Beschreibung
Vorteile und Besonderheiten
Hauptmerkmale
Typische Anwendungen
Komponenten und Aufbau
Messverfahren und -ablauf
Software und Bedienung
Ergebnisse, Datenformate und Schnittstellen
Normen und Richtlinien
FAQ
Description
To monitor quality during the coating of brake discs, individual parts are currently removed from the process and inspected on a sampling basis, e.g. through visual inspections, coating thickness measurements or cross-section micrographs. These methods are time-consuming and inspection-intensive and are only suitable to a limited extent for rapid assessment directly within the manufacturing process. Especially in brake disc coating, reliable evaluation of coating quality is crucial in order to detect relevant deviations at an early stage and remove defective parts from the production process in time.
With the VQC system solution for brake discs, dynamic parameters (natural frequencies and damping) are determined and evaluated using frequency bands (pass/fail). The measurement is completed within a few seconds and can be used at various manufacturing stages, e.g. on raw discs, coated discs or ground discs. Thanks to reproducible excitation with an automatic modal hammer and non-contact vibration measurement using a laser vibrometer, even complex brake disc designs can be analysed reliably.
Coatings have a clearly measurable effect on the brake disc’s natural frequencies. Even for brake discs with bolted hats, which introduce additional modes, these effects can be identified reliably using advanced evaluation algorithms and AI-assisted analysis. This makes it possible to detect coating deviations, geometric changes and process-related quality differences at an early stage.
MAUL-THEET supports manufacturers in making production processes more stable and cost-effective. By using the VQC for brake discs, defective parts are identified at an early stage—saving time and material, reducing scrap and increasing process efficiency. At the same time, MAUL-THEET ensures that only brake discs with demonstrably high structural and coating quality are shipped.
Advantages & Innovations
- Cost and time savings through non-destructive testing (NDT)
- Determination of coating quality
- Early detection of relevant deviations
- Clear pass/fail result for quality control
- Reduction of scrap, rework and inspection effort
- Testing at different stages of the manufacturing process
- More stable and cost-effective production processes
- Reliable evaluation even for complex brake disc designs
- Measurement within a few seconds
- Determination of natural frequencies and damping
- Reproducible excitation with automatic modal hammer
- Non-contact vibration measurement using a laser Doppler vibrometer or microphone
- Evaluation using static and dynamic frequency bands
- AI-assisted analysis with advanced algorithms
Application & Integration
- Quality control
- Series testing
- End-of-line testing
- 100% inspection
- In-line testing
- Testing of complex brake disc designs
- Coating inspection
- Material and structural inspection
- Natural frequency measurements
- Damping measurements
Components
Excitation unit
The broadband excitation is carried out with an automatic modal hammer
- Frequency ranges up to 60kHz
- Impact forces up to 150N
- High reproducibility
Vibration sensor
The VQC for brake discs can be operated with the following vibration sensors
- Laser Doppler vibrometer
- Microphone
Measurement data acquisition
4-channel measuring system with synchronous scanning
- AC, DC and IEPE coupling
- Anti-aliasing filter
- 24-bit resolution
- Measurement range up to 100kHz
- 100 to 25,600 FFT lines
Windows PC
- Standard or industrial PC, also according to customer requirements, with Windows 10/11
Software
The VQC software controls the entire test process. It includes automatic brake disc measurement (one click), data analysis, as well as documentation and report generation.
Specification of the test object
- Name and meta data
- dB values for attenuation calculation (0.5 to 3dB)
- Frequency range 1 to 100kHz selectable
- Frequency resolution (number of FFT lines) selectable
- Frequency bands and permissible tolerance ranges
Measurements for a test object
- Measurements on a component
- Presentation of results and measurement report for a component
Automatic measurement procedure
- Triggering the automatic modal hammer
- Measurement of the excitation force and the vibration response
- FRF averaging
- Peak picking, attenuation calculation and quality assessment
Report creation and output of results for each examinee
- Custom report template
- Printer, PDF, Excel, CSV, etc.
What we can do for you
In addition to manufacturing and supplying standard measurement systems for determining natural frequency and damping, we design, plan, and develop customized solutions tailored to your requirements. We are also happy to perform the measurements for you as a service.
Contact us and we will provide a tailored quote.