in-process testing Axle - Sub Assembly

Test Description: Axle turned by

drive motor at different speeds with
and without output load.
70

axle manufacturing
Torque - Sub Assembly Test
70a Test Description: Measure input shaft torque against angle as motor drives axle in
forward and reverse, with and without output load.
Signatures: Breakaway and running torque vs. angle.
Ratio and Backlash Check - Sub Assembly Test
Defects: Damaged gears, tight assembly, dirt and debris, incorrect gear contact
pattern (visual).
70b
Test Description: Measure input shaft position and output shaft position as motor rotates
input shaft.
Signatures: Input and output shaft position (encoder), forward and backward rotation.
Defects: Incorrect ratio, incorrect gear backlash.

Vibration - Sub Assembly Test

70c
70d
Other Data - Sub Assembly Test
Test Description: Measure vibration as motor rotates input shaft. Sensors contact
axle casing.
Signatures: Vibration vs. time and vs. angular position (order tracking).
in-process testing
Test Description: Enter various other data, such as; Gear mark (classification of
mesh pattern using marking compound), Build dates, Serial number (Bar Code). Defects: Gear knock, poor gear finish and geometry, damaged gears, shaft rubs, axle manufacturing
incorrectly shimmed pinion, damaged bearings.
Defects: Incorrect gear mark.

Gear Quality Verification Gear Transmission Error

M10 M20 Test Description: Measure gear error (commonly Sciemetric delivers
®
test instrumentation and manufacturing intelligence software
Test Description: Verify machining quality through to detect defects and analyze root causes to provide quality improvement in
vibration analysis on gear test machine prior to assembly. known as transmission error) as gear set is rotated. axle manufacturing.
Signatures: Vibration vs. time or encoder. FFT and order Signatures: Input vs. output position, filtered and FFT
tracking. analysis of difference.
Defects: Gear geometry, machining problems, nicks, Defects: Gear geometry, gear machining problems,
burrs, alignment, surface finish, sub-micron machining nicks, burrs, alignment, etc. PROVEN IN-PROCESS TESTING: FLEXIBILITY: The flexible nature of
errors, etc. Sciemetric has a range of affordable and scaleable
®
Sciemetric ’s systems allows universal application
®

solutions with built-in signature analysis software across assembly lines since the same software and
Gear Mark - Sub Assembly Test and proven applications to add in-process testing to equipment can be used for many applications such
new and existing axle assembly lines to improve as press monitoring, leak testing, torque testing,
70e Test Description: Image capture and storage quality and productivity. gaging, cold testing, vibration analysis, thread
(using vision system). ZONE DATA COLLECTOR verification, balancing, welding, and many others.
Traceability: Allows review of mesh patterns for Q10
Function: Upload all test and operation status results
defect containment and recall management.
from RF tag /PLC device to QualityWorX™™ for a birth
history record.

Advanced Features: Allows operation data and status to

be available in Repair Bay.

Tube Press Monitoring

80
Ring Gear Run Down Test Description: Verify force curve
50 and final press depth as tubes are
pressed into casing.
Press Monitoring Test Description: Monitor torque
Signatures: Force vs. distance.
10 Test Description: Monitor press load and displacement as parts are pressed together.
vs. angle during run down.
Signatures: Torque vs. Angle. Defects:
Oversize/undersized,
Signatures: Force vs. time, distance vs. time, and force vs. distance. Defects: Cross threads, out of round, debris, not
damaged bolts. to final depth.
Defects: Loose part, oversized parts, not fully bottomed out part, damaged or bent parts, cracked
bore, debris, incorrect bearing, out of round. Traceability: Store entire torque
waveform in a database.

