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Automotive&Components Testing_Part 1 23/11/54
1
Automotive Components Testing
Presented By:Mr. Chanachai Marangsri
Automotive Components Testing
Introduction
Objective of components testing:
• The tests required to validate a product that will i l h d l d isimulate the stresses and exposures related to its
intended environment. (ISO 9001)
• Tests are required to be carried out in the Design Validation (DV) stage and then in the Process Validation (PV) stage. (ISO9001 and TS/ISO 16949)
Automotive Components Testing
• Continuous Conformance Tests maybe required during normal production
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Design Validation Flowchart
Mechanical Parts
M l N lMetal Non-metal
Strength
Tensile Stress
Bending test
Natural Rubber Synthesis Rubber
Viscosity
Stress & Strain
Weathering
Gray scale
Automotive Components Testing
Bending test
Torsion
Salt Spray
Ozone
Rain
Spring rate
y
Flammability
Design Validation Flowchart
Electrical Characterization
Resistance to Electro Static Discharge
Bulk current injection closed loop
Bulk current injection:
Dielectric strength
Insulation Durability Humidity Cycles
Humidity soak Technical Characterization
Thermal Characterization Dust test
Immunity to radiated field semi-anechoic
Brief Voltages dip
Bulk current injection: substitution method Cranking
Sinusoidal vibration
Thermal shocks Spraying Water
Radiated immunity: Stripline test
Conducted RF emission
Conducted emission: current probe method
Measurement of conducted transient
Power supply voltage ripple
Resistance to non usual battery voltage
Voltage offset se
Ground offset test
Thermal Characterization Handling drop
Resistance to storage
Technical characterization
Condensation
Automotive Components Testing
Radiated emissions: Antenna method
Radiated emissions: Stripline test
Magnetic field emission
Transient immunity
Switch off de-activation test
Resistance to brief supply failures
Slow increase & decrease of supply voltage
Resistance to ground & positive supply short circuit
Resistance to dynamic shock
Electrical Characterization
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Process Validation Flowchart
Electrical Characterization
Thermal Characterization Dust test
ASIA:HeadquartersTÜV SÜD Asia Pacific Pte. Ltd. Singapore
Durability Humidity Cycles
Humidity soak Technical Characterization
Sinusoidal vibration
Thermal shocks Spraying Water
Thermal Characterization Handling drop
Resistance to storage
Technical h t i ti
AMERICAS:HeadquartersTÜV SÜD America Inc. Danvers, Massachusetts
EUROPE:HeadquartersTÜV SÜD AG Munich, Germany
characterization
Condensation
Resistance to dynamic shock
Electrical Characterization
Automotive Components Testing
Continuous Conformance Flowchart
Electrical Characterization
Durability Thermal Shock Humidity soak
Thermal Characterization
Thermal Characterization
Electrical Characterization
Automotive Components Testing
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List of components
Press Parts
Automotive Components Testing
List of components
Interior Trims
Automotive Components Testing
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List of components
Engine component
Automotive Components Testing
List of components
Automotive Components Testing
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Typical Test Parameters to Consider
• Electrical Characteristics
• Electromagnetic and Electrostatic Characteristics
Cli i S• Climatic Stresses
• Mechanical Stresses
• Solids/ Fluids Stresses
• Chemical Stresses
• Durability Test
Automotive Components Testing
• Durability Test
• Flammability
Testing - Solutions
Electro Magnetic Compatibility
• This category includes tests to demonstrate EMC such as Magnetic Emissions and Immunity, Electromagnetic Susceptibility, Conducted Disturbance Immunity etcetc.
