Development Services in Automotive TESTING LABORATORY Accredited - - PowerPoint PPT Presentation

Development Services in Automotive

L 1552

TESTING LABORATORY

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

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 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

Vibration testing lab

Large parts vibration tests

• Eigenfrequency

assessment

• Durability

CAD/CAE and manufacturing of the testing jigs (all in-house]

• Design tailored to the vibration system limits
• As-high-as-possible number of tested samples

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

Rear-view mirrors

• Rear view distorsion by vibrations
• Vibration analyses, measurements during driving tests

Headliners

• Natural modes of vibration and

eigenfrequency measurements Z Y Armrest

• Eigenfrequency assessment
• Durability testing

Closure systems

• Shock pulses

and vibration profile loading

Vibration testing lab

Vibration tests – special customer-defined tests

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 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

Components testing lab

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

• verloading

– Durability Defined loading – Loading according to request – Maxima identification

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

Components testing lab

Torsional stiffness

• Precise torsional loading
• Cyclic torsional loading

Components testing lab

Special requests – Centrifugal force loading – Abrasion loading – High-speed camera recording

• f the test – image data

acquisition in sync with other variables Fatigue endurance tests – Long-term cyclic load – Loading at various temperatures

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)

Environmental testing lab

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

• r customers specifications

– Special sealing tests defined by customers

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

• 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

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

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

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)

Other services

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

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

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

Accreditation

Test lab - References