Fully automated end-of-line acoustic test bench for fresh-air grilles increases process reliability

SPIE AUTOMATION developed and implemented an end-of-line acoustic test bench for 100% testing of fresh-air grilles in series production. The aim of the project was to create a highly precise, reproducible yet flexible test solution that reliably covers different product variants and can be seamlessly integrated into existing production processes.

Challenge and Objective

The customer faced the challenge of implementing an acoustic end-of-line test for its products for the first time. There were no relevant empirical values or existing test systems. At the same time, the requirement was to develop a solution that can test a wide range of fresh-air grille variants reliably and reproducibly. The goal was therefore to create a flexible test-bench concept that meets current requirements and can also accommodate future product variants with ease. The basis was the customer’s existing modular workstation concept, which was specifically expanded and technically enhanced. A particular challenge was the design of the acoustic measurement technology. It had to be engineered to deliver precise and stable measurement results even under real production conditions. At the same time, external interference such as airborne and structure-borne noise had to be consistently minimized. This was achieved through a decoupled test setup, damped machine feet, and a specially designed loading door.

Solution

The project was implemented by an interdisciplinary team from the SPIE AUTOMATION Haßfurt branch, covering design engineering, software development, electrical design, test-bench construction, and control cabinet manufacturing. The development process was clearly structured and divided into several phases. First, the specifications were analyzed in detail to fully capture all functional and technical requirements. Based on this, the mechanical design of the test bench was created, developed in close coordination with the customer, and approved. In parallel, all electrical components were selected and a holistic system concept spanning mechanics, electrics, and software architecture was created. This was coordinated with the customer and approved as the basis for further implementation. After the planning phase was completed, manufacturing of the mechanical components began, along with the build-up of the electrical infrastructure including the control cabinet. At the same time, the software was developed to support both manual and automated test sequences and to allow flexible adjustment of test parameters. This was followed by electrical installation and the step-by-step commissioning of the system. Integration of the acoustic measurement software was the final step, followed by comprehensive validation of all functions. For quality assurance, the acoustic measurement was additionally verified through comparative measurements with the end customer. The sensors used were checked with calibrated reference devices and validated using special test programs. Finally, the complete technical documentation was prepared and the system’s CE conformity ensured. Handover to the customer included all required documents for safe and smooth operation. The system enables fully automated testing of all relevant functions and quality features. These include, among other things, acoustic evaluation of the adjustment motors, electrical tests, camera-based inspections, and complete documentation and traceability of all measurement data. Thanks to its modular design with interchangeable test fixtures, the test bench can be used flexibly for different component types.

Benefits

With the implemented solution, the customer now has a fully automated test system that enables complete end-of-line testing without manual intervention. This significantly increases process reliability, reproducibility, and efficiency in production. The modular design of the test bench allows quick adaptation to new product variants. At the same time, the intelligent software architecture ensures that future changes in acoustic evaluation can be implemented flexibly and with minimal effort. Full data storage and traceability of all test results also ensure a high level of transparency and audit readiness.

These SPIE AUTOMATION Strengths Were Applied

About our customer
Our customer is an internationally active industrial company focused on the development and production of technologically sophisticated components and systems. With decades of experience, it is one of the established global providers of innovative solutions for various industrial applications.

Industry
Automotive supplier

With this solution, we provide the customer with maximum flexibility and efficiency—thanks to a scalable acoustic measurement solution that reliably meets future requirements as well. I am very satisfied with the project implementation, as we were able to deliver several test systems on schedule from a single source and exactly to the customer’s specifications. The solution meets all technical requirements while also offering maximum flexibility for testing a wide range of types.