Crack detection
Detect microcracks reliably, automatically and non-destructively with the QASS measuring system
Real-time, in-line & production-ready
The permanent and force-fit connection of the QASS structure-borne sound sensor to the machine, enables the Optimizer4D to seamlessly monitor your straightening process. The data is processed and evaluated in real time.
Minimization of scrap
Fast processing of measurement data in real time: 3 million samples per second, spectral processing using Fourier transform, as well as noise reduction with adaptive filters and pattern recognition.
Quality assurance through pattern recognition
Real-time evaluation of measurement data based on pattern recognition: cracks are found and analyzed by means of stored signal patterns. Interfering signals are filtered out. This is followed by immediate transmission of the result (IO/NIO) via Profinet interface.
Plug & Play Retrofit
We retrofit your machine in less than a day. Our retrofit does not require an upgrade of the machine: Same I/Os and same mounting points for the new hardware.
Crack detection with the Optimizer4D
QASS is the world market leader in the field of crack detection during straightening. Especially for straightening machines, we now recommend our new, innovative crack detection system: the Optimizer4D. The Optimizer4D uses a new analysis concept and reduces previously unavoidable pseudo scrap. This occurs when systems incorrectly interpret electrical or mechanical interference signals as cracks.
Conventional crack detection systems analyze the intensity and energy profile of structure-borne noise during straightening. The Optimizer4D adds a third dimension to the analysis: frequency.
With 25,000 spectral analyses per second, Optimizer4D reveals every detail of the straightening process. This makes it possible to distinguish between the signals of a real crack and interference signals. This information can also be used to optimize the process, which reduces scrap even further: crack prevention through improved process recognition.
The microscopic image of a cracked component shows that the crack has closed again after forming on the surface. Many downstream inspection methods such as magnetic particle or laser thermography fail when the surface appears flawless. Optimizer4D detects the crack the moment it appears. This makes it irrelevant whether the damaged area has closed again after the straightening process has been completed.
Top: Crack in a component | Bottom: The crack signal in the process landscape
Would you like to learn more about structure-borne sound?
Our highly accurate measurement method HFIM explained in detail.
Possible applications of crack detection
Here you can find some application examples for our crack detection. If you do not find your process here, please send us an inquiry. We have a lot of experience in the implementation of individual solutions and regularly implement research projects. We are sure to find a solution for your problem as well!
Straightening processes
During the bending of shafts, rods, tubes and sheets, the deformation of the material can lead to the formation of extremely fine hairline cracks and other types of cracks (e.g. microcracks). Using structure-borne sound technology, QASS is able to detect these cracks in real time during the series production process. In this way, we ensure that your production meets the highest quality standards.
Test stands
Determine the operating limits of your processes through structure-borne sound analysis. QASS crack detection can be used in forming processes, torsion test stands and bearing test stands. Early damage in bearing test stands caused by white-etching cracks (WEC) can also be detected using structure-borne sound analysis.
Deep drawing processes
Damage such as cracks can quickly occur during deep drawing. With Optimizer4D, every phase of the deep drawing process is made visible. By monitoring and controlling the process, trends can be detected at an early stage and timely intervention prevents quality-critical failure in components or tools.
Welding processes
The Optimizer4D not only detects cracks that occur during bending processes but also at all other points where cracks could occur due to plastic deformation or thermal change. The system acts as familiar and proven means of detecting cracks and enables targeted and precise rejection of defective parts despite sometimes enormous ambient noise.
Request
You contact us, by phone or by mail, and describe your situation.
Target definition
We difne the goals of the project together with you
Data analysis
QASS measurement equipment is installed and collects data that is subsequently analyzed.
Application
The measurement technology is specially adapted to your purposes.
Evaluation
Our system is tested and optimized at your site under production conditions.
Detect grown cracks by summation of energies
Atypical crack signals:
- considerably smaller amplitude
- low frequency expression
- no low frequency component
Summation over several straightening processes:
- cracks that occur cumulatively
- signals are counted over straightening processes, energy of the processes is summed up
- exceeding the limit value - grown crack
- parallel monitoring with conventional methods
New ways of looking at things through customizable applications
- Transfer of data into a quickly adaptable application (in Python)
- Changed approach allows statements to be made about the deformation work applied
- Unacceptable processes can be detected
Pattern Recognition & Clustering
Pattern recognition uses the operator network and is its core function. For this purpose, different existing operators are linked to each other simply by dragging and dropping. At the beginning there is the sensor signal (stream buffer), which comes as a transformed signal directly from the HFIM.
