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Automotive
Quality Analysis - Automotive
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quality assurance in the automotive industry

Reliable, holistic quality management for the automotive industry

The challenges for the automotive industry include short development times and new technologies. Along with combustion engines and highly complex gearboxes, the focus in future will be on batteries, power electronics, electric motors and fuel cells. These areas will bring new production and assembly processes. Quality Analysis offers you complete quality assurance for the entire drive train for combustion engine, electric and fuel cell vehicles.

For this purpose, along with tactile and optical measurements, we rely on non-destructive computed tomography as well as destructive material tests. Using our correlative analysis methods, we combine individual measurement and test techniques across disciplines for even more precise, informative results. Please send us your enquiry, our experts will provide help and support.

 

ANALYSIS OF GEARBOXES, DRIVE TRAIN, SUSPENSION AND CHASSIS

For the complex drive train, we offer the following measurement and analysis options for shafts, gearwheels and housings:

  • Preparation and validation of measuring programs
  • Geometric dimensional inspection of standard geometries and freeform surfaces, as well as shape and position tolerances
  • Surface and contour measurements on radii, chamfers, roughness or corrugations
  • Gear tooth measurement including evaluation in accordance with the standards, with and without rotary table, of internal and external gear teeth
  • Preparation of initial sample test reports according to drawing requirements (ISTR/PPAP)
  • Surface comparisons (nominal-actual/actual-actual comparison) to identify shape deviations in any alignment and colour-coded depiction of the deviation
  • Non-destructive analysis of pores, cavities and wall thickness
  • Metallographic material testing and microstructure analysis, hardness testing, analysis of the alloy composition as well as weld seam inspection
  • Analysis of damage mechanisms, e.g. fractures, cracks or corrosion
  • Verification and identification of particulate and filmic contamination

ANALYSIS OF POWER ELECTRONICS

For electronic components such as sensors, printed circuit boards and their components, we use imaging methods and measuring solutions with resolutions down to the nano-range:

  • Non-destructive and destructive analyses as per the acceptance criteria for electronic assemblies (IPC-A-610) and printed circuit boards (IPC-A-600)
  • Inspection of components sensitive to electrostatic in ESD protection zones
  • Serial checking of soldered joints using 2D X-ray inspection
  • Depiction and analysis of coatings and their structure
  • Light, electron and X-ray microscopy for the depiction and analysis of flaws and anomalies in electronic assemblies
  • Verification and identification of particulate and chemical-filmic contamination for the prevention of leakage currents

INSPECTION OF COMBUSTION ENGINES

For quality assurance on combustion engines we offer for all parts and components, e.g. crankcase, cylinder head, crankshaft, piston rods, camshafts, turbochargers and all functional fittings, as well as the complex intake duct and exhaust system, the following measurement and analysis options:

  • Tactile and optical dimensional inspection of standard geometries, freeform surfaces as well as shape and position tolerances
  • Geometric evaluation and surface comparisons (nominal-actual/actual-actual comparison) for identifying shape deviations
  • 3D-digitisation of component surfaces as well as complete components
  • Wall thickness analysis with colour-coded depiction of deviations
  • Non-destructive analysis of porosity, inclusions or cavities
  • Metallographic material testing and microstructure analysis on prepared specimen
  • Weld seam and hardness testing
  • Analysis of damage mechanisms, e.g. fractures, cracks, corrosion or faulty weld seams
  • Verification and identification of particulate and chemical-filmic contamination

 

ANALYSIS OF ELECTRIC MOTORS

For highly magnetic components in the electric motor, e.g. rotors, stators, lamination stacks and hairpins, we offer dimensional measurements, material testing and residual dirt analyses:

  • Tactile and optical measurement of individual laminations for flatness and freedom from burrs
  • Dimensional measurement of highly magnetic lamination stacks using special probe systems for checking the positioning of the individual laminations, dimensions and positions of grooves, contour features, shape and position tolerances
  • Non-destructive and destructive weld seam analysis to identify pores and cavities in the weld seams
  • Microstructure analysis and particle size determination on lamination stacks (eroded, laser-cut, punched)
  • Analysis of damage mechanisms, e.g. cracks, corrosion, inhomogeneities in the microstructure, material inclusions and faulty welded joints
  • Verification and identification of particulate and filmic contamination

ANALYSIS OF BATTERY CELLS

Non-destructive and destructive inspection of individual battery components all the way up to the fully assembled battery:

  • Optical 3D digitisation of individual battery components as well as complete battery trays
  • Tactile and optical checking of dimensional accuracy and hole formation
  • Assembly checking after fitting the individual components in the battery housing
  • Depiction and analysis of the change in individual component groups due to the application of pressure
    • Graphic evaluations of individual levels of force on the related geometries
    • Actual-actual comparison for the depiction of the absolute change due to the application of pressure
  • Analysis of the increase in cell thickness due to charging and discharging processes
    • Nominal-actual comparisons in relation to CAD to illustrate the expansion at the end plates
    • Microscopic analysis for the identification of crack propagation, pore formation or loss of mechanical stability
  • Non-destructive and destructive analysis of the design of battery cells and their structures
  • End-of-line inspection of complete battery packs for particulate contamination using particle suction extraction

ANALYSIS OF FUEL CELLS

Non-destructive and destructive inspection of individual components all the way up to fully assembled cell modules:

  • Metallographic analysis and weld seam inspection on fuel cell modules as well as various stack components, e.g. metallic bipolar plates, end modules and media modules or seals
  • Analysis of the structure and characteristics of cell membranes (GDL/MDL incl. CCM foils)
  • Technical cleanliness verification of all components, incl. end modules and media modules with special solutions for extraction
  • Analysis of chemical-filmic contamination on surfaces for the evaluation of suitability for welding

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QUALITY ANALYSIS, THE RIGHT PARTNER FOR YOUR ANALYSIS TASKS IN THE AUTOMOTIVE INDUSTRY

What can we analyse for you?
We would be pleased to advise you about the numerous possibilities and combined analysis methods.
The goal: the best, most cost-effective and most efficient analysis of your component.
Call us, we look forward to hearing from you!

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