Automatic station for 100% cracks control on brake discs and brake drums

Innovative system for the control of cracks for brake discs and brake drums, based on Eddy Current technology:

•    Greatest flexibility for the management of control cycles.
•    Greatest velocity for the type change.
•    Minimum costs for retooling.
•    Locking of the disc on the centring hole with elastic pliers or on the external diameter with 3 jaw pliers.
•    Possibility to check discs coming from different lines.
•    Possibility to change the measuring program at each piece.  
•    Simplicity of dialogue with the line.
•    Outputs totally configurable.
•    Load/Unload with robot, manual or with specific systems.
•    Automatic management of master verification.

Different mechanic configurations are available, according to the requested control plan and to the type of the production line. The probe movement can be managed by a precision robot or by Cartesian manipulator. Both solutions allow maximum flexibility and simplicity for the management of the type change and for modifications to the control plan: the addition of a new zone to be controlled will demand only the modification of the probe path. In case of stations with manual load/unload, are provided protections and barriers.

If it is necessary to control also the support plane, the bench will be equipped with an automatic tilter.

The station is composed of:

•    Double electrical cabinet with air cooler
•    PC with monitor, keyboard, mouse
•    Software Itanoise^©
•    1 channel Eddy Current instrument  
•    Bench in painted heavy carpentry
•    Precision mandrel with adjustable rotation speed (up to 1.200 turns/min)
•    Cartesian manipulator with electric axes, wrist with rotation
•    Tilter  (option)

The bench is modular, it can be integrated in an existing line and it’s possible to add the sonic control (elevator + Itasonic 2010^© system), it’s possible to manage the generation of a serial number in case of good piece and the dispatch of the same to a marking system.  
The mode of manage of the probe allows to easily reach all the areas demanded by the control plan.

The cycle time depends on the number and on the dimension of the areas to be controlled. The total control on the rotation speed of the disc (up to 1.200 turns/min) and on the speed of the axis of the manipulator allows to reduce the control times.    

The type change can demand the substitution of the locking pliers and/or of the support plate: this operation demands only few minutes.

The bench is managed by the software Itamatic^©, specifically developed in order to simplify the management of complex benches, equipped with control systems made by third party and with management of movement. The logic of management is the same of Itageo 6^©, Itastat 6, Itasonic 2010^©, etc... with control plans and measuring batches.  
The data are saved in the Itastat/Itageo database.

Software Itamatic^© - Main features

•    Simple and intuitive.
•    Logic structure as in Itageo 6^©, Itasonic 2010^©, Itastat 6, with batches and measuring programs.
•    Data saved in Itastat6 database in SQL format.
•    Users management with operator permissions.
•    Auxiliary Data management.
•    S/N management.
•    Traceability management.
•    Master verification management.
•    Guided creation of the control plans – measuring programs, where define all the parameters of the test.
•    Permission to integrate also other software for example Itasonic 2010^© for FRF control.
•    Large possibility to personalize the user interface.

Example of a control plan of brake discs

Example of a screen in case of disc without cracks.
Good piece

Example of a screen in case of a disc with a crack detected on the upper braking surface.
Rejected piece

Itanoise^© is the system for the measuring of the noise of mechanical components during their functioning.

It can be used in laboratory or directly in a production line for the 100% control of the produced components.

The equipment is composed of:

•    Software Itanoise^©
•    PC
•    Sensor Box Idaq4Sonic
•    Power supply iPower4Sonic
•    Sensor – Accelerometer, Automatic Accelerometer, Microphone.

The choice of the sensor depends on factors like: 

•    Working environment: verification of the influences external to the test (noise, vibrations, etc…)
•    Type of the control: in line for 100% control or in laboratory
•    Time available for the execution of the test
•    Complexity of the control system

Software Itanoise^©

The software is entirely developed by TQM Itaca Technology and it is easy and intuitive.
It has the same logic structure as Itageo, Itasonic, Itastat, with batches and measuring programs.
There are available different analysis mode:

Third octave analysis

In the picture above it’s shown the sonic imprint revealed by 2 sensors: to channel 1 is connected an accelerometer – in the picture it’s represented by the light green graph, and to channel 2 is connected the microphone – in the picture it’s represented by the grey graph. The analysis is made in third octave: it’s possible to note the tolerances diversified for the 2 sensors, and different for each frequency. Note in the last column on the right the dbOverall values of the 2 sensors.

