The FOERSTER FlexDrive can be configured to match your products, inspection equipment, and production environment.