Quality control The sound of quality: Intelligent sound detection in production

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DS Automation introduces advanced sound sensors capable of detecting even the slightest anomalies in metal, glass, or ceramic parts. These innovative sensors identify defects early in the production process, enhancing efficiency and preventing costly errors, a game-changer for manufacturers seeking precision and reliability.

Sound detection is suitable for many in-process, comprehensive quality checks in production. Especially in industrial mass production, anomalies or deviations in the production process can be detected at an early stage and the risk of failure minimised. DS Automation is successful in this special field. The company develops sound sensors that use acoustic properties to reliably check the quality of small metal, glass or ceramic parts. The dsound USS4 airborne sound sensor, for example, hears the slightest changes in sound and can draw conclusions about the quality of the component or material. “If, for example, there are fine cracks in screws, inclusions in snap rings or geometry errors in turned parts, our sensors notice this immediately,” says Ronald Meyer, development engineer at DS Automation. In series production, the sound sensors recognise in real time whether a component or precision part has the right sound and can immediately eject defective parts from the production process. This makes quality inspection possible in areas where other systems, such as cameras, are too expensive or maintenance-intensive, too complex to install, or where defects are simply not visible.

“This has many advantages for industrial manufacturers,” explains Arndt Kritzner, Managing Director of DS Automation. “With our acoustic method, they can check the quality of their products at an early stage and quickly detect defective material. Defective parts do not enter the downstream manufacturing process, which ensures flawless end products. As a result, our customers have better control of their processes, avoid costs and the stress of complaints, and avoid having to reject entire batches. Overall, the efficiency of the entire manufacturing process is increased.” DS Automation has developed a range of sensors for different applications, which solve both simple and very demanding tasks, and work extremely precisely and in sync with production.

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In the production process, dsound sound sensors check parts for dimensional accuracy, correct material composition, cracks, assembly completeness, tooth flank clearance in the gear, pressure tightness and other quality criteria. In many cases, ultrasonic testing is used to check features that would be almost impossible to detect using other testing methods.

Material properties, cavities or angled structures can be holistically and accurately checked for compliance with target criteria using sound. Both airborne and structure-borne sound can be recorded and analysed with dsound sensors.

Depending on the application, the complexity of determining a valid test result varies. For this reason, DS Automation offers sensors in two different performance levels, suitable for the application of either simpler or more complex test algorithms. Depending on the application requirements, there are also limited or comprehensive configuration options to adjust the detection. With sound sensors, frequency spectra can be accurately detected well into the ultrasonic range and individual frequencies can be very finely determined and differentiated. The transient and decay behaviour of a test specimen can also be recorded and included in the classification. The test method can be easily integrated into new or existing production lines.

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