Analysis in the time domain

In this image the sound recorded for 2 seconds is represented in the time domain: it’s possible to clearly discern 5 peaks from the background noise.

FFT Analysis

In this graph it’s possible to see highlighted all the single frequencies which compose the sonic spectrum acquired during the test.

Individual values chart for each frequency

In this image are represented the individual values charts of the two characteristics: dbOverall sensor 1 and dbOverall sensor 2 measured on 73 pieces. The result of the test, at the right bottom, is total and it considers all the analysed frequencies.

Main features:

•    Data saved in Itastat6 database in SQL format
•    Users management with operator permissions
•    Auxiliary Data management
•    Menu for the station configuration
•    Guided creation of the control plans/measuring programs, where define all the parameters of the test
•    Possibility to manage up to 4 sensors at the same time
•    Noise analysis in octave and in one-third octave, with tolerances which can be defined for each frequency
•    Automatic calculation of the tolerances on the base of the pieces defined “Good”
•    Measure in db and in dbA
•    Measuring of the db Overall for each sensor used
•    Configurable duration of the test
•    Availability of an advanced Transfer Function in order to compare the measures made by different sensors
•    I/O management for the interfacing with the line and/or with the load system
•    Possibility to manage the piece ID, both from the keypad and from readers integrated in the bench
•    Large possibility to personalize Hardware and Software
•    Hardware components easily integrable in existing lines
•    Special contact sensors, with automatic activation, studied for the use in 100% control.

Itanoise^© is available in manual version for laboratory and in automatic version to be integrated in existing lines.
It’s possible to realize complete test stations, with load/unload system, piece clamping, power supply, automatic test cycle, unloading after test and separation good/reject.

Itasonic 2010^© utilises the Sonic Resonance method for non-destructive controls on raw or processed metallic, ceramic or sintered parts.  

            Sonic controls are based on a precise principle of physics: every type of part has its own resonance frequency that generates a unique characteristic curve. The resonance frequencies in fact depend on clearly defined factors:

•    Weight
•    Structure
•    Form
•    Integrity
•    Chemical composition
•    Mechanical characteristics

The resonance curve will be practically identical for all of the pieces, which conform to the specifications. It will change in presence of variations to the above listed parameters.

Advantages of the sonic control
•    Quick and easy to use.
•    It controls the entire part.
•    It does not require immersion in liquids, cleaning, washing, drying, demagnetisation, etc...
•    The result of the test does not depend on the operator.
•    Easily inserted in production lines.
•    Easy and quick type change.
•    Significantly reduction  of the costs of control.
•    Fast return of the investment.

Main field of application for the sonic control
•    Automotive – brake system components and components for safety in general.
•    Heat treatments.
•    Aluminium die castings.
•    Brass molding.

Part suited for sonic control
•    Aluminium die casting parts.
•    Sintered parts.
•    Spheroidal cast iron.
•    Brake pads.
•    Molded parts.
•    Industrial ceramic.
•    Parts that require 100% integrity control.

Some examples
•    Valves in general.
•    Hubs, Pinions, Pulleys, Connecting rods, Gears, Cams.
•    Arms supports (steering, suspension, etc…).
•    Synchronizer rings.
•    Pump bodies.
•    Brake discs and Brake drums.
•    Brake pliers.
•    Brake pads.
•    ABS rings.
•    Components for turbo compressors – rotors and nuts.
•    Parts subjected to heat treatments.

