Crack detection during spring coiling

Detect cracks reliably and automatically with the QASS measuring system.

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Inline crack detection


QASS enables real-time crack detection when coiling springs. We monitor every millisecond of the process and any defective components are automatically ejected from the system.

Data analysis through pattern recognition


Real-time evaluation of measurement data using pattern recognition: cracks are detected and analysed using stored signal patterns. This is followed by immediate transmission of the result (IO/NIO) via the Profinet interface.

Full quality control

Coiling and winding processes are seamlessly monitored by our structure-borne sound sensors, minimising the need for downstream quality checks. The system works fully automatically and visual samples are no longer necessary.

100% non-destructive monitoring

Due to our measuring principle based on structure-borne sound, our sensors record all the details of your process completely non-destructively.  


Efficient quality assurance in spring production


During the production of springs, there is a recurring occurrence of the typical formation of cracks, which can later lead to the need for replacement or defects in the component. More and more industries in the manufacturing sector are striving to elevate safety standards to a higher level and counteract this issue. Each spring is carefully inspected to ensure that it meets the high standards through visual inspections, measurements, and possibly even functional tests. By utilizing QASS, we can significantly simplify this process and free up working time for the employees.


QASS can now detect cracks that are of significance fully automatically, taking quality assurance to a new level.

Your branches

Automotive

Aerospace

Wind energy

Medical technology

Mechanical engineering

How it works

The QASS Optimizer4D in use.
Structure-borne sound image of a coiling process of a spring in the QASS Optimizer4D measuring system. 

With over 50 million scans per second, our structure-borne sound sensors seamlessly record every piece of information from your production process. The collected data is then analysed, categorized and processed in real time by our Optimizer4D measuring system. The recorded structure-borne sound signals can be displayed and tracked in our FFT landscape as shown in the image below. Our new features such as clustering and the associated pattern recognition, as well as corresponding frequency filters and masks, allow us to precisely separate important signals from background noise or machine noise and analyze them within milliseconds.

Users of QASS measurement sensors benefit from

  •  Reliable crack and micro-crack detection​
    Cracks that reach critical size can be detected and ejected by Optimizer4D. A warning is automatically forwarded to the system.

  • Monitoring of the tool condition (Tool monitoring)
    Our measurement system not only enables the detection of cracks, but can also detect damage to the machine tools (e.g. wear on the wind pins)

  • Quality assessment of the primary material​
    Based on characteristic differences in the structure-borne sound data, we can draw conclusions about cracks in the primary material.

Our concept

The monitoring of the spring coiling process is divided into three degrees of complexity.

 

Basic

The Basic version activates process monitoring, which monitors the development of structure-borne sound signals during the process. This enables us to:​

  • Evaluation of the quality of the primary material: Material with many cracks or fundamentally “poorer” material shows higher emissions than standard-compliant material
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  • The detection of damage to wind pins.
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  • Monitoring of the feed rollers, depending on the number and position of the installed sensors



Advanced

The Advanced version builds on the Basic monitoring system and also includes crack detection. 
Cracks that reach critical sizes can be detected and ejected by Optimizer4D. The system automatically issues a warning..



Expert

In addition to the Basic and Advanced functions, the Expert level offers a deeper analysis of the process. It enables:

  • The detection of microcracks
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  • The connection of additional sensor sources for extended data evaluation

  • The use of AI and machine learning to create meta-statements about the process

This level is ideal for experienced users who not only want to optimize their processes economically and technically, but also want to understand in-depth mechanics and correlations in order to be able to optimize the process as such or to better understand it.
 

Scope of delivery:
 Optimizer4D Measurement system
2TB SSD Hard disk
Optimizer4D measuring chain ( preamplifier, structure-borne sound sensor, cable )
12“ o. 15“ Touch Display

The Optimizer4D is intended for installation in a machine control cabinet. This must be air-conditioned or have ventilation.

Options:
8TB hard disk instead of 2TB
Optimizer housed in its own control unit (at an extra charge)
Accommodation of the Optimizer in a mobile "expert case" (at an extra charge)

Machine communication:
24V/IO-Communication ( inclusive )
ProfiBus ( at an extra charge )
ProfiNet ( at an extra charge )

Graphical User Interface ( GUI )
The Optimizer user interface has several levels. The top level, which is visible to everyone, is the "PenGUI", a customizable interface on which the simplest information can be viewed easily and intuitively. Crack rates, trend developments or simple "red"-"green" displays provide the machine operator with the necessary information quickly and clearly. If someone with higher access rights logs in, they can delve deeper into the process, view signals in their raw state, adjust the pattern library, etc. The focus is on displaying only the absolutely necessary data on the machine.

 




Request

You contact us by phone or e-mail and tell us about your situation


Target definition

We define the goals of the project together with you.


Data analysis

The QASS measurement technology is installed and records data, which is then analyzed.


Application

The measurement technology is specially adapted to your purposes.

Evaluation

Our system is tested and optimized at your premises under production conditions.


Arrange a consultation now!

Ask our experts about the possibilities for your industrial processes without obligation.

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