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Testing - quality assurance through precise control

From simple measurements to complex vision systems: Modern inspection technology ensures quality, minimizes costs and increases competitiveness in industrial production.

What do a quality inspector, a materials scientist and an Automation technologies engineer have in common? They all test. The term comes from Latin and refers to a procedure for determining knowledge, skills or performance by means of specific tasks or measurements [1]. In industry, the quality of testing processes determines the functionality, reliability and market acceptance of products. For companies, efficient testing therefore represents a decisive competitive advantage.

What does testing mean in the industry?

Testing procedures are a central process step in industrial production. Skilled workers or automated systems inspect the products for quality, completeness and functionality. The results of these tests determine delivery, rework or rejects and therefore have a significant impact on the economic efficiency of production.

Modern Inspection systems work with the highest precision. They inspect products using various techniques such as dimensional measurements, surface inspections, functional tests or leak checks. Depending on the requirements, fully automatic, semi-automatic or manual processes are used.

A central element of many inspection systems is the 100 percent inspection. This means that each individual unit of a production batch is fully inspected using defined inspection characteristics. DIN 55350-17 defines this method as a quality inspection of all units in an inspection lot [2]. This comprehensive inspection strategy ensures maximum product safety.

Test procedure in detail

Industrial quality control can be divided into different categories:

  1. Dimensional inspection
    Checking dimensions, tolerances and geometric properties
  2. Surface inspection
    Inspection for scratches, inclusions or color deviations
  3. Functional test
    Test of the intended product functions
  4. Material testing
    Analysis of material properties and composition
  5. Thermal testing
    Recording and evaluation of temperature curves or heat distributions

Thermal testing is essential for processes in which temperature plays a central role, such as Shrinking(process), sealing or curing of materials. With the help of this test, overheating, uneven heating or thermal weak points in the product can be detected at an early stage.
Precise testing methods are particularly crucial in Automation technologies. Here, every characteristic must be measured exactly in order to guarantee the function of the overall system. Modern testing technology therefore uses sensors, cameras and sophisticated evaluation algorithms [3].

Test procedureArea of applicationTechnology (exemplary)Advantages
Dimensional measurementDimensional and form testingCoordinate measuring machines, laser measurementHigh accuracy, objective results
Visual inspectionSurface inspection, completenessCamera systems, vision technologiesFast inspection, detailed documentation
Leak testSealed components, containersCompressed air, vacuum testsReliable detection of leaks
Temperature measurementHeat development, material behaviorThermal sensors, thermal imaging camerasContactless testing, real-time monitoring
Function testEnd product qualityAutomated test systemsRealistic testing, comprehensive evaluation

The selection of the right inspection technology depends on various factors. Optical systems check surfaces and completeness, while Sensor technologies record physical variables such as temperature or pressure. Destructive testing provides deep insights into material properties, but is only suitable for random samples.

Modern testing technologies

Quality control has changed fundamentally as a result of technological innovations. While manual inspection used to be the focus, companies now rely on automated and digitalized inspection systems.

Vision systems and optical inspection

Industrial Image processings makes machines “capable of seeing”. Cameras, Sensor technologies and intelligent software are used to capture, inspect and evaluate objects. Industrial PCs are at the heart of this and process large amounts of data in real time.

Vision systems offer decisive advantages:

  • Zero-defect production thanks to precise optical control
  • Fast and reliable testing of large quantities
  • Cost reduction through automation of manual inspections
  • Flexible adaptation to different product variants
  • Complete digital documentation of all test results

Modern camera systems for position control use high-resolution industrial cameras with up to 64+ megapixels, specialized LED lighting and powerful image processing computers. The software includes real-time algorithms for object recognition and AI modules for deep learning [4].

Sensor technologies for precise measurements

Temperature sensors such as PT100, PT1000 and NTC are used for precise temperature measurements in industrial applications. The temperature is clearly assigned to the measured resistance, which enables continuous measurement and further processing in control systems [5].

The practical guide to industrial temperature measurement describes various measurement methods:

  • Contact measurement (e.g. thermocouples, PT100, NTC):
    Offers high accuracy and measures directly on the component, but requires physical mounting

  • Contactless measurement (e.g. pyrometer, thermal imaging camera):
    Enables rapid testing of moving or hazardous parts, but is dependent on the emissivity of the surface [6]

  • Distributed fiber optic temperature measurement systems (DTS) are suitable for long distances

  • Calibrated thermistors or thermocouples are used for precise measurement

Statistical process control (SPC)

Statistical process control (SPC) is a data-based method for monitoring, controlling and improving manufacturing processes. Real-time SPC reduces variability, improves product quality and minimizes waste [7].

Laser testing device

Testing at BERNING: Customized solutions for complex requirements

BERNING Maschinenfabrik specializes in tailor-made Inspection systems. The company develops and manufactures machines that are precisely tailored to the individual needs of its customers.

The testing technology portfolio includes:

1.

