Automated Test System for Automotive Gear Sets for Transmission Error & Axle Noise
When a Tier 1 automotive supplier required a production line test system to assess final drive transmission errors, they naturally called upon the expertise of Signalysis to deliver a solution.
Challenges
Objectively Identify Root Cause of Errors
Validate Functional Specifications, Ergonomics and Human Machine Interface (HMI)
Have a Minimal Impact on Production Time
An Automated Solution
Signalysis designed and developed an IQC™ test system that was integrated into the production line for 100% unit testing.Quality Inspection SystemThe IQC system includes a computer control system, multi-channel data acquisition system, digital I/O interface hardware, accelerometers / automated placement devices and SigQC™ analysis software.
The system was integrated with a 3rd party test station to conduct 100% part inspection. The system acquired and processed running data, assessed pass/fail, and archived the pertinent data. The inspection station was installed at the earliest point possible in the assembly line to identify “bad” gear sets prior to full axle build.
System Functions
Confirms the test cell achieved correct speed and quasi-static running torque
Calculates dynamic torque amplitude at mesh frequency for each steady state torque condition
Calculates peak torque value at mesh frequency for torque sweep
Compares torque amplitude to established limits to assess pass- fail limits
Exports metric values to central manufacturing database for SPC activities
Automatically processes data from different models (i.e., F/D ratios)
Delivering Results
The Signalysis IQC test system met all test objectives enabling our customer to:
Pinpoint and eliminate causes of errors
Effectively validate aesthetic and functional specifications
Minimize the impact on overall production cycle time
Eliminate cost and subjectivity associated with human inspection
