Wheel Inspection Testing for Quality and Structural Health

The Signalysis wheel inspection system makes structural testing smarter, faster, and easier, enabling wheels to be tested for quality as they come off the production line. Our Wheel Inspection System is rooted in structural dynamics and derives modal parameters of your wheel.

These parameters are analyzed using principal component analysis and fed into our machine learning model to identify a GO or NOGO condition:

• The Frequency Response Function (FRF) pinpoints shifts in resonance caused by cracks, bent rims, porosity, and other structural defects
• Principal Component Analysis (PCA) highlights even the most subtle quality variations
• Ready to roll with minimal operator training and seamless SigQC integration
• Ideal for on- and off-highway applications, including automotive, truck, heavy equipment and aerospace wheel lines where quality and safety are critical
• Our quality inspection systems arm manufacturers with the insight to make fast, accurate calls that keep up with the speed of production.

Physics-Based Structural Verification for Manufacturing Environments

We apply non-destructive, physics-based testing methods to identify manufacturing defects and process drift that traditional inspection techniques often miss. Combining controlled excitation with high-resolution sensing and advanced analytics exposes changes in structural behavior that directly affects real-world wheel performance.

Designed for cast, forged, flow-formed, and machined wheels, Signalysis’ solutions scale from laboratory validation to fully automated, in-line production inspection, supporting both launch-phase process development and high-volume manufacturing.

Common Manufacturing Quality Issues in Automotive Wheels

Automotive and equipment wheels are safety-critical components subjected to extreme operating conditions, including cyclic loads, high rotational speeds, thermal gradients, impacts, and corrosive environments. Even minor defects can reduce fatigue life, induce NVH issues, or lead to catastrophic failure.

At the same time, manufacturers must meet strict SAE, ISO, JWL, VIA, and OEM-specific requirements while maintaining throughput and yield. Quality issues can originate at any stage of the manufacturing process, from raw material handling through finishing operations.

Common issues include:

• Porosity - Gas entrapment or incomplete mold filling that creates weak pointsand crack initiation sites.
• Cracks - Caused by thermal stress, improper cooling, or fatigue; often undetectable visually.
• Distortion - Driven by residual stress, tooling wear, or machining error; leads to vibration and sealing issues.
• Imbalance - Results in ride discomfort, NVH concerns, and excessive balancing.
• Surface and Cosmetic Defects - Pits, inclusions, or polishing irregularities that affect appearance and coating adhesion.
• Corrosion or Pitting - Linked to impurities or insufficient coatings; reduces long- term durability.
• Incorrect Alloy Composition or Heat Treatment - Compromises strength, ductility, and fatigue resistance.
• Weld Defects - Porosity, misalignment, or incomplete penetration that weaken
  structural integrity.

Identify Structural Flaws & Validate Functional Performance

Our quality inspection systems go beyond defect detection to validate that wheels will perform as intended under real-world conditions. Using resonance-based analysis, acoustic response, and dynamic measurements, Signalysis systems provide objective, repeatable insight into both structural integrity and functional behavior, without damaging parts.

Capabilities include:

• Non-destructive resonance and acoustic testing to detect cracks, porosity, weld defects, and internal discontinuities
• Dynamic balance and NVH analysis to uncover vibration-inducing structural irregularities
• Surface and cosmetic defect analysis (profiling and vision)
• Continuous, real-time quality monitoring that flags systemic issues and supports statistical process control and improvement

All results are captured through integrated software tools that generate traceable, auditable data aligned with OEM and regulatory expectations.

Why This Is Critical for Automotive Suppliers

For wheel manufacturers and automotive suppliers, early detection of defects is essential to protecting both customers and brand reputation.

By identifying issues before wheels leave the facility, manufacturers can:

• Prevent recalls, warranty claims, and field failures
• Reduce scrap, rework, and unplanned downtime
• Improve yield and overall equipment effectiveness
• Meet OEM and regulatory requirements with confidence
• Strengthen customer trust and long-term supplier relationships

In safety-critical applications, consistent delivery of defect-free wheels is not optional, it is a competitive necessity.

Why Choose Signalysis

Signalysis combines decades of expertise in non-destructive testing, resonance-based defect detection, and NVH analysis with proven success in manufacturing environments worldwide.

From stand-alone test stations to fully automated, in-line inspection systems, Signalysis delivers scalable solutions supported by robust analytics, reporting, and integration capabilities.

As a trusted partner to automotive manufacturers and suppliers, Signalysis provides the precision, objectivity, and confidence required to ensure every wheel meets the highest standards of quality, safety, and performance, before it ever leaves the production line. Contact us here.

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