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Transmission and drive shafts - quality inspection and classification with LOTOS

09. August 2021, pzube - 3D measurement and inspection

In vehicle construction, the dimensional accuracies between the parts of the drive or the entire drive train play an important role for the vibration behavior on the vehicle. Especially at high speeds and torques, deviations from the nominal values become noticeable through noises and vibrations or, in the worst case, through malfunctions and lead to quality loss or even total breakdown.

It is therefore necessary to check an increasing number of geometries for their exact dimensional accuracy. In addition, established tactile measuring methods and inspections using tracing gauges can no longer cope with the required production cycle times in view of the increasing number of dimensions to be inspected.

The degree of automation required in modern production facilities demands fast and fully automated component inspections that are directly integrated into the production process.

With LOTOS 3D measuring systems, drivetrain components can be inspected quickly and reliably for dimensional accuracy. Furthermore, the parts can be classified and sorted directly into different tolerance zones.

For this purpose, the test parts are placed on the measuring system either manually by hand or fully automatically via robot. Automatic quality inspection is then performed for both external and internal dimensions using predefined measuring programs.

This can be, for example, the geometric inspection of a drive shaft: (LOTOS Video)

Inner contour of the test part
Inner contour of the test part
Contour of the external gearing
Contour of the external gearing
3D comparison of the inner contour to the CAD model
3D comparison of the inner contour to the CAD model
3D comparison of the external gearing to the CAD model
3D comparison of the external gearing to the CAD model
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Cross-location analysis of network disturbances

04. August 2021, mjesinghausen - Digital fault recording

Cross-location analysis of network disturbances

Merging and superimposing disturbance records from different data sources is a common practice in the analysis of network disturbances. For example, the effect of network faults at different locations, even across several voltage levels, can be clearly displayed, evaluated and documented.

The SHERLOG analysis software from KoCoS has mastered this superimposition since the first generation. Thanks to the globally standardized COMTRADE data format for disturbance recordings, the superimposition even works across manufacturers and devices. Thus, recordings from different disturbance recorders, digital protection relays and power quality monitors with disturbance recorder function can be very conveniently and quickly transferred to a common recording.  

 

The results of the superposition are as better, as more precisely the individual data sources are time-synchronized. Time deviations result in phase errors. For example, a time deviation of only one millisecond results in a phase error of 18° in 50 Hz networks. In 60 Hz networks even 21.7°.

The first choice for disturbance recorder systems with the highest time accuracy requirements is therefore synchronization by means of GPS time telegram and second pulse or alternatively via the communication network by IEEE 1588 /IEC 61588 standard (PTP). The time deviations in these systems are in the nanosecond to microsecond range and thus practically do not generate any phase errors (<0.1°). 

However, it is very popular and widespread to realize the time synchronization with GPS time servers, which send the time information via the communication network (LAN) using the NTP protocol. This usually results in deviations of between 0.2 and one millisecond in local networks. In distributed networks (WAN), deviations of up to 10 milliseconds are even possible.

With time synchronization using DCF 77 receivers, deviations of 5 to 15 milliseconds are to be expected.  

Basically, it can be stated that the time deviations due to different synchronization methods in practice may well be up to 15 milliseconds. Added to this are even greater deviations due to faulty or completely missing synchronization.

To cope with this situation, KoCoS analysis software offers efficient methods for reliably and quickly compensating for existing time differences between data sources, thus enabling detailed and correct analysis.

Incidentally, the SHERLOG and EPPE measuring systems from KoCoS ensure that time differences between individual devices cannot occur in the first place. The internal GPS receiver or the optical and electrical inputs for connection to external GPS sources synchronize the systems exactly.

But even when using a time source with larger deviations, such as DCF-77 receivers or SNTP, the master-slave principle ensures exact time synchronization between the devices via KoCoS's own interlink interface. Although there may be an absolute time difference due to the accuracy of the time source used, all the devices connected via the interlink interface run absolutely synchronously.

 

This method ensures perfect overlapping of disturbance records at all times. Even in the event of a total failure of the time source used.

 

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ARTES - USPs should offer an added value

03. August 2021, mkraemer - Protection relay testing

The comparison of actual test systems shows that the technical data of the devices from different manufacturers are similar in many points. And there are specifications where the devices differ to a greater or lesser extent. When evaluating, however, it should always be questioned what this means for the practical use of the devices.
 

Specifications as a result of development

In some cases, the technical data are much higher than required by the application. And this was not always the aim during development. Rather, some values are just the result of the development, quasi what has come out.
 

USPs without added value

And there are certainly manufacturers who deliberately work towards generating "unique selling points", which in the end, nobody needs. A real USP only becomes more important when the existing advantages also offer added value and a special benefit for the customer.
 

Technical data does not tell the whole story

Technical data are easy to compare. But purely numerical values say not much about which product is best suited for the customer. Product features and properties that cannot be evaluated with numbers, or only with difficulty, often lose their importance in the comparison. And it is often here where the advantages can be found that offer real added value for the customer.
 

Real USPs are not easy to find

The special features of our ARTES testing systems are pointed out in brochures, articles or blog posts. Customers appreciate, for example, that ARTES can be operated in an upright position. The status LEDs in the front or the operation of our devices on DC supplies are also appreciated by many users.