Liquid Gasket Verification

Tone/Exciter Ring Gaging Thread Verification Pinion Nut Torque Balance Station (Partnership Solution)
20 30 40 60 90
Test Description: Using an encoder and laser or Test Description: Verify the presence Test Description: Measure drag torque Test Description: Spin the input shaft to Test Description: Monitor the dispensing
inductive sensor, verify ring profile, number of and integrity of major fastening points as the pinion nut is tightened to set determine weight amount and position to process while beads, swirls or drops of liquid
notches, and symmetry and on axle assembly before it goes bearing pre-load. Collapsible or solid balance assembly. gasket or sealant is applied.
depth of each. to the vehicle assembly plant. spacer derivatives. Signatures: Vibration vs. angle (X-Y, 1 plane). Signatures: Pressure vs.
Signatures: Depth vs. angle. Signatures: Eddy current or Signatures: Torque vs. angle. An out of balance assembly yields a sinusoidal time, flow vs. time.
REPAIR BAY MANAGER
Q20
Defects: Improper spacing, laser sensor vs. thread depth. Defects: Incorrect pre-load, acceleration signature where the amplitude is Defects: Air bubbles,
proportional to the amount of weight, and the
bad machining, missing or Defects: Missing threads, wrong spacer integrity, dirty blocked nozzles, incorrect Leak Test
damaged teeth, wrong number
of teeth, eccentricity.
pitch, shallow holes, undrilled
holes, damaged threads.
bearings, thread quality. phase of the peak is used to calculate the
correction weight position.
Function: Associate test and
operational step failures to defects
nozzle, too little or too
much sealant, etc.
100
and repairs. Test Description: Verify casting and seal
integrity using a pressurized air test.
Advanced Features: Defect Signatures: Pressure decay vs. time or
Prediction based upon volumetric mass flow.
or statistical data.
Defects: Missing or leaking or damaged
components (plugs, gaskets, RTV, seals),
casting porosity.

REPAIR BAY MANAGER

Q30
Function: Associate test and operational step failures to defects and repairs.

Advanced Features: Defect Prediction based upon volumetric or statistical data.

Mechanical - End of Line Test Brake Test - End of Line Test
130a
Test Description: Measure input shaft torque against Test Description: Measure input shaft torque against
angle as motor drives axle with and without output
shaft load.
angle as motor drives axle with and without hydraulic
and cable brakes operated. (Hydraulic system verified
using compressed air). Leak test of hydraulic circuit.
Signatures: Breakaway and running torque vs. angle,
Force/Distance measurement of cable pull.
input/output shaft position, gear ratio, backlash.
Signatures: Drive torque vs. angle, cable pull force
Defects: Damaged/incorrect gears, tight assembly,
rubs, debris. vs. distance, hydraulic circuit pressure vs. time (leak).
Defects: Missing brake components,
snagged/stiff cables, leaky
seals/joints.
ABS Sensor/Circuitry - End of Line Test
130c
Test Description: Measure ABS sensor output as axle
is driven by motor. Also verifies the presence of the
tone ring and identifies correct tone rings.
Signatures: ABS pulse value vs. shaft angle, Pulse
spacing.
Defects: Damaged/faulty ABS sensors, damaged
wiring/connections.
130d
Hand Brake Force Test Oil Fluid Level Test
120 110
Test Description: Pull hand brake cable to Test Description: Estimate oil level using
pressure change and reference volume.
verify resistant force.
Signatures: Force vs. cable displacement. Signatures: Pressure change vs. time,
PV=nRT ideal gas law, Vtest = (P1/P2-1) * Vref
Defects: Binding cables, missing drum
springs, damaged rivets, missing Defects: Too much or too little oil.
brake components.

End of Line Test

130 Test Description: Axle is turned by a drive motor at Sound/Vibration - End of Line Test
different speeds with and without output load, all
functions verified.
Test Description: Measure sound and/or vibration as the
130b Engineering Workstation Reporter/
Q40 LEGEND NAME: AXLE MANUFACTURING BLUEPRINT DATE: NOVEMBER 2005 REVISION: 02
Web Reporter Workstation
axle is driven at various speeds.
Signatures: Sound/vibration vs. time, Function: Used to review data and generate reports for individual
Q40 COMPANY: SCIEMETRIC INSTRUMENTS INC.
= KEY IPT APPLICATION
sound/vibration vs. shaft speed (order parts as well as to review and generate reports of trend data for a Toll-free in North America: 1-877-931-9200
tracking), psycho-acoustic parameters range of parts. Visit our Web site for international contact information
(e.g. loudness). = MACHINING LINE
Defects: Damaged/poor quality Advanced Features: Create waveform overlays where test data
email: inquiries@sciemetric.com
gears, bearings, splines, resonance's, from multiple parts can be compared, generate repair reports that = ASSEMBLY LINE
Web: www.sciemetric.com
loose items, axles which will be noisy can be used to identify problem areas on the manufacturing line.
in-vehicle.
= END OF LINE TESTS NOTE: Refer to Automotive section of our Web site for more details on Sciemetric in-process testing solutions. The applicability of each
®

test and the defect detection success depends on many factors including the axle design and manufacturing process. Contact
Sciemetric to obtain more information.
®
IPT 009
= SAMPLE QualityWorX™
STATION(s) © 2001-2010 Sciemetric Instruments, Inc. All brand and product names are trademarks or registered trademarks of their respective companies. Printed in Canada.