An OEM of electric vehicles has standardized on Shield for end-of-line NVH and functional testing across their product lines. Vibration signatures are combined with many other status signals from the motors to produce a birth record for each part. High-volume data collection, archival and reporting is accomplished with Trove, our data collaboration server. The implementation of Shield with Trove is further extended to multiple laboratories and full vehicle testing to enable a common data set to be shared in collaboration with design, development and production activities.
Shield is used to test over one million axles annually for NVH acceptance in locations around the world. In these systems the NVH Controller works at the direction of a system PLC to acquire and process axle response data and provide metrics that can indicate impulsiveness, whine propensity, etc. Signal.X assisted a leading machine builder to design these production axle testers, which successfully produce repeatable data quickly and autonomously.
Production engine cold tests spin non-firing engines through multi-step profiles where metrics designed in Shield and measured by the NVH Controller identify torque, vibration and sound anomalies.
Full data retention facilitated by Trove allows batch processing to explore “what-if” metric behavior. Here 14,000 engines are used to refine joint audio and vibration nick detection limits in order to predict future failure rates.
Turbocharger testing is a challenging task where success depends upon the precise tracking of frequency components through extreme RPM gains over very short periods. Use Shield to design metrics to quantify rub detection, spool instability, blade defects, leaks, etc. Traditional order tracking methods cannot match the discrimination offered by NI’s patented Gabor order analysis method as implemented in Shield. No longer will signal processing limit ramp rates in rotating machinery order analysis.
A leading heavy-duty transmission manufacturer relies on the Shield system to automate laborious and time-consuming laboratory procedures by embedding the NVH Controller in a development dynamometer. A custom Signal.X application communicates with the NVH Controller to define gear mesh fundamental frequencies and harmonics to extract meta data which propagates through the data file headers to subsequent test reports. Now an operator can complete in a day measurements and analysis that previously took several weeks.
Hydraulic Pump Testing
Signal.X is helping to develop metrics for aircraft hydraulic pumps as part of an effort to implement laboratory and in-flight Predictive Health Maintenance (PHM) capability. Shield is deployed in an R&D setting to provide monitoring of pumps undergoing flight profile qualification testing in order to define detectable machine degradation. Both high-speed (acceleration and dynamic pressure) and low-speed (temperature, flow, etc.) plus extensive meta data go into each data file. Data analysis relies extensively on Trove and its built-in batch processing capability.