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Application Note: Short Block Crank Torque to Turn Test
A major engine manufacturer was experiencing customer complaints and costly warranty repairs and quickly required a solution that could detect defects early in the Short Block assembly process, specifically defects caused by crankshafts. Sciemetric’s Short Block Crank Torque to Turn test measures the torque as the crank is rotated, applying advanced algorithms for consistent and reliable detection of defects such as contaminated bearings, debris, incorrect fit, bent or nicked cranks, etc. Read the Application Note to learn more.
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Application Note: The True Cost of Medical Packaging
In medical device packaging it is extremely important to have a reliable sterile sealing process, however in many cases it is the last piece of the puzzle before going to market with a product. When a proper seal packaging process is not practiced, it quite often leads to returns and having to re-package the product or dispose of it all together while additional unnecessary costs are incurred. Read the Application Note to learn more.
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Application Note: Dispense Operations
Downstream issues on the production line with leaks, non-secure parts and components, or unwanted noise and vibration can often be traced back to a flawed fluid dispense operation. The Sciemetric solution, using digital process signature analysis, allows manufacturers to identify faulty dispense operations as they occur and take corrective action. The result is reduced downtime, scrap, rework costs, warranty claims, and improved production efficiency and product quality.
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Application Note | Axle Suspension Component Assembly: Press Force Verification of Bushing Assemblies
Since the part is welded to the front axle, the assembly of the front axle bushing into a stamped metal bracket is a critical process. The visual and random mechanical inspections conducted post-assembly by a manufacturer were insufficient to identify defective parts and provide 100% guarantee of the integrity of the assembly during the service life of the vehicle. Read the application note to learn how Sciemetric fixed the problem.
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Application Note: Production Testing of Brake Integrity Including Press Monitoring
When a reputable brake pad manufacturer shipped defective brake pads to their customers they realized that their quality testing methods needed to change. The manufacturer required a solution that would be able to test 100% of brake pad production to catch all defects while having the ability to create reports demonstrating to their customers that each pad met their specification. Read our Application Note to learn how Sciemetric solved the problem.
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Application Note: Engine Vibration Testing
A major engine manufacturer was very concerned about the inconsistent quality of their shipped engines and the issues with unwanted noise and vibration, which often affect customer satisfaction. Traditional subjective testing failed to identify defects, which were eventually discovered at vehicle assembly plants or by customers. This led to expensive warranty repairs and productivity disruptions. The manufacturer required a solution with minimal tooling and fixturing modification that would reliably improve engine quality without affecting yield. read the Application Note to learn how Sciemetric solved their problem.
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Application Note: Cam Shaft Grinding Application
A major automotive manufacturer was looking for an accurate quality and process monitoring system to improve yield and reduce costly defects. They were having issues with chatter marks in a cam shaft grinding operation causing engine noise and vibration (NVH) and accelerating engine component wear. Sciemetric’s test and process monitoring system resolved the problem: it measures vibration quality control, condition-based wheel dress frequency, monitors machine health to prevent future defects and more. Read the Application Note to learn more.
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Application Note | Piston Connecting Rod Fracture: Force Monitoring in V8 and V10 Assembly
An engine manufacturer required a solution to successfully monitor the crank force to verify the correct range of key parameters to ensure the quality of the connection of the connecting rods joining the pistons to crankshaft was not compromised. Sciemetric’s process monitor resolved the issue by closely monitoring the crank and peak force, bushing, falling slope and area under the curve while simultaneously monitoring both the cranking process and bushing press forces with a single system with a five second machine cycle time. Read the Application Note to learn more.
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Application Note: Wire Crimp Monitoring (AN120)
An automotive manufacturer of wire harnesses chose Sciemetric to monitor the crimping of copper terminals into wires. The manufacturer experienced dramatic improvements in manufacturing quality and repeatability. This high speed process takes 30 mS to complete, with 0.5 seconds between crimps.
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Application Note: Spool Valve Optimization and Assembly (AN165)
Spool valves require crimping at a precise location in order to ensure uniform and balanced flow characteristics. Before approaching Sciemetric, a spool valve manufacturer had been attempting to solve this problem with another company. After spending about $30,000 and many months attempting to develop another system to do the job, they still could not get the system to work. A 30-minute discussion with Sciemetric solved the problem: a simple five-line program was all that was needed to complete the task.
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