Mike Albright 248-935-4237 albright@signalxtech.com - - PowerPoint PPT Presentation

Production NVH Test Tools and Methods

Mike Albright 248-935-4237 albright@signalxtech.com www.signalxtech.com

Production NVH Test Tools and Methods

Requirements of successful deployment :

• Good test machine
• low machine self-noise,
• stiff repeatable clamping mechanisms,
• proper isolation from environmental noise contamination
• The ability to exercise the product to optimize defect signatures
• Comprehensive sensor suite
• Data acquisition system that is fast, reliable, and maintainable
• Metric design environment with batch processing capability
• Database system with automated archival and reporting

Production NVH Test Tools and Methods

Good Test Machine :

• Good test machine
• low machine self-noise,
• stiff repeatable clamping mechanisms,
• isolation from environmental noise contamination

Static torque Static and dynamic torque Torsional acceleration Spindle with Integral Encoder Spindle with Integral Encoder Spindle with Integral Encoder

Compliance couplings The “Golden T” Is formed from the elements inside the dashed circle

Production NVH Test Tools and Methods

Optimize Defect Signatures :

• The ability to exercise the product to optimize defect signatures

Production NVH Test Tools and Methods

Comprehensive Sensor Suite :

In-line Rotary Torque Sensor Microphone Vibration Touch Probe Laser Vibrometer

Production NVH Test Tools and Methods

Fast, Reliable, Maintainable System :

MajX NVH Controller

• PXI and LabVIEW RT
• Very Fast
• Limited services running
• Stable execution timing
• High uptime reliability
• Local data storage
• Commercial of the Shelf availability
• Scalable I/O
• High temp & 24/7 option

Production NVH Test Tools and Methods

Interactive metric design environment with batch processing capability : From Signals to Features To Metrics

Meaningful Metrics for Automated Test

What Makes a Good Metric?

Properties of effective metrics : 1. Discrimination: 2. Repeatability: 3. Dynamic range: 4. Distribution: 5. Stability: 6. Understandable: 7. Diagnostic Aid:

• Isolate the defect signature
• Essential requirement of any metric
• Grade defect severity
• Normal or other tailed distribution
• No uncompensated change over time
• Accessible and standardized
• Suggest corrective action

.

Failed Seat Adjusters

Defect Detection

• One or more metrics will indicate a defect
• Cannot reject good parts
• Cannot let bad ones out of the factory
• Classification is Human-driven - initially
• Defects become associated with patterns
• Metric refinement will be ongoing
• Intuitive metric design environment
• Batch processing capability
• Metric set should be:
• Discriminating
• Repeatable
• Understandable
• Suggest corrective action

Meaningful Metrics for Automated Test

Production NVH Test Tools and Methods

Database system with automated archival, retrieval, reporting, batch processing

Reports

• Storable report definition
• Source data from Query
• r batch processing runs
• Automated alarms with

electronic notification

• Selection of report types
• Cross Correlation
• Regression Analysis
• Run Charts
• Histogram

Scanner

• Manage Upload Schedule for

all NVH controllers in a domain

• Retrieve raw data, processed

results and meta data

• Populate database
• Report NVH Controller Status

Database Query

• Build Action List
• Sort Metrics/files
• Storable Queries
• Report source

Job List

• Define individualized

reporting tasks

• Schedule stored Queries
• Schedule stored Batch

Processing runs

• Schedule reports with

automated source data update from Query or Batch processing jobs

Data Management Functions

Batch Processing

• What-if metrics
• Re-use datafiles
• Storable Batch def.
• Report source

NVH Controllers

Production wants a Solution Engineering Wants an Explanation

PASS FAIL

Production NVH Test Tools and Methods

Production test data serves two communities

Production NVH Test Tools and Methods

On the floor – NVH system presence is minimal

MajX NVH Controller

Final Metric Results Signals

Production NVH Test Tools and Methods

But engineers need fast access to detailed analysis of raw signals Without interrupting ongoing production

When a part fails, detailed analysis must be immediately available