Acoustic tests, tightness tests, torque measurements

The mission of our company is to facilitate work in series production of different types of products. Production should be completed with accurate testing before sending the product to the end-customer, therefore we specialise in tests of various products, especially in acoustic tests, tightness tests, mechanical tests with torque measurements.

The components used: ITEM, BOSCH, Festo, Destaco, Siemens, IFM, MURR, Turck, Balluff, National Instruments,Rittal, Phoenix Contact, Keyence, Cognex, Sick, Pilz, Atlas Copco, Kistler with pressing-in path and force measurement. 

 

 

 

 

 

Test stations

Our products are test stations for vibrations and all kinds of noises coming from the mechanisms installed in such products as, e.g. Audi backrest which possesses complex mechanisms inclining it forwards and backwards which may generate noises in the car. In addition, in the electric version, adjusting the backrest is performed with an electric motor which also may be a source of noises and vibrations. We have created our own system of backrest measurement in production conditions. With the surrounding noises from assembly lines we are able to successfully separate it from the noise coming from the backrest itself. 

    Vibro-accoustic station

      For many years Amister company has been cooperating with Sitech company in the filed of solutions for automotive industry. Thanks to the cooperation we have produced fully-automated workstations allowing vibration diagnostics of electric and manual car backrests.

       The vibration diagnostics we use is a perfect tool for products verification, especially with moving components as gearings, engines, all kinds of movable connections which all may be a potential reason for faults in the final product. The essence of measurements we perform is not only registration of vibrations and noises but also assessment of important parameters in reference to rated values set by manufacturer’s requirements. Such diagnostics also allows to find the phase of the production process in which the fault was made which in turn leads to efficient detection of the source of damage and finally to the solution. Our system significantly increases the production efficiency, decreases the number of faulty goods and optimises the early phases of production.

      What do we offer?

      Within measurement stations, in which the main measuring components are accelerometers, we also offer measurement of additional physical quantities which are indispensable for proper assessment of the backrest condition, i.e. motor current measurement, backrest inclination angle with inclinometers or linear encoders, backrest position measurement with laser limit sensors.
       

      The vibro-acoustic station is an extended control-measurement system based on LabVIEW application and measurement cards from National Instruments. The application realises tasks in: 

       

      • PROFINET communication,
      • PLC control,
      • accelerometers diagnostics,
      • accelerometers calibration, 
      • defining limit values
      • measurements registration, 
      • measurements analysis,
      • reporting,
      • statistics compilation, 
      • user administration.

       

      A detailed analysis of measurement data is based on unprocessed data registered with an appropriate sampling frequency which are subject to an advanced analysis of time and frequency domains (e.g. octave analysis, spectral analysis, RMS value determination). The calculated parameters are compared with limit values given by the manufacturer and classified by specified typical damages for backrests.

      Online measurement and analysis 

      The station becomes a part of the assembly line consequently imposing a strict time regime for measurement analysis during movement of the backrest and the result is known immediately after the movement is finished. The information of the result of the analysis is passed to the operator. 

      All measurements are saved as unprocessed data in TDMS files, analysis results in PDF report file, statistics in MS Excel files. MS SQL Server is used to gather data about events in the system and about conducted analyses. 

      Automatic Audi backrest acoustics measurement

      Tightness test station

      Until now tightness control was performed with servomotors and pneumatic drives. However, it was not efficient and adapted to production needs. Designing a station with a SCARA robot and two tightness controlling sockets improved the final product quality and increased production line efficiency. 

       

      Audi backrest torque measurement

      Audi backrest torque measurement. To avoid problems for drivers or passengers after purchasing a car with manual backrest setting, we have constructed automatic stations testing such products. The station consists of Siemens Sinamics servo system and an analogue Burster sensor. The sensor measures the torque in the range of  0-6Nm, in the controller there are fixed torque limits set over which the backrest is classified as NIO. On the sensor a proper head is mounted which enters the cage. The whole inclination range forwards and backwards of the backrest is tested. After the test, the backrest is in an assembly position in the car. Each backrest has its own report archived in the database system. 

       

        Audi backrest torque measurement

        EKS/KABA readers

        For a complete tracing of the product optionally we install EKS/KABA readers to log the employees for identification and assign their ID numbers to the installed product or RFID system in automatic stations. After a proper installation, a DMC code and description label are printed and put on the product for further identification. In addition, all data concerning tests, e.g. vibration value, tightness test, torque, worker's ID are stored on the data server and are available online via a web browser.