Module assembly

July 14, 2020 by

Reliable monitoring of assembly processes with QASS

More and more assembly processes are being automated and carried out with pre-assembled components that are joined together to form assemblies. The connection of the assemblies often takes place inside, so that the process and the result cannot be checked by visual inspection by the user or by means of visual sensor technology. With our expertise in the field of structure-borne sound analysis, we at QASS offer a suitable solution, the benefits of which we have recently increased even further through our latest developments.
By applying our new scripting concept, we can now program our analysis precisely to the requirements of the respective assembly process.

An example - Assembly of a drive shaft

Think of the assembly of a drive shaft. The drive shaft is a safety-relevant component that is installed in millions of cars and other motor, commercial and rail vehicles, ships and machines. They are used every day to get us from A to B or to manufacture and transport goods. When assembling a drive shaft, the retaining ring must engage in the groove provided. The assembly process itself happens partly inside and invisible. It can therefore not be monitored either by a human being or by an optical sensor. The engagement itself takes place without any measurable force, so the force/displacement measurement is of only limited help here and does not allow any qualitative statement on the success of the process. It is therefore not possible to determine with certainty whether the retaining ring is exactly engaged. QASS on the other hand, with its structure-borne sound analysis, has the unique ability to listen into such an assembly process.

The magic behind QASS structure-borne sound analysis

The QASS structure-borne sound analysis is used in a wide variety of production processes – not only in assembly processes. With this method we have become the world market leader in crack detection during the straightening of drive shafts. During assembly, the method can also be used, for example, for the pressing of components or cold welding in order to monitor the process with the help of its inherent acoustics. We find a reliable answer to questions such as “Is the retaining ring really clicked in” or “Was the friction between the components really high enough?”.

To monitor production processes by means of structure-borne sound analysis, we use high frequency acoustic sensors that record the sturcture-borne emissions triggered in the process. The recorded sensor signals are evaluated by our software simultaneously with the production process. Our data analysis is based on configurable methods based on data flow models as well as a unique pattern recognition. The operators used in the data analysis can be adapted to customer requirements and combined individually.

Our measuring system Optimizer4D listens reliably even if other measuring technology fails due to a rough production environment. With our software, irrelevant information for the evaluation of the process success, such as disturbing or machine noise, can be filtered out, so that only relevant data is included in the evaluation of the process quality.

Thanks to our innovative analysis concept, we can easily process other sensor signals as well: Other sensors can either be fed into the measuring computer via our preamplifier and measuring card or your sensors or measuring devices can be integrated via the interfaces of the Optimizer4D (TCP/IP, USB or Profinet). Your benefit? The possibility to view these data simultaneously and thus an improved basis for the decision whether the assembly process was successful.

The result is displayed on a specially developed and intuitive graphical interface. What for? To make access to the measurement data and its evaluation as easy as possible for you. After all, it’s all about good and bad, OK and NOK – a simple yes or no. You can easily adapt the graphical interface to your needs with just a few clicks. You want to display measurement data from different sensors? Do you want to display live images from production in addition to the measurement data? You want to use models of your components in the result display? No problem with our new user interface!

Even complex assembly sequences can be understood and evaluated with the script programming of the analysis logic and machine communication. 
An adapted measurement logic for exactly this assembly process within the shortest time.

Your advantages at a glance

Fast and easy integration: With the software innovations, the setup time of our measurement technology is reduced to a minimum. QASS is immediately ready for measurement and analysis.

Adaptability: Our measurement technology is thus immediately ready for use in a wide variety of applications - completely independent of the component, machine and process.

Sensor fusion: Use multiple sensors, offset their data with our software and benefit from the additional informative value.

User-friendliness: Our graphical user interface tells you quickly and easily whether the component was OK or NOK. You can easily adapt the result view to your needs with just a few clicks.

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