Electromagnetic Dent Remover

The Electroimpact Electromagnetic Dent Remover (EDR) system is a high-tech handheld repair tool designed to repair dents in aluminum parts. The EDR uses eddy currents to pull the dents with single sided access and can provides significant cost savings advantages by reducing the time and labor associated with conventional repair techniques

SYSTEM OVERVIEW

  • The Electroimpact EDR is a portable dent pulling system that can easily be deployed anywhere in the world
  • EDR technology has been in use by airlines and aircraft manufactures for decades and is an FAA approved dent removal process
  • The EDR dent pulling process is unique in that it only requires single sided access and is intended to be used on the part without removal from the aircraft

APPLICATIONS AND ADVANTAGES

  • For dents where an EDR process is applicable, maintenance and downtime costs associated with repair or replacement of parts can be substantially reduce
  • Many parts without back side access must be removed before repair or completely replaced without an EDR option
  • In situations where access to the rear side of the panel is possible the economic advantages of an EDR process can be substantial due to saved time and labor

QUICK SETUP AND TURNAROUND

  • The Electroimpact EDR can be set up and ready to start work within a few minutes
  • The pulse cable and pulling head are stored onboard and can be deployed and ready to charge without making any connections
  • The EDR process does not cause any additional damage to the painted part surface and the aircraft can usually be returned directly to service

THEORY OF OPERATION

An EDR operates on the principle of eddy current induction produced by a specialized flux concentrator coil. The pulsed magnetic field is shaped in the time domain to first set up a very strong magnetic field, which is then rapidly reduced to induce a strong current in the workpiece. This is accomplished by firing two high energy capacitor banks in a precisely timed sequence. The magnetic field set up by the flux concentrator coil powerfully attracts the magnetic field associated with the induced current in the part, causing the part to be reshaped around the area of highest flux concentration.

QUICK SPECS

Power Requirements 120VAC 15/20A
Machine Weight 1110lbs (504kg)
Height 44in (1110mm)
Width 62in (1575mm)
Depth 35in (888mm)
Pulse Cable Reach 20ft (6100mm)

EDR CHASSIS

  • The machine chassis encloses the power supplies and includes storage space for the pulse cable and pulling head
  • 8in (200mm) suspension casters with breaks for quick machine positioning
  • Fork pockets and lifting points ease of transport and working in elevated positions
  • Onboard compartment for additional storage

EDR HEAD

  • Ergonomic and easy to use interface allows full control of all functions from the head without removing hands from grips
  • The energy level is selectable in 1% increments to fine tune desired pulling force
  • Change Coil warning mitigates risk of overheating a single work coil
  • Rotating coil clamp eases alignment of pulling foot on part

RFID-ENABLED WORK COILS

  • RFID chip imbedded in every coil to automatically track coil usage
  • Shot data is automatically stored after each fire cycle
  • Tracks coil cooling to prevent use of overheated coil

MAINTENANCE AND SAFETY

  • High voltage isolation barrier for high energy circuits with leakage current monitoring
  • Redundancy in all safety and monitoring systems
  • Third party UL compliance inspected
  • Status lights shows machine state and can easily be seen from all angles
  • Shielded pulse cable
  • Modular components and onboard system diagnostics make for easy repair and reduced down time

DENT REMOVAL EFFECTIVENESS

  • The effectiveness of an EDR depends on the character of the dent and surrounding structure
  • Dents that are creased, excessively deep, scratched, stretched, or in thick material are not good candidates for an EDR process
  • Dent removal typically requires a series of shots to progressively correct dent
  • The pulling foot of the coil can be specifically positioned around the dent as needed

RANGE OF MATERIAL AND THICKNESSES

  • EDR has proven extremely effective when used on various alloys of aluminum with skin thickness of 0.063” (1.6mm) and under, and has shown positive results with thicker material up to 0.090” (2.3mm)
  • EDR is also effective on aluminum honeycomb parts
  • The operator has the ability to fine-tune the system energy for each shot and dent location

DOWN TIME AND REPAIR COST

  • If a dent can be repaired using EDR it can usually be done for less than 25% of the cost of conventional methods
  • EDR repair can be completed on location and requires only a fraction of the downtime when compared to remove and repair or remove and replace techniques
  • EDR only requires single sided access, this is beneficial where back side access is restricted or difficult to access and can improve mechanic ergonomics