Sound QC

End-of-line quality control by sound and vibration for motors, fans, compressors and other rotating machinery.

Each machine has its own sound level and frequency characteristics. The frequencies in its sound reflect the condition of the internal components of each machine type. Today, most inspection and quality control on production lines is done by listening: experienced people judge quality by ear, which carries a high chance of human error. Sound QC detects abnormalities using machine fingerprinting, the analysis of each machine's unique acoustic spectrum, much like reading a fingerprint. By examining the frequency spectrum of a machine's sound, the system separates units that work properly from those that have problems, and can identify the specific fault.

Key features

Objective pass/fail decisions instead of judgement by ear
Consistent results between shifts and operators
Faulty units found before they leave the factory
Test data stored for traceability and analysis
Short test time that fits the production line
Specific faults identified from the sound spectrum

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Sound QC (ภาษาไทย)

เครื่องจักรแต่ละเครื่องมีระดับเสียงและลักษณะความถี่เฉพาะตัว ความถี่ของเสียงบ่งบอกถึงสภาพของชิ้นส่วนภายในเครื่องจักรแต่ละประเภท ปัจจุบัน การตรวจสอบและควบคุมคุณภาพผลิตภัณฑ์ในสายการผลิตส่วนใหญ่ยังใช้การฟังด้วยหูของผู้มีประสบการณ์เป็นเกณฑ์ตัดสิน ซึ่งมีโอกาสเกิดความผิดพลาดจากคนได้สูง ระบบ Sound QC ตรวจจับความผิดปกติด้วยหลักการ Machine Fingerprinting คือการวิเคราะห์สเปกตรัมเสียงเฉพาะตัวของเครื่องจักร คล้ายกับการตรวจลายนิ้วมือ เมื่อวิเคราะห์สเปกตรัมความถี่ของเสียง ระบบจะแยกเครื่องที่ทำงานปกติออกจากเครื่องที่มีปัญหาได้ และยังระบุปัญหาหรือความผิดปกติที่เกิดขึ้นได้อีกด้วย

How the system is connected

A sensor is attached to the product under test (motor, air conditioner, compressor and so on). The SoundQC analyser reads the signal and sends it by USB to a computer running the SoundQC software developed by SP SONIC, which shows the result for every unit.

Why measure structure-borne vibration

Noise travels in two ways: through the air (airborne) and through the structure of the machine (structure-borne). On a busy production line, airborne sound from other machines easily disturbs a microphone. An accelerometer mounted on the product measures the vibration of the product itself, so the test result is much less affected by factory noise.

New software: OK / NG by machine fingerprint

The software learns the frequency fingerprint of good units. Each new unit is compared with it, and the screen shows a large QC Pass (OK) or QC Reject (NG) together with the spectrum against the limit line and the test time.

NG detail and fault identification

When a unit is rejected, NG Detail shows exactly which frequency bands exceeded the limit, so the cause can be traced. As an option, the software can also identify the type of fault from the spectrum pattern.

New function: choose the measurement mode

At start-up the operator chooses SPL Full, SPL 630 Hz–20 kHz or Vibration 630 Hz–20 kHz. Limiting the band to 630 Hz–20 kHz removes low-frequency background noise from the factory and focuses the test on the frequencies that reveal faults.

Specifications

SYSTEM
Analyser	SoundQC Systems precision sound analyser (Class 1, IEC 61672-1)
Sensor	accelerometer on the product (structure-borne vibration); Class 1 measurement microphone for airborne noise
Connection	USB to computer
Software	SoundQC software, developed by SP SONIC
TESTING
Method	machine fingerprint, comparing each unit's frequency spectrum with the reference
Result	automatic QC pass (OK) or reject (NG)
NG detail	shows which frequency bands are outside the limit
NG case identification	option
Measurement modes	SPL full band, SPL 630 Hz–20 kHz, Vibration 630 Hz–20 kHz
FIXTURES
Magnetic mount	for ferrous surfaces
Flange clamp	for aluminium motors
Vacuum mount	for motors with no clamping points
APPLICATIONS
Products	motors, air conditioners, compressors, fans, gearboxes and bearings