These properties and the many features and functions of ARTES are often not known. For example, the internal control unit, the low-level outputs, the analogue inputs, the multifunctional inputs or the internal GPS synchronisation unit are already included in the standard scope of delivery of the ARTES 600. In competing products, these features are often found, if at all, as options for which a charge must be paid. ARTES also scores points, for example, with its very low noise level, a feature that is difficult to express in numbers.
 

The software matters

The software plays a major role in relay testing. The device hardware of a test instrument is primarily a freely programmable function generator. Even though ARTES offers much more with its on-site operation, the test software in the end makes a decisive contribution to the high functionality of a professional testing system.

The ARTES 5 software is not only convincing because of its many useful features. It also has the most advanced user interface and the most intuitive operating concept. With ARTES 5, the user reaches his goal faster and easier, and thus saves time. In a following blog post, we will focus on the features and advantages of the ARTES 5 testing software.
 

ARTES experience live

The special features of ARTES are also highlighted regularly in social media such as Facebook, LikedIn, Twitter or YouTube. However, a live demonstration also offers the opportunity to find out what a customer's requirements and needs are. Only then is it possible to work out the features of ARTES that are important for the customer and to demonstrate their benefits.

Particularly in view of the diverse functions of the software, we are always pleased to offer our customers practical product presentations. Here, the customer not only learns a lot about ARTES, he can also experience ARTES live.

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PROMET R300/R600 – Efficiency through automation

22. July 2021, jdreier - Resistance measurement

Automation in the field of low-resistance measurement is increasingly required in the factory or laboratory. Be it in the automotive/electromobility sector, in the investigation of soldered or welded joints of high-current connections or in a wide variety of other applications.

For special requirements, e.g. for use in test stands, the easy-to-use PROMET PI programming interface is available for control and measurement with the PROMET R300/R600 resistance measuring devices. This can be used in COM/ActiveX-supporting as well as in .NET environments.
By programming the measurement sequence once, it is possible to integrate the PROMET R300 or R600 resistance measuring instruments into the test equipment via the programming interface and to perform measurements automatically.

Concept of a resistance measuring system with PROMET R300/R600 in automated processes

A driver is installed with the programming interface, via which the connected devices are addressed. Communication between the software/PC and the external PROMET R300/R600 is made possible by the installed ActiveX component. This allows communication via USB or Ethernet interfaces.
As an example, an Excel sheet is used to control the PROMET R300/R600 and to evaluate the measurement results in this description, via which the programmed VBA macros (Visual Basic for Applications) are executed. Programs can be modified and adapted according to the requirements.

The PROMET R300/R600 precision resistance meters are an ideal tool for characterizing components for high current and low resistance due to their four-wire measurement and ability to accurately measure both current and voltage. 
As demonstrated in the article, a resistance measurement system controlled via external software can be easily integrated into an automated application. Using the PROMET R300/R600 resistance measuring instruments to perform such measurements simplifies the test setup, reduces programming time, and enables efficient test sequences.

Further information on the use of the PROMET PI programming interface can be found in the application report PROMET R300/R600 - The intelligent way to measure resistance!

Do you have any questions about resistance measurement or our measuring devices? Then contact us via the comment function here on the blog or by mail to info(at)kocos.com.

Postscript
The EPOS 360 three-phase signal generator can also be integrated into your own test applications in a similar form via the EPOS PI programming interface!

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INDEC selflearning

13. July 2021, gherrmann - Vacuum inspection

Thanks to the excellent, semi-automatic self-learning procedure for determining the sensor parameters (recipes) of the INDEC vacuum inspection systems, commissioning is possible without a KoCoS technician.

Ensuring the highest product quality is a primary and indispensable objective, especially in food production. The tightness of the product containers are an important role in this.

Leaks can cause the contents to leak out. But it is much more important that germs penetrate the container and spoil the product.

The INDEC vacuum testing systems monitor the tightness of containers fully automatically directly in the production process. A wide variety of containers such as bottles, jars and cans are checked for leaks without contact and defective containers are removed from the product flow.

Often, the necessary technician charges for commissioning, especially in Europe or overseas, are not in good proportion to the purchase price of an INDEC system. Sometimes these costs amount to another 30-40% of the purchase price for the equipment.

For this reason, it is very important to have good and meaningful documents such as the operating instructions and suitable videos. We have all those resources in good quality with the INDEC vacuum inspection system.

To make the start easier for the customer, we offer to send us some bottles and jars from his range. We already save predefined sensor parameter sets (recipes) in his ordered INDEC device ex works. If fine-tuning is still required, this can be completed between the end customer and us using modern communication media.

This has already been proven several times in the past, both in Germany with the company STANGL, in the EU with the French company ANDRESY and overseas with PRINCES TUNA in Mauritius. These screen shots illustrate the self-learning process.

centre the good container under the sensor
centre the good container under the sensor
Press OK button
Press OK button

The system automatically adjusts the threshold to distinguish between good and bad containers. The more containers are fed to the tester, the more representative the result is for a good separation of good and bad containers.

Due to the excellent, semi-automatic self-learning procedure for determining the sensor parameters (recipes) of the INDEC vacuum testing systems, it is possible for the customer to commission the system on his own. The use of a KoCoS technician or a technician from our local representative on site is not mandatory.

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