production-testing-for-automotive-components

Production testing for automotive components

Incorporating acoustic quality analysis and vibration production testing as an integral part of the manufacturing process ensures the quality and customer acceptance of the entire powertrain in order to limit recalls, maximize production line yield and cost effectiveness.

Production testing that matches your production line and product is required to ensure the quality, customer acceptance and cost effectiveness of the entire powertrain. And all of that results in minimized recalls and maximized production line yield.
Incorporating acoustic quality analysis and vibration production testing as an integral part of the manufacturing process that enables rapid, reliable and thorough noise, vibration and harshness (NVH) testing for all kinds of mechanical assemblies. When developing a comprehensive test system for powertrain production lines, you need to cover everything from end-of-line pass-fail gear testing (which is the incoming quality assurance for gearbox testing) to end-of-line transmission testing, to end-of-line engine testing. And the system should include in-car testing of a finished product for correlation with test-stand data. A complete system that logs data for each stage in the production line provides traceable data that identifies and enables the elimination or mitigation of the root causes of unwanted noise, vibration or durability issues. And it is the elimination of root causes that ultimately results in greater production line yield and cost effectiveness.
The Rotas NVH Analysis System performs end-of-line testing on test benches that simulate driving conditions, and the testing is optimized for the short cycle times (time between the start of each test) typical for quality assurance (QA) in industrial production, including:

  • Gear testing
  • Gearbox testing, including manual, automatic and dual-clutch transmission designs as well as axles and transfer cases
  • Tapered roller bearing analysis
  • Diesel injection pump analysis
  • Engine analysis, including electric motors

In a completed assembly, cabin noise evaluation can be used for correlation with test-stand data so that faults found in a completed vehicle can be traced back to their root causes.

gear-testingGear manufacturing is a relatively high volume area and production faults at this stage are relatively low cost. The ideal test system for this scenario is an automated pass-fail test that automatically sorts the gears to either continue to the next production line or be kicked back to be reworked or melted down and made again. And to cut down on future failures, logging data concerning the nature of the failure can help to identify patterns and trends and refine predictions based on tool-wear, for example.

System suggestion
RotasPro Gear Test and Noise Analysis is and end-of-line test for gears. This system can perform single- or double-flank testing – depending on the production requirements – to identify nicks, surface waves (or ripples), and geometry problems. The Rotas NVH Analysis System comprises transducers and a front end for data acquisition, a state-of-the-art PC for processing, analysis and data storage. The measurement data is stored in a database and is available for analysis and traceability. This capability aids in identifying trends and refining tool wear predictions in order to minimize failures, both at the test stand and on down the production line.


transmission-testing

Transmission production is medium volume. Because transmissions are too expensive (both in material cost and time) to be scrapped on a failure, testing should provide detailed information on the problem and its source so that the failure can be repaired. Transmissions are made up of many rotating and intermeshing parts, so the test system must be capable of isolating individual parts in order to pinpoint the source of the problem. Once the problem is identified and fixed, the root cause of that problem needs to be traced and, ideally, eliminated.  

System suggestion
RotasPro Noise Analysis is an acoustic quality, end-of-line test for transmissions, gearboxes and axles. As part of the Rotas NVH Analysis System, it is comprised of data acquisition hardware, databases for storing relevant information and analysis tools for identifying and mitigating problems.
This is an acoustic noise analysis QA system with a short measurement cycle.  The system integrates analysis methods that concentrate on periodic signals (order synchronous resampling), which allows the identification of individual parts. In this way, internal noise and vibration sources can be located and analyzed to identify the nature of the problem. All of the data is stored in a database that, along with analysis, can be used to continuously refine test parameters for the elimination of root causes of and identification and prediction of trends.


engine-testing

Engine production is medium to low volume production area, where missed faults can incur considerable cost, loss of durability and a drastic impact on customer acceptance. Simple pass/fail results will not suffice. Testing should provide detailed information on the problem and its source so that the failure can be repaired. The test system must be capable of isolating individual parts in order to pinpoint the source of the problem. Any data that leads to the elimination of a root cause of the failed component can save time, money and reputation.

System suggestion
RotasPro Noise Analysis for Engine Test is an acoustic quality, end-of-line test for engines, including electric motors. As part of the Rotas NVH Analysis System, it is comprised of data acquisition hardware, databases for storing relevant information and analysis tools for identifying and mitigating problems.
This is an acoustic noise analysis QA system with a short measurement cycle.  The system integrates analysis methods that concentrate on periodic signals (order synchronous resampling), which allows the identification of individual parts. In this way, internal noise and vibration sources can be located and analyzed to identify the nature of the problem. All of the data is stored in a database that, along with analysis, can be used to continuously refine test parameters for the elimination of root causes of and identification and prediction of trends.

cabin noise

After the finished product leaves the production line, it should be tested in a completed vehicle because there are a multitude of transfer paths from engines and transmissions to the cabin. So it is important to correlate the actual vehicle interior noise with the production line test-stand data. An in-vehicle test can aid in the identification of frequency bands that may be masked or accentuated via a transfer path. Once problem areas are identified, the relevant tolerance parameters at the gear, transmission or engine test stands can be adjusted to ensure that passing components and assemblies leaving the test stands will also pass testing in the finished product.

System suggestion
Rotas Mobile is a universal measurement, analysis and assessment system for portable acoustic measurements. The system comprises of four microphones, one accelerometer, a front-end data acquisition subsystem and a laptop PC with the Rotas Mobile software installed for data analysis. Once the data has been acquired, it is processed and ready for comparison with test stand data, which enables the test stand tolerance limit parameters to be refined, improving the end-of-line test results.

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