The sensor signal is linked to a comparison operator that searches for patterns in this incoming live sensor signal. The patterns are provided by a pattern database (pattern provider). The patterns are sensor signals to which a referenced state has been assigned. The pattern is taken directly from the three-dimensional spectral data plot and stored, automatically when process boundaries are known or manually during initial setup. The pattern is searched for in the comparison operator (Significance Comparer) with respect to its shape, amplitude scaling and time scaling in the sensor signal and compared with the reference state. A similarity factor is determined from the comparison with the reference. Of course, different patterns can be searched in parallel.
After the comparison operator it is decided what to do with the result. Various further data analyses, complex and cascading forwarding to further networks, signal message to the machine or communication modules are already available.
More on the Analyzer4D Software
More on Clustering
Example operator network for bending processes
The QASS strategy for crack prevention
With QASS's Optimizer4D, you benefit from the advantages of the next generation of measurement technology for monitoring your straightening processes. Non-destructive, in-process and ready for optimization. Pattern recognition and learning capabilities now provide us with the opportunity to effectively avoid cracking and scrap during straightening.
1. Upgrade:
Implementation of QASS pattern recognition systems. The groundbreaking, intelligent software from QASS offers you significantly improved selectivity in crack detection. It is a prerequisite for targeting 0% scrap.
Result: A significantly lower reject rate due to the significant reduction of pseudo-cracks.
2. Training:
Your Optimizer4D learns the typical signals that occur during the straightening of your components. Thus, even very specific straightening emissions can be clearly distinguished from cracks according to their classification.
Result: You have achieved an even lower crack rate, because the measuring system detects pseudo scrap precisely. The reduction of pseudo scrap is complete.
3. Expertise
Benefit from QASS's extensive experience in monitoring and optimizing straightening processes as well as from our close cooperation with straightening machine manufacturers. We provide you with target-oriented support in adapting your straightening strategy to prevent the formation of real cracks in your components.
Result: A renewed reduction of the crack rate by optimizing your straightening strategy. The occurrence of real cracks is reduced.
4. Automation
Upgrades to the straightening machine software and seamless integration of QASS intelligence apply everything learned fully automatically in the straightening process. Adaptive responses to process variations and predictive crack warnings become possible. Information available online from production can be correlated with QASS data for optimization.
Result: The crack rate is nearly 0% due to the automated prevention of cracks. Mostly crack-free straightening is achieved.
5. Care
QASS Care ensures that the achieved production and quality level is maintained. Remote assistance, constinuous innovations in our measuring technology, including AI, ensure nearly crack-free straightening even with increasingly complex components and materials. Continuous optimization is our mission.
Result: Mission accomplished – virtually a 0% crack rate in straightening has been achieved. Crack-free production is a reality.
Pattern Recognition & Clustering
Pattern recognition uses the operator network and is its core function. For this purpose, different existing operators are linked to each other simply by dragging and dropping. At the beginning there is the sensor signal (stream buffer), which comes as a transformed signal directly from the HFIM.
The sensor signal is linked to a comparison operator that searches for patterns in this incoming live sensor signal. The patterns are provided by a pattern database (pattern provider). The patterns are sensor signals to which a referenced state has been assigned. The pattern is taken directly from the three-dimensional spectral data plot and stored, automatically when process boundaries are known or manually during initial setup. The pattern is searched for in the comparison operator (Significance Comparer) with respect to its shape, amplitude scaling and time scaling in the sensor signal and compared with the reference state. A similarity factor is determined from the comparison with the reference. Of course, different patterns can be searched in parallel.
After the comparison operator it is decided what to do with the result. Various further data analyses, complex and cascading forwarding to further networks, signal message to the machine or communication modules are already available.