Shape, position and dimensional inspection

All relevant geometric properties of a component are checked during the shape and dimensional inspection. This includes the determination of shape and position tolerances as well as target/actual comparisons [8]. BERNING develops specialized inspection systems with high-precision measuring methods that reliably detect even the smallest deviations.

2.

Completeness check

The completeness check is a crucial element of quality assurance. It ensures that all required components are present and have been correctly assembled. For this, BERNING relies on intelligent camera systems that can reliably check even complex assemblies.

3.

Leak test

Tightness is often a decisive quality feature for sealed components or containers. BERNING develops customized leak testing systems that detect even the smallest leaks using compressed air or vacuum tests. These test methods are suitable for medical technology products as well as for applications in Packaging and industrial production.

4.

Temperature test

Temperature testing can be carried out using either highly sensitive Sensor technologies or thermal imaging cameras. These non-contact measurement methods allow the thermal properties to be tested without affecting the product. BERNING integrates these technologies seamlessly into production lines to ensure continuous quality monitoring.

5.

Position check

The exact positioning of components – for example a sleeve on a product before Shrinking (process) – requires high-precision control technology. BERNING relies on a combination of Sensor technologies, cameras and vision sensors to reliably check even complex positioning relationships.

Testing as an integrated process

Modern quality assurance takes a holistic approach. Instead of isolated inspection steps at the end of production, inspection processes are integrated directly into the production line. Inline inspections offer considerable advantages:

  • Immediate detection of deviations
  • Minimization of rejects and rework
  • Continuous process optimization
  • Seamless documentation of all quality parameters

Did you already know? Failure mode and effects analysis (FMEA) is an important method for identifying and evaluating potential sources of error in the production process, especially in the development phase [9].

Challenges of industrial testing

Quality control in industrial production is faced with constantly growing demands:

  1. Miniaturization: ever smaller components require greater testing precision
  2. Variety of materials: Different materials require special testing techniques
  3. Wide range of variants: Flexible inspection systems must be able to process different product variants
  4. Documentation obligation: Every test step must be reliably documented

Innovative solutions and expertise in testing technology are needed to meet these requirements.

BERNING testing technology expertise

BERNING Maschinenfabrik combines decades of experience with innovative technologies. Each Inspection system is individually designed and tailored to the customer’s specific requirements. Factors such as Cycle time, scope of testing and integration into existing production lines play a decisive role.

Test equipment selection
The right measuring devices and Sensor technologies are crucial for the precision and reliability of the test. BERNING advises its customers comprehensively on the selection of optimum test equipment.

Scope of testing
Depending on the product and application, a decision must be made as to whether 100% testing is necessary or whether statistical testing is sufficient. BERNING analyzes risks and requirements and derives the ideal testing strategy from this.

Inspection time
The integration of inspection processes at strategically important points in the production line minimizes rejects and optimizes the use of resources. BERNING designs end-to-end inspection concepts from incoming goods to final inspection.

Automation
The degree of automation has an impact on throughput, personnel costs and inspection consistency. BERNING develops scalable automation solutions that grow with the company.

From concept to customized test system

The path to such a system from BERNING follows a tried and tested process:

Analysis of requirements
First, all technical and economic requirements are recorded. Which parameters should be checked? What quantities are planned? What quality standards must be met?

Design and production
Once the concept has been approved, the detailed design begins. Each element of the system is precisely designed and then produced in our in-house production facility.

Installation and commissioning
The finished components are assembled into an Inspection system and comprehensively tested. After successful commissioning, the customer receives a detailed briefing.

The future of testing technology

Testing technology is constantly evolving. New technologies and requirements are shaping the industry:

  • Artificial intelligence
    optimizes testing processes and detects even complex error patterns
  • Digital twins
    simulate and improve test sequences as early as the design phase
  • Modular systems
    enable maximum flexibility with changing product variants
  • Edge computing
    accelerates data analysis and reduces latency times
  • Networked inspection units
    create continuous quality assurance chains

BERNING remains at the forefront of these developments. The company continuously invests in research and development in order to always be able to offer its customers the optimum solution.

Efficient testing as a competitive advantage

Efficient testing processes create decisive advantages:

  1. Higher product quality through precise fault detection
  2. Lower costs by minimizing rejects and complaints
  3. Improved process reliability through continuous monitoring
  4. Faster time to market thanks to optimized development processes
  5. Comprehensive documentation for audit and certification requirements
  6. Sustainable use of resources by avoiding waste

With a customized Inspection system from BERNING, these advantages can be fully exploited. The company provides its customers with comprehensive advice and develops solutions that are precisely tailored to their needs.

Testing at BERNING: Your partner for success

BERNING Maschinenfabrik sees itself as a partner in quality assurance. The company accompanies its customers from the initial idea to the finished Inspection system and beyond. With a deep understanding of a wide range of testing processes and decades of experience, BERNING creates solutions that impress.

Whether shape, position and dimensional inspection, completeness check, leak test, temperature measurement or position check – BERNING offers the right technology for every challenge.

If you want to find out more about the possibilities of modern Inspection systems, BERNING offers competent advice and customized solutions. For every testing process, for every requirement, for every customer.

Sources

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