Development Services in Automotive TESTING LABORATORY Accredited - PowerPoint PPT Presentation

Development Services in Automotive

TESTING LABORATORY Accredited Testing Laboratory Nr. 1552 Environmental testing lab L 1552 Vibration testing lab Components testing lab Air-conditioned measuring lab

Vibration testing lab Vibration tests • Frequency and modal analyses (parts, assemblies) • Vibration analyses and measurements • Vibration durability and fatigue tests – sinus, sweep, random, shock , sine on random … • Vibration tests in climatic conditions ( -70 ÷ 180 ° C, 0 ÷ 98% r.h.) • Vibration tests at high temperatures – up to 1000 ° C • Design and manufacturing of testing jigs (all in -house) • Monitoring, special customers requests Technical equipment • Vibration electrodynamic systems 1,6 kN / 22 kN / 35 kN – including slip tables – vibrations in all XYZ axes • External climatic chamber for vibration tests 1150 l • Heating sources for high -temperature tests (up to 1200 ° C) • Mobile equipment for modal analyses and data acquisiton in field

Vibration testing lab Vibration tests CAD/CAE and manufacturing of the testing jigs (all in-house] - Design tailored to the vibration system limits Large parts vibration tests - As-high-as-possible number of tested samples - Eigenfrequency assessment - Durability

Vibration testing lab Vibration tests Vibration tests under climatic conditions High-temperatures up to +1000 ° C - (various heating sources) Functionality tests from -70 ° C up - - Controlled climate (temperature-humidity profiles) Controlled humidity 0 – 98% r.h. -

Vibration testing lab Vibration tests – special customer-defined tests Headliners Rear-view mirrors - Natural modes of vibration and - Rear view distorsion by vibrations eigenfrequency measurements - Vibration analyses, measurements during driving tests Z Y Closure systems - Shock pulses and vibration profile loading Armrest - Eigenfrequency assessment - Durability testing

Components testing lab Components tests • Functionality tests of components, parts and assemblies • Low -/High-cycle fatigue tests • CAE models validation • Electro -mechanical parts testing • Special customer -defined tests • Dynamic shock testing • High -speed processes analysis, synchronized data acquisition • Development and validation tests for automotive suppliers Technical equipment • • Servo -pneumatic testing axes DYNA-MESS 10 kN, 2.5kN, speed up to 600 mm/s • Controllable rotary axis Bosch- Rexroth up to 200Nm • Controllable pneumatic cylinders linear 0,5 – 10 kN, rotational 10- 100 Nm • Sets of electronic sensors for power, dimensions, moments, acceleration, pressure, temperature, and humidity measurements • Drop tower for dynamic tests, max. 10 kN, max. 2,5 m/s • High-speed camera Basler + NI Vision Development Kit, lighting system • Set of LASER trigonometric tracking units (up to 20kHz) • Measuring unit HBM - MGA II • Measuring cards NI (USB, PCI) + SW for data sampling and processing: LabView – NI

Components testing lab Components tests – Large parts and assemblies testing – Loading up to10 kN – Cyclic and long-term tests – Linear- and rotary- movements combinantions Destruction tests – Single-cycle / multi-cycle overloading – Durability Defined loading – Loading according to request – Maxima identification

Components testing lab Dynamic shock tests – Drop tower design according to the tested part – max. force 10 kN; max. speed 2,5 m/s – Punches according to request Torsional stiffness - Precise torsional loading - Cyclic torsional loading

Components testing lab Special requests – Centrifugal force loading – Abrasion loading Fatigue endurance tests – High-speed camera recording – Long-term cyclic load of the test – image data acquisition in sync with other – Loading at various variables temperatures

Environmental testing lab Climatic and corrosion tests • Temperature tests – deformation, hardening, aging • Climatic tests - thermal cycling, artificial aging • Corrosion tests – salt-spray tests • Condensation tests • Thermal shock tests • Combined climatic and mechanical tests • Climatic and corrosion tests of surface treatments, coatings, parts and assemblies • Enclosure testing (up to IP X9K) Technical equipment • Temperature chambers 110 ÷ 250 l, programmable, up to 300 ° C • Climatic chambers 350 ÷ 1000 l, -70 ÷ 180 ° C, 0 ÷ 98% r.h. • Corrosive chamber Liebisch, 450 l • Temperature shock chamber VT3 7012 S2, -80 ÷ 220 ° C, 120 l • Variable chamber for climatic-mechanical tests • Enclosure testing equipment (IPX9K acc.to DIN 40050-9)

Environmental testing lab Climatic tests – Humidity-temperature profiles loading according to standards and specifications – Cyclic durability tests in changing climate conditions – Broad in-test monitoring options Sealing tests – Enclosure tests (IP) according to standards or customers specifications – Special sealing tests defined by customers

Air-conditioned measuring lab Mechanical tests • Material properties testing (metals, polymers, adhesives, composites,… • Testing of metallic and non-metallic bonds and polymers – glues, welds, rivets, clinches, bolts,… • Conditioning and testing at precisely defined climatic conditions • Microspopic analyses (phases, lengths, circumferences, angles etc.) • Thermal resistance in liquids • Tests of insulation resistance, breakdown voltage, dielectric strength up to 100 kV, inner- and surface resistivity, monitoring of electrical parameters Technical equipment • Universal testing machine 50 kN, LabTest 3.5 • Extensometer MFN A, 0-4 mm, 0-800 mm • Thermostats Huber -70 ° C ÷ 200 ° C • Trinocular stereoscopic microscope with digital recording, SW for image analysis • Calibration owen to 900 ° C • Multimeters, dielectric strength gauges,…

Air-conditioned measuring lab Mechanical tests – Test of formed parts – cut-outs of finished parts – In-house design and manufacuring of testing jigs and fixtures

Other services Testing and measurements at customers locations Design and manufacturing of Driving tests, field testing jigs, measurements stands and equipments Numerical simulations support by the SWELL CAE Department during test methods definition phases, jigs design,…

Other services Other services • Technology consultancy • New test methods and procedures proposal • CAE – numerical simulations – jigs design, loading conditions calculations, limits, thermal expansion, modification of non- conforming parts, etc. • CAE models validation • Customers presence at the tests • Complete solutions of parts and assemblies development CAD → CAE → tests → production • Accredited testing laboratory services (ISO/IEC 17025)

Standards and procedures Standards • Tests according to international and national standards: EN, ISO, IEC, MIL, ASTM, DIN, JIS, … • Test s according to automotive OEM standards: VW (PV, VW), Ford (FLTM), Daimler (DBL), Nissan (NES), Kia (MS), GM (GMW), Renault (D) • Swell is contractually involved in the VW Group Supply.com system, utilizing the „Online - Normentexte“ application to access up-to-date VW standars and other technical prescriptions • Tests according to products specifications • Testing methods proposals based on customers defined boundary conditions Non-disclosure and security • all test samples declared and handled as items subject to trade secret • all facilities of the Test lab are approved by the Technical development of Škoda Auto for works with prototype parts, assemblies and complete vehicles. • no access to tested items and setups for unauthorized personnel and other customers

Accreditation ISO/IEC 17025:2005 Accredited Testing Laboratory nr. L 1552 • Tensile tests at ambient temperature • Shear tests • Environmental tests • Salt-spray corrosion tests • Vibration tests • Enclosure tests IPX9K • Electrical components testing Complete list of accredited test procedures with relevant standards identification (in Czech): http://www.swell.cz/images/OA_m.pdf

Test lab - References