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KDS Metrology Management - Safeguarding the Excellent and Reliable Product Quality of KDS Traction Machines

2025-09-26

KDS Metrology Management - Safeguarding the Excellent and Reliable Product Quality of KDS Traction Machines

Product quality improvement is inseparable from data, and data comes from measurement. Therefore, without measurement, there can be no improvement.

In the production and delivery process, manufacturing enterprises usually face the following two types of quality risks:


1. Producer Quality Risk (α Risk)

During the production inspection process, employees or inspectors mistakenly identify qualified products as unqualified ones, resulting in additional rework or scrap costs and increasing operating costs.


2. Customer Quality Risk (β Risk)

During the production inspection process, employees or inspectors mistakenly identify unqualified products as qualified ones, which are then delivered to customers or the site, increasing the customer's quality risk costs.


Generally speaking, these two quality risks are a pair of contradictory variables, and their relationship is like a seesaw: when the producer quality risk increases, the customer quality risk decreases; when the producer quality risk decreases, the customer quality risk increases.


The ideal state is certainly α = β = 0. The actual situation depends on whether the product quality indicators can be accurately measured and judged, and the most important basis for accurate measurement is "measuring tools with precise accuracy". The metrology testing management of KDS Quality Assurance Department is the guarantee of this basis.

Compliant Metrology Qualifications


KDS holds calibration qualifications for measurement equipment in categories such as length, mechanics, and electromagnetism, authorized by national statutory institutions. It conducts metrology-related work in strict accordance with relevant national laws and regulations. KDS provides timely calibration and metrology for length-based testing equipment (various calipers, micrometers, gauge blocks and rods for dimension detection) in production workshops and QA departments, mechanical equipment (torque wrenches and torsion meters for torque detection), and electromagnetic equipment (withstand voltage testers, bridges, and capacitance meters for electrical performance testing).


Experienced and Professional Metrology Team


KDS metrology engineers have obtained metrology qualification certifications from national professional certification institutions, with more than 10 years of professional calibration theory and practical experience in various measurement equipment, including length, mechanics, and electromagnetism categories.


Relevant Certificates


High-Precision Metrology Testing Equipment


KDS Metrology Laboratory is equipped with various high-precision metrology standard testing equipment, such as:

• A multi-function calibrator with 0.1% accuracy, which can accurately calibrate various electrical measuring instruments;

• A precision withstand voltage tester calibrator with 0.5% accuracy, which can accurately calibrate various withstand voltage testers on the production site;

• A complete set of high-precision grade 4 class 2 standard gauge blocks for calibrating length-based instruments;

• A grade 1 precision digital torque meter for accurately calibrating torque wrenches.


KDS metrology standard instruments are subject to periodic verification by national statutory metrology institutions at or above the county level in strict accordance with relevant national laws and regulations, ensuring the reliability of standard testing equipment and the traceability of testing data.


• Multi-function calibrator with 0.1% accuracy, capable of accurately calibrating electrical instruments such as multimeters


• Withstand voltage tester calibrator with 0.5% accuracy


• High-precision digital torque meter for calibrating mechanical torque wrenches


• Complete set of standard gauge blocks for calibrating length-based instruments

Systematic Metrology System


KDS has a total of 8,766 pieces/sets of production testing tools and equipment, all of which are included in the metrology ledger management system for unified management. The metrology management system oversees the entire process of measuring tools and equipment, from initial on-site registration, first submission for inspection, in-life metrology, to in-life evaluation and management. The metrology management ledger enables effective monitoring of the status of each measuring instrument, timely early warning of abnormal situations, prevention of instrument failure and measurement inaccuracy, thus providing a reliable guarantee for ensuring the accuracy and reliability of measuring tools and equipment. KDS has achieved zero errors in the metrology ledger management of testing tools and equipment for 12 consecutive years.


Metrology Ledger Management System


Comprehensive Metrology Management


In terms of the management of testing equipment, preventive measures are also taken to address the risk of measurement errors caused by equipment inaccuracy.


First, equipment operators conduct itemized performance checks when starting the equipment to ensure that the equipment is always in a normal state. At the same time, for high-precision testing equipment, the temperature and humidity of the testing environment are strictly monitored in accordance with the equipment's operating environment requirements to ensure the accuracy and reliability of test data. The company attaches great importance to talent development and has formulated a comprehensive and effective rolling training plan to ensure that equipment operators can quickly master equipment operation skills. In 2023, the Metrology Laboratory conducted 6 special training sessions on the use and precautions of testing equipment, training 35 backbone equipment operators for the company. For important equipment, a detailed GAUGE R&R analysis plan has been formulated. In 2023, GAUGE R&R analysis was conducted on multiple key testing equipment, and the actual deviation was significantly lower than the acceptable deviation requirements of the equipment.

• Daily equipment check sheet for effective monitoring of equipment status

• Effective monitoring of temperature and humidity in the testing environment by the Measurement Laboratory to ensure measurement accuracy

• Active participation in equipment operation training

• Effective MSA-GAUGE R&R analysis


Special Measurement Applications


In addition to conventional testing equipment, in response to the actual needs of motor applications, KDS has developed measurement equipment tailored to the performance characteristics of traction machines to conduct quality monitoring on the key performance of important components. For example:

a) Encoder Testing

Under the same conditions, the waveform amplitude, waveform peak-to-peak value, and Lissajous figure area of encoders from different brands are tested to quantitatively compare the anti-interference performance and signal resolution of the encoders.


b) Rotor Magnetic Performance Testing

KDS not only calculates and evaluates the remanence, coercive force, magnetic energy product, and thermal demagnetization of permanent magnets during the design stage to provide a quantitative basis for product selection but also focuses on the research on changes in the magnetic induction intensity and magnetic poles of permanent magnets during the mass production stage.


Through special sensors, the magnetic induction intensity on the rotor surface is collected when the rotor rotates, and converted into voltage. By processing and analyzing the voltage waveform levels, the distribution of magnetic poles and the strength of the magnetic field of the permanent magnet rotor are quantified. These measured data also serve as important indicators for evaluating the performance of traction machines, promoting continuous improvement.



Relying on an experienced team of metrology engineers, high-precision metrology testing equipment, standardized metrology management procedure documents, and systematic metrology system management, KDS Metrology Management ensures that the measured values of inspected measuring tools and instruments are accurate and reliable, with excellent reproducibility and repeatability. It effectively reduces the producer quality risk and customer quality risk caused by detection deviations. KDS Metrology Management safeguards the excellent and reliable product quality of KDS traction machines.



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