Itasonic 2010^© is used for:    
•    FRF Analisys, to test the vibration frequencies, or Natural Vibration Frequencies: a requirement which has become fundamental for components in vehicle braking systems. Itasonic 2010^© verifies the project specifications, obtained through modal analysis, referring to appropriate tolerances that can be set.
•    To find structural defects such as variation of shape and weight (parts with incomplete forms, casts or sintered), presence of cracks, stress cracks or discontinuity (Aluminium die casting parts), density differences and elasticity modules (controls on % of nodularity in spheroidal cast iron parts), presence of oxidation and contamination (e.g. presence of iron waste in sintered aluminum parts), inclusions, stripping of the material.
A fundamental requirement in the application for defect control is that the sonic system must be able to recognize at least one frequency, among the resonance ones, which allows the separation of good pieces from rejects. This activity is necessarily experimental and must be performed at a preliminary level with a simple procedure of Itasonic 2010^© software.

Itasonic 2010^© software - Main specifications

•    Multilingual
•    Management of operator permission
•    Saving of the measuring programs and of the batches in SQL database.
•    Scanning range: from 1 Hz to 50.000 Hz.
•    Resolution and measuring time, on all the scanning range:
Resolution         8 Hz: control time 0,125 sec.
Resolution         4 Hz: control time 0,25 sec.
Resolution         2 Hz: control time 0,5 sec.
Resolution         1 Hz: control time 1 sec.
Resolution         0,5 Hz: control time 2 sec.
Resolution         0,25 Hz: control time 4 sec.
•    Minimum distance between two frequencies: 2 Hz.
•    Impact and sonic acquisition synchronized.
•    Correct management of overlapping tolerances.
•    FFT, FRF and FRF analysis with congruence calculation configurable.
•    Special functions for 100% control: “Repeat measure if out of tolerance” and “Repeat measure if out of congruence”.
•    Auto-creation of the measuring program, with auto-research of the frequencies, with visual support and interactive charts.
•    Clear visualisation of the result of the test (Good/Reject).
•    I/O management with differentiated out for each frequency.  
•    Possibility to save the charts of the test in the database for further analysis.
•    Visualisation of the “sonic imprint” chart or of the “single values” chart.
•    Simple procedure for setting defect research programs.

 Manual unit

The manual unit consists of a PC with the Itasonic 2010^© Manual Software, a manual hammer, a special industrial microphone with adjustable support, Sensor Box iDaq4Sonic + iPower4Sonic power supply, connecting cables, a special sponge sheet as support for the parts to be controlled.   
Itasonic 2010^© Manual unit allows the control of the natural vibration frequencies and the control of defects, with the automatic research of the frequencies.    
Optionally it’s available a module for the statistical analysis and the process control (Itastat 6 Analysis).

Automatic unit

The automatic unit consists of a PC with Itasonic 2010^© Automatic Software, a compact automatic hammer with programmable impact force with special industrial microphone integrated, a special power supply for the hammer, Sensor Box iDaq4Sonic with I/O board integrated for the management of the dialogue with the automatic production line, iPower4Sonic power supply, connecting cables.
Itasonic 2010^© Automatic allows automatic controls of the eigenfrequencies and defect controls with automatic search of the frequencies which identify them. It allows also to configure the impact force of the hammer for each piece to be measured.  
Optionally available:
•    Itastat6 module for the statistical analysis and the process control.
•    Module for mould cavity reading, with management of the measures for each cavity.

Itasonic 2010^© Automatic can be easily integrated into automatic lines.
It’s possible to realize complete stations according to customer’s requirements.

The natural vibration frequencies (or eigenfrequencies) control is a fundamental requirement for the brake systems components for automotive (FRF Analysis).
Itasonic 2010^© verifies the project specifications, obtained through modal analysis, referring to appropriate tolerances that can be set.
The eigenfrequencies can be controlled on rough or worked pieces.
The technical specifications often show nominal values and the relative tolerances of the frequencies to keep under control.
In Itasonic 2010^© it is possible to create a “measuring program”  with the frequencies required: after having set the parameters of the hammer, the system will be ready for the control of the pieces.
The measured frequencies will be saved in the database of Itastat/Itageo 6^©.
Itasonic 2010^© can easily connect to stations of dimensional/geometric control: it's possible to have two distinct stations, with two support plans, which anyway can save the data in the same database, or it's possible to totally integrate the sonic control in the dimensional station with one only support plan, one only Pc, etc...