Optimizer4D – FAQ

In the 3D diagram of the Optimizer crack signals always show in the form of a broadband, high-frequency signal that starts abruptly and then calmly decreases. It is typically not bound to a certain frequency area and differs from machine noise, because it is moving across the time axis. It also has a sharp beginning and it expands across the bigger part of the frequency spectrum starting in the audible area of under 20 kHz and rising to the extreme high-frequency area of 1.5 MHz and beyond. The duration of a typical crack signal is rarely longer than 20ms.

Rarely. Generally, crack signals clearly stand out from production-related noise. Frequency areas can also be masked and filtered out of the measuring results.

In tool monitoring it is important that the signals of the respective tool can be distinguished from the machine noise in a matter of time or area, which is possible in most cases.

A test measurement will shed light on this.

Echoes and feedbacks are always part of the acoustic emission measuring and the process characteristics. Either they are there or not. For the measurement and its evaluation using HFIM they are irrelevant, because either way a typical display of the process will be generated.

No. The measuring device detects cracks and process parameters in real time, i. e. during their occurrence.

A component can, therefore, not be tested downstream, i. e. after its processing. It can only be done during the production process.

It depends. Often the impulse emissions of fluids are too small to distinguish them from the process noise of a machine without a doubt. There are, however, machines where the flow of a fluid is clearly visible and emerges as a frequency band. If that is the case, an automated monitoring can be realized. It generally applies that: The moment a parameter inside the process is changed, the measuring results change too. When a lubricating film tears off, for example, it is clearly visible. Similar can be said when the cooling system fails. The perfect answer for this is, however, difficult and depends on each individual case.

QASS, therefore, recommends a test measuring to clarify details.

Optimizer4D can continue. For successful crack detection and tool monitoring it is advantageous to teach the changed parameters before the process and tell Optimizer4D in-process to react to changes. Crack signals differ greatly from the other process sounds. Optimizer4D can additionally monitor different parameters in a process. It can monitor a predetermined frequency band or the condition of a tool and afterwards communicate with the machine (via e. g. SPC).

No.

One optimizer can, basically, only carry out one measurement at a time. The measuring system can receive signals from up to 4 data channels at once. These channels can be used independently from each other and can each be used to regulated and control. However, all data channels start simultaneously at the beginning of a measurement. If the device detects a crack on one of the channels, for example, it can be evaluated separately from the other channels and can then be used to regulate or control the production machine. Prerequisite for the use of the Optimizer at multiple machines is that the machines are clocked with each other in the aspects of starting and ending times of the measurement.

Yes, there are different cases for the Optimizer, which also include different mobile versions (e.g. in a mobile case) or a box for uses as a single unit at manual presses. One variant is the robust transport case QASE, included is a touch screen monitor. The standard variant is for mounting into a control cabinet with a connection to the machine controls (e. g. SPC).

A UPS is a basic part of the Optimizer4D. The UPS uses supercapacitors (“Supercaps”) and provides enough power to shut down the system safely in case of a power failure.

The device uses an uninterrupted power supply (UPS) and thusly no problems should occur due to a power failure. In case of frequent starts and shutdowns data errors and data loss are possible.

Often, but now always. It is possible for cracks to close at the surface of a component, while it is still being worked. These cracks, while still there, are no longer visible and cannot be seen anymore by magnetic particle inspections or eddy current tests. Optimizer4D is able to detect these cracks the moment they occur.

The measuring system gives out a signal immediately after the crack is detected and during the deformation, but after 100ms, after the measuring window ends, at the latest.

The Optimizer4D software allows a distinction of measured crack signals into micro cracks, cracks, and breaks. These three states can be clearly parametrized. Basically, the Optimizer4D’s automatic crack detection is provided using a clearly definable frequency band in combination with a clearly definable period of time. Additionally, it is possible to define a noise level which leads to only energy levels higher than the defined level being consider for the analysis. The automatic crack detection can be started and ended by external trigger signals like SPC machine control

The terms crack, micro crack, and break are labels for different crack-parameters, i. e. for different definitions of frequency band, time period, and noise level. The machine is not able to recognize cracks or breaks by itself, it has to be adjusted to each production process. Measured data from processes are saved. This enables you to replay the measured data again and again, like a film made of structure-borne sound signals. The crack parametrization can be applied to these recordings and can be adjusted to set them to the required parameter area.

