Design, Testing and QA

This category includes the noise and vibration engineering requirements that are covered under the scope of one or more of the following functions: design and development; testing and validation; quality assurance. Due to the nature of the work, the most of these tasks far too often require a close interaction between the experimental and the analytical studies at an early stage to prevent the cost-heavy and time consuming problems from creeping up in the design at a later stage. A series of design modification and testing and validation activities are undertaken in the course of the development of the product to achieve all the functional, design, reliability and quality targets.

Envicon works with its clients throughout the product-cycle and provides them cost-effective and timely solutions which can be easily incorporated in their engineering. We hold the trust our clients place in us to help them with the design solutions in high regard and make every possible effort to surpass their expectations. The tasks we provide consultancy and services in, are:

  • Acceptance Testing
  • Product Benchmarking
  • Noise Source Identification
  • Quality Assurance
  • Experimental Modal Analysis

Acceptance Testing

It is a test conducted in the final design stage to verify a product’s conformance with a given standard(s) and determine if the requirements of a contract in terms of the product’s noise and vibration specifications are met. The testing and analysis procedure are most commonly prescribed in the standard(s) to be followed. Acceptance Testing helps the manufacturers and buyers to ensure the product they supply/buy are meeting the desired noise and vibration criteria.

Envicon is a specialized and trusted source in carrying out the acceptance tests as per many ISO and MIL standards, for example, MIL 740-2SH and MIL 1474D for airborne and structure borne noise of ship board equipment. We also provide solutions to the manufacturers that can be implemented in their final design and/or prototype stage if a products fails the acceptance criterion.

Product Benchmarking

Benchmarking is a process of comparing design, assembly and performance metrics of two or more products, typically from different manufacturers but serving the same functional requirements. The various aspects and parameters related to the design and performance of the products are evaluated, usually within a peer group defined for the purposes of comparison. The exercise allows a manufacturer to develop plans on how to make improvements or adapt specific best practices, usually with the aim of improving a particular aspect of performance.

Benchmarking may be a one-off event, but is often closely linked with the reverse engineering element of the design and testing phase. Many a times, benchmarking is also employed to compare “GOOD” and “BAD” product samples from a single manufacturer therefore making it a continuous process through which a continual improvement of the engineering practices is sought regularly.

To benchmark a new or an existing product for its dynamic performance such as noise, vibration, fatigue and reliability etc., an adequate knowledge of acquiring, processing and analyzing the sound and vibration data is not only a must but it plays a critical role in the final results obtained from the testing. Envicon’s team has a thorough experience of working on benchmarking projects and help the manufacturers optimize their design by providing them with precise and accurate analysis reports and measurement data.

Noise Source Identification

Noise source identification is a technique of locating the dominant sound/noise sources in a complex system which is otherwise not possible by measuring only the sound pressure levels. Such a technique is usually employed in the development stage after a prototype is made for making finer refinements to reduce the sound power and improve the sound quality of a product. There are various DAQ and signal processing techniques that are employed for this purpose and Sound Intensity Mapping is one of them.

Sound Intensity is the sound power radiating out of a unity area with units as W/m2. It is measured by computing a dot product between the pressure and the particle velocity of the sound wave. The international standards for determination of sound intensity are well laid out in ISO 9614-1, ISO 9614-2 & ISO 9614-3. Envicon has the subject knowledge and the world-class resources for measuring and analyzing the sound intensity data according to these standards and has served various industries in the past.

Quality Assurance

In all the engineering sectors, irrespective of the production philosophy a manufacturer follows, quality assurance and/or control is a crucial process in the production system. High quality of the products is always needed to meet customer requirements and to avoid expensive recall campaigns. Unwarranted squeaks and rattles in delivered products may be perceived by the customer as an indication of poor quality. Moreover, they may be indicative of component or assembly faults leading to reduced life or unreliable operation.

Envicon has over the years formulated a novel and specialized approach to use noise and vibration signature of a product as a tool for determining its quality. We have evolved various means of assessing the product defects during the manufacturing. A few examples include quality testing of alternators, starter motors, gears, automotive transmission units and shock absorbers.

Modal and Harmonic Analysis

Modal analysis is a technique to study the dynamic characteristics of a structure by building a modal model in terms of the modal parameters of the structure which are the modal frequency, modal damping, modal scaling and the modal shapes. Once a modal model is obtained, it can be used to predict the response of the structure under the dynamics loads which it is subjected to during the operation for evaluating its fatigue life and many other parameters.

The dynamic characteristics of a structure play a vital role in the radiated noise and vibration. The right understanding of the dynamic behavior of a system, especially the mode shapes at the resonance frequencies, is the key to controlling the noise and vibration and optimizing the design of the structure. Due to this reason, the modal analysis is used extensively by the industry during the design and development as well as testing and validation stage to diagnose the design and failure modes of a product and make any structural modifications. However more often than not, the engineers without fully understanding the criticality of each step involved in the process, skip one or more of them resulting in not only an inaccurate modal model but also the further predictions and modifications turn out to be incorrect.

Envicon is an industry expert in this niche and the other related areas of analyzing the dynamic characteristics of the structures by both the experimental methods involving the dynamic frequency response function measurements and the numerical method involving the finite element analysis. We have worked with various major business organizations across the globe in the past and helped them achieve the most optimal designs in terms of both cost and performance.

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