Enhancing Brake Disc Quality with Siemens Anovis
Driving Precision: ADT Systems Automates Brake Disc Inspection with Siemens Anovis
When it comes to critical vehicle components like brake discs, there's no room for error. High reliability, traceability, and consistency are non-negotiable. That’s why ADT Systems recently partnered with a manufacturer to deploy Siemens Anovis in an inline testing setup—enhancing the precision of natural frequency quality checks in disc brakes.
The project involved full PLC integration with Siemens Anovis software to replace a manual inspection system that was prone to human error and inconsistency. With this upgrade, our client now benefits from 100% automated quality control, real-time decision-making, and traceability at every step of production.
The Challenge: Manual Inspections Fall Short
Before the Siemens Anovis upgrade, brake disc inspections relied heavily on human judgment—making the process vulnerable to:
Subjective decisions and inconsistent quality results
Slower throughput and longer inspection cycles
No traceability or historical data collection
This approach significantly limited both productivity and confidence in final part quality.
Our Solution: Siemens Anovis + PLC Integration
ADT Systems implemented a tailored solution using Simcenter Anovis software from Siemens, known for its high-speed signal analysis and reliable classification capabilities based on vibration and acoustics.
Combined with a custom-configured PLC control system, the automated setup now:
Performs real-time quality assessment for every brake disc
Assigns clear results: OK, NG (No Good), or Invalid
Sends pass/fail data directly to the manufacturing line
Eliminates the need for human interpretation
Supports traceable records for audits and process improvements
📌 The system was installed and tuned by ADT engineers, ensuring seamless signal capture and efficient integration into the existing line with minimal disruption.
Implementation Highlights
Integration of Siemens Anovis into an active end-of-line station
Connection to PLC for automated part routing based on test results
Engineering support to fine-tune trigger sensitivity and signal thresholds
Operator training to monitor system diagnostics and alerts
With this smart upgrade, the factory achieved:
Reduced inspection time
Zero human bias in testing
Greater production throughput
Enhanced product traceability
A scalable template for other lines
Why Siemens Anovis for Brake Disc Testing?
Brake disc quality directly affects vehicle safety, making consistent inspection critical. Simcenter Anovis uses natural frequency signatures to determine product integrity without damaging the part. This makes it an ideal choice for:
Non-destructive quality checks
Fast, inline inspections
Process stability monitoring
The ADT Systems Advantage
We don’t just install—we optimize. ADT Systems delivers:
End-to-end support from concept to commissioning
Seamless PLC and software integration
Local technical support and user training
Experience across brake, tire, and vibration testing setups
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