The measuring system counts the crack, micro crack, and break events and displays a warning on the screen and/or the I/O-port if the number of events exceeds a threshold value.

Yes. You can parametrize different starting times for every port.

You get optimal testing conditions when the machine is idle. If the machine’s working noise is low, the self-test should work even with the machine active.

One test takes less than 100ms. If an error occurs, the self-test can be repeated to save the measuring. This prolongs the time accordingly. If you repeat the self-test twice, the period is still under 300ms. More than two repeats are unnecessary.

Yes, even over a few days’ time. You have to consider this when ordering the system, since we need to install extra memory space.

Yes. It is possible to assign different user groups with different access authorizations. Nearly every option in the settings (function, parameter) can be configured individually. On the one hand you can have the machine operator with access to only the most basic functions to see the information without access to the system. On the other hand, you can assign a highly authorized user with access to every setting. This user group system uses passwords as protection.

It is, generally, possible to delete the raw data and only save compressed data, which is not as precise as the raw data. Using compressed data saved up to 32 times more memory storage capacity.

The QASS head office in Germany ensures a worldwide service to all clients. Included are training, process accompaniment, and repairs. These services are provided either by our German technicians or our distribution partners in

• China
• USA
• Mexico
• Korea
• Brazil
• Japan
• Argentina (Buenos Aires)

Yes. Our head office in Wetter/Ruhr offers a free telephone number to contact service technicians on weekdays during the usual office hours. We offer this service in German and English. We are also able to give you support in Spanish, French, Portuguese and Arabic.

Urgent services are provided by QASS as soon as possible. For common service calls we have a lead time of approximately four weeks.

Usually, QASS has the parameters and client settings of all clients’ measuring systems due to the annual calibration. This enables us to send a replacement device with the correct parameters at a charge. Delivery time without customs is usually 24 hours. As soon as the client receives the device he has to send the broken one to QASS. It is a good alternative to keep a replacement device in stock.

Generally, yes – you need to configure the network access using a standard Ethernet connection. The Optimizer must be connected to the internet. Therefore, Gateway- and DNS data must be entered in the Optimizer4D. If the Optimizer4D is connected to the internet, you can run Firefox, which is preinstalled. Team Viewer can be installed afterwards (www.teamviewer.com; download rpm. You can ask us for details concerning this procedure.)

There are other, easier options to get remote support. We suggest to configure the router with a so-called Port Forwarding on SSH Port (22). Generally, we don’t support a wireless communication for Optimizer4D. In some cases this is possible, we had good results using the DLink DWR 512 router, for example.

Yes, Monday to Friday between 8.30 a.m. and 4.30 p.m. German time. Usually, the support is free within the first year. The costs for support afterwards are individual.

Six to eight weeks.

For prices please contact us directly via Mail (info@qass.net) or by calling +49 (02335) 80200. Payment terms are individually fixed as Optimizer4D is custom made.

Yes. Loan costs depend on the application field and the QASS service technician’s efforts and thus are fixed individually.

QASS offers a detailed Optimizer4D manual. We offer additional material at our in-depth training courses. A training for crack detection and process optimization using Optimizer4D is held regularly. Find the dates on www.qass.net.

Yes. A maintenance agreement generally offers price advantages concerning the traveling costs for a calibration. The more clients QASS has in a certain region, the better the possibility to split the traveling costs.

The cables are wearing parts. The maintenance interval depends on the working environment of the cables. Sensors are, also, wearing parts and have to be calibrated annually. Furthermore, QASS recommends to exchange the hard drive every second year. Cables, sensors, and hard drives can be stored as spare parts and can be exchanged by the users themselves. The exchange can be done by a QASS technician on request.

Spare parts like sensors and cables are permanently in stock and can be dispatched the day the order is placed. If the delivery is not urgent, spare parts are usually dispatched within three days after receipt of the order.

The warranty period is one year and starts with the day of delivery. If the device should be calibrated within the course of this first year, the warranty is extended for one year. The total time of two years may not be extended.

Usually, the device is calibrated at the client’s site. This offers several advantages: The calibration is more precise and the technicians can check if it is properly integrated into the process. It is also possible to send the device to QASS, but together with the entire measuring chain (measuring device, cable, preamplifier, sensors).

600 € plus traveling expenses.