Practice

Acoustic test technology in practice.

How industrial customers deploy SonicTC – with measurable results. Real parts, lines and industries.

SonicTC.NVH

EOL noise testing on high-voltage e-drives

Challenge: Tier-1 supplier with 240,000 e-drives per year had pseudo-rejects up to 6.3 % – customers reported comfort noises the EOL bench did not detect.

Solution: SonicTC.NVH integrated into existing bench. Order tracking, psychoacoustic KPIs and AI classifier. Hardware: existing B&K microphones reused.

Result: Pseudo-rejects reduced from 6.3 % to 0.8 %. Slip rate < 0.1 %. Customer claims halved. ROI in 7 months.

−87 %Pseudo-rejects

< 0,9 sTest time

7 Mon.Payback

SonicTC.AT

Crack detection on cast iron brake discs (100 % inline)

Challenge: Production line 1,200 brake discs/hour. Previously sampling + visual inspection. Required detection threshold: micro-cracks from 0.3 mm.

Solution: SonicTC.AT with contactless hammer excitation and microphone array. Resonance analysis with FRF comparison to master. Fully integrated into conveyor.

Result: 100 % inline testing instead of sampling. Detection rate 99.7 %. Pseudo-rejects 0.4 %. Test time 0.7 s per part.

99,7 %Detection

0,7 sTest time

100 %Inline

SonicTC.DSP

Early tool break detection on CNC machining centers

Challenge: Each tool break caused 4.2 hours of downtime plus consequential damage to workpieces. Sensors in place, but no intelligent evaluation.

Solution: SonicTC.DSP retrofitted onto existing accelerometers. Adaptive thresholds per machining operation. PROFINET connection to PLC.

Result: Early warning 28 seconds before break. Downtime per incident reduced from 4.2 h to 18 min. Consequential cost 92 % lower.

−92 %Consequential cost

28 sEarly warning

24/7Monitoring

SonicTC.NVH

Acoustic end-of-line testing on dishwasher pumps

Challenge: Manufacturer with 1.8 M pumps/year. Acoustic anomalies only noticed by end customers – claim rate 2.1 %, high warranty cost.

Solution: SonicTC.NVH with 4-channel microphone array in acoustically isolated test booth. AI classifier for 8 fault classes. EOL-capable, 4.5 s cycle time.

Result: Claim rate reduced to 0.3 %. 100 % inline testing. Warranty cost reduced by 78 %.

−86 %Claims

4,5 sCycle time

8Fault classes

SonicTC.AT

Sintering grade classification on hard ferrite magnets

Challenge: Sorting problem: sintering grades 1, 2, 3 not unambiguously distinguishable visually or magnetically. Manual sorting cost 11 FTE.

Solution: SonicTC.AT with defined excitation energy and resonance analysis. 3-class model trained on natural frequency shift. Fully automated sorter.

Result: Sorting accuracy 99.8 %. 11 FTE reallocated. Throughput from 6,500 to 18,000 magnets per day.

99,8 %Sorting accuracy

×2,8Throughput

11FTE reallocated

SonicTC.AT

Resonance testing on hip joint implants

Challenge: Titanium-alloy implants – post-forging defects not detectable via CT (too time-intensive for 100 % inspection).

Solution: SonicTC.AT with clinically certified hardware and FDA-validated process. FRF analysis with ML classifier. Inline integration with tracking.

Result: 100 % material inspection instead of sampling. Detection of structurally anomalous parts at 99.3 %. Audit-compliant per ISO 13485.

99,3 %Detection

ISO 13485compliant

100 %Inline

With SonicTC we made the jump from sampling to 100% inline testing – without replacing our existing hardware.

Dr. M. Hofmann Head of Quality Engineering · Tier-1 Automotive Supplier

Your part as the next use case?

Send us a sample. First assessment within 24 hours.

Request feasibility study Request demo

Or call directly: +49 (0) 721 94650-0