Crack detection during spring coiling

Detect cracks reliably and automatically with the QASS measuring system.


Inline crack detection

QASS enables real-time crack detection when coiling springs. We monitor every millisecond of the process and any defective components are automatically ejected from the system.

Data analysis through pattern recognition

Real-time evaluation of measurement data using pattern recognition: cracks are detected and analysed using stored signal patterns. This is followed by immediate transmission of the result (IO/NIO) via the Profinet interface.

Volle Qualitätskontrolle

Coiling and winding processes are seamlessly monitored by our structure-borne sound sensors, minimising the need for downstream quality checks. The system works fully automatically and visual samples are no longer necessary.

100% zerstörungsfreie Überwachung

Auf Grund unseres auf Körperschall basierten Messprinzips zeichnen unsere Sensoren alle Details Ihres Prozesses völlig zerstörungsfrei auf. 

Efficient quality assurance in spring production

During the production of springs, there is a recurring occurrence of the typical formation of cracks, which can later lead to the need for replacement or defects in the component. More and more industries in the manufacturing sector are striving to elevate safety standards to a higher level and counteract this issue. Each spring is carefully inspected to ensure that it meets the high standards through visual inspections, measurements, and possibly even functional tests. By utilizing QASS, we can significantly simplify this process and free up working time for the employees.

QASS can now detect cracks that are of significance fully automatically, taking quality assurance to a new level.

Your branches



Wind energy

Medical technology

Mechanical engineering

How it works

The QASS Optimizer4D in use.

With over 50 million scans per second, our structure-borne sound sensors seamlessly record every piece of information from your production process. The collected data is then analysed, categorized and processed in real time by our Optimizer4D measuring system. The recorded structure-borne sound signals can be displayed and tracked in our FFT landscape as shown in the image below. Our new features such as clustering and the associated pattern recognition, as well as corresponding frequency filters and masks, allow us to precisely separate important signals from background noise or machine noise and analyze them within milliseconds.

Structure-borne sound image of a coiling process of a spring in the QASS Optimizer4D measuring system.

Our concept

The monitoring of the spring coiling process is divided into three degrees of complexity.



Die Basic-Version aktiviert eine Prozessüberwachung, die die Entwicklung von Körperschallsignalen während des Prozesses überwacht. Dies ermöglicht uns:

  • Die Bewertung der Qualität des Vormaterials: Material mit vielen Rissen bzw. grundsätzlich „schlechteres“ Material zeigt höhere Emissionen als normgerechtes Material

  • Die Erkennung von Beschädigungen an Windestiften

  • Die Überwachung der Zuführwalzen, abhängig von der Anzahl und Position der installierten Sensoren


Die Advanced-Version baut auf der Basic-Überwachung auf, und beinhaltet zusätzlich eine Risserkennung.
Dabei können Risse, die kritische Größen erreichen, vom Optimizer4D erkannt und ausgeschleust werden. Das System gibt automatisch eine Warnung aus.


Das Expertenlevel bietet über die Funktionen von Basic und Advanced hinaus eine tiefere Analyse des Prozesses. Sie ermöglicht:

  • Die Detektion von Mikrorissen

  • Den Anschluss zusätzlicher Sensorquellen zur erweiterten Datenauswertung

  • Die Nutzung von KI und Machine Learning zur Erstellung von Metaaussagen über den Prozess

Dieses Level ist für erfahrene Anwender optimal, die nicht nur ihre Prozesse wirtschaftlich und technisch optimieren möchten, sondern auch tiefgreifende Mechaniken und Korrelationen verstehen möchten, um de Prozess als solchen optimieren zu können, bzw. besser zu verstehen. 

Scope of delivery:
Optimizer4D Measurement system
2TB SSD Hard disk
Optimizer4D measuring chain ( preamplifier, structure-borne sound sensor, cable )
12“ o. 15“ Touch Display

The Optimizer4D is intended for installation in a machine control cabinet. This must be air-conditioned or have ventilation.

8TB hard disk instead of 2TB
Optimizer housed in its own control unit (at an extra charge)
Accommodation of the Optimizer in a mobile "expert case" (at an extra charge)

Machine communication:
24V/IO-Communication ( inclusive )
ProfiBus ( at an extra charge )
ProfiNet ( at an extra charge )

Graphical User Interface ( GUI )
The Optimizer user interface has several levels. The top level, which is visible to everyone, is the "PenGUI", a customizable interface on which the simplest information can be viewed easily and intuitively. Crack rates, trend developments or simple "red"-"green" displays provide the machine operator with the necessary information quickly and clearly. If someone with higher access rights logs in, they can delve deeper into the process, view signals in their raw state, adjust the pattern library, etc. The focus is on displaying only the absolutely necessary data on the machine.



You contact us by phone or e-mail and tell us about your situation

Target definition

We define the goals of the project together with you.

Data analysis

The QASS measurement technology is installed and records data, which is then analyzed.


The measurement technology is specially adapted to your purposes.


Our system is tested and optimized at your premises under production conditions.

Arrange a consultation now!

Ask our experts about the possibilities for your industrial processes without obligation.