More on the Analyzer4D Software
More on Clustering
Example operator network for bending processes
The QASS strategy for crack prevention
With QASS's Optimizer4D, you benefit from the advantages of the next generation of measurement technology for monitoring your straightening processes. Non-destructive, in-process and ready for optimization. Pattern recognition and learning capabilities now provide us with the opportunity to effectively avoid cracking and scrap during straightening.
1. Upgrade:
Implementation of QASS pattern recognition systems. The groundbreaking, intelligent software from QASS offers you significantly improved selectivity in crack detection. It is a prerequisite for targeting 0% scrap.
Result: A significantly lower reject rate due to the significant reduction of pseudo-cracks.
2. Training:
Your Optimizer4D learns the typical signals that occur during the straightening of your components. Thus, even very specific straightening emissions can be clearly distinguished from cracks according to their classification.
Result: You have achieved an even lower crack rate, because the measuring system detects pseudo scrap precisely. The reduction of pseudo scrap is complete.
3. Expertise
Benefit from QASS's extensive experience in monitoring and optimizing straightening processes as well as from our close cooperation with straightening machine manufacturers. We provide you with target-oriented support in adapting your straightening strategy to prevent the formation of real cracks in your components.
Result: A renewed reduction of the crack rate by optimizing your straightening strategy. The occurrence of real cracks is reduced.
4. Automation
Upgrades to the straightening machine software and seamless integration of QASS intelligence apply everything learned fully automatically in the straightening process. Adaptive responses to process variations and predictive crack warnings become possible. Information available online from production can be correlated with QASS data for optimization.
Result: The crack rate is nearly 0% due to the automated prevention of cracks. Mostly crack-free straightening is achieved.
5. Care
QASS Care ensures that the achieved production and quality level is maintained. Remote assistance, constinuous innovations in our measuring technology, including AI, ensure nearly crack-free straightening even with increasingly complex components and materials. Continuous optimization is our mission.
Result: Mission accomplished – virtually a 0% crack rate in straightening has been achieved. Crack-free production is a reality.
QASS as a technology partner
QASS has over two decades of experience in process optimization, sensor technology, component monitoring and quality assurance. Our measurement technology, coupled with intelligent pattern recognition software, enables almost 100% crack prevention in straightening processes.
The foundation of our expertise lies in our own research and development efforts, from which new solutions are constantly emerge. Research projects in cooperation with renowned university institutes and well-known companies complement these. We contribute our know-how to the implementation of projects for our customers.
Automotive groups and suppliers worldwide rely on our expertise in crack prevention, process optimization and quality assurance. The continuous development of our products ensures that the monitoring of your straightening process is state-of-the-art. With the help of Optimizer4D, you can therefore not only precisely detect cracks that occur during straightening, but also prevent them from forming in the first place. Through our technology and service, you sustainably reduce the risk of failure of the steel shafts used. In addition, an optimally running straightening process is guaranteed.
At QASS, we live and love what we do. The basis of our philosophy is the pursuit of ever better results and the search for more efficient ways. See for yourself our solution expertise and our passion for technology and innovation.
QASS as a technology partner
QASS has over two decades of experience in process optimization, sensor technology, component monitoring and quality assurance. Our measurement technology, coupled with intelligent pattern recognition software, enables almost 100% crack prevention in straightening processes.
The foundation of our expertise lies in our own research and development efforts, from which new solutions are constantly emerge. Research projects in cooperation with renowned university institutes and well-known companies complement these. We contribute our know-how to the implementation of projects for our customers.
Automotive groups and suppliers worldwide rely on our expertise in crack prevention, process optimization and quality assurance. The continuous development of our products ensures that the monitoring of your straightening process is state-of-the-art. With the help of Optimizer4D, you can therefore not only precisely detect cracks that occur during straightening, but also prevent them from forming in the first place. Through our technology and service, you sustainably reduce the risk of failure of the steel shafts used. In addition, an optimally running straightening process is guaranteed.
At QASS, we live and love what we do. The basis of our philosophy is the pursuit of ever better results and the search for more efficient ways. See for yourself our solution expertise and our passion for technology and innovation.
Arrange a consultation appointment now!
Ask our experts about the possibilities for your industrial processes without obligation.