Automotive Components Testing
EMC Chambers
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Electromagnetic Compatibility Tests
• Electromagnetic Emission Measurements (Radiated/Conducted)
• Harmonics Emission and Voltage Fluctuation
Automotive EMC Testing (Electronic Systems)
Harmonics Emission and Voltage Fluctuation Testing
• Electromagnetic Susceptibility Measurements (Radio Receivers)
• Electrostatic Discharge Immunity Testing • RF Radiated Immunity Testing • Electrical Fast Transient / Burst Immunity
Testing
Automotive Components Testing
• Voltage Surge Immunity Testing • Conducted Disturbance Immunity Testing • Magnetic Emissions and Immunity• Mains Voltage Variations/ Interruptions
Immunity Testing
Electromagnetic Compatibility Tests
Automotive EMC Testing (Electronic Systems) –available standards for EMC
CISPR 25• Radiated Emissions• Conducted Emissions
ISO 7637-1/ -2/-3• ISO 7637-1Definitions & General Considerations.• ISO 7637-2 (12V & 24V Supply Lines) Test Pulses
1a, 1b, 2, 3a, 3b, 4, 5a, 5b.• ISO 7637-3 (Other Lines) Test Pulses 3a, 3b via
Coupling Clamp.Applications• Engine Controlled Module• Car audio system• Electrical Control Unite (ECU)
Automotive Components Testing
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Component Testing
Climatic Stresses
• This category includes tests to demonstrate compatibility with climatic stresses such as temperature, humidity and solar radiation.
Xenon Arc Weatherometer
Solar Climatic Chamber
Combined Environmental Chamber and Vibration
Tester
Temperature/ Humidity Chambers
Automotive Components Testing
Component Testing
Mechanical Stresses
• This category includes tests to withstand effects of mechanical stresses such as vibration, load test, mechanical shock and package/ handling drop.
Automotive Components Testing
Steering Wheel Vibration Test
Car Seat Lateral Vibration Test
Door Handle Load Test Spring TestLoad Test
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Component Testing
Solids / Fluids Stresses
• This category includes tests to demonstrate component resistance to solids d fl id h d t t d iand fluids such as dust, water and rain.
Automotive Components Testing
Dust Test Rain Test High Pressure Water Spray Test
Water Submergence
Test
Component Testing
Chemical Stresses
This category includes tests to demonstrate component resistance to corrosive environment caused by the presence of certain gases and fluids - such as gasoline/engine oil for under-hood locations and coffee/cola for cabin compartment locations.
Automotive Components Testing
Salt Spray Test Salt Fog Test Fluid Compatibility Test
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Component Testing
Durability Test
• This category includes tests to demonstrate the components’ durability, fatigue strength and reliability.
Automotive Components Testing
Car Horn Endurance Test
Shock Absorber Endurance Test
Switch Endurance Test
Master Brake Cylinder Cyclic Actuation Test
Environmental and Reliability Tests
Climatic Test
1. Operating Temperature/ Humidity
2. Storage Temperature/Humidity
3. Altitude Test
4. Thermal shock/cycling
Automotive Components Testing
5. Environmental Stress Screening
6. Biased Power Temperature Cycling
7. Ingress protection
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Temperature/ Humidity
• Scope of products:
- Metals, synthetic resin parts and plastic
components
- Automotive components or materials to
high humidity
• Purpose:
- Determine the resistance of metals and
other protective coatings to high humidity.
- To evaluate the changes of physical or
mechanical properties of materials under
the specified temperature and humidity
Automotive Components Testing
Temperature and Humidity Test
• Evaluation:Abnormalities in configuration, size, appearance, color tone of the sample surface properties
E l l f h d h idi• Example: a cycle of heat and humidity;
•Automotive Components Testing
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Thermal Shock
Product scope:o Interior or exterior parts on organic-coated product (painted)
Purpose:o Determine the change at low
and high temperature cycles
and visual inspection;p ;
– No visible distortion, change of color, discoloration, deformation, tears, cracks, peeling off, tack, hardness change etc.
– No loosening of fastener, caulking and so on.
– No deformation resulting in functional disturbance of internal component.
Automotive Components Testing
Accelerated Weathering Tests
Accelerated Weathering1. UV Exposures (UV- A and B)
• Polymer Durability • Body paint work • Rubber Weatherstrips & Adhesives
2. Controlled Temperature and Humidity Conditions• Durability of automotive interior materials • Thermal shock resistance
Electronic parts & components failure
Automotive Components Testing
• Electronic parts & components failure • Methods(ASTM ,ISO, SAE, MIL, JASO)
ApplicationsDash-board, Rubber seals, Hoses, Plastic parts, Adhesives, Sun-block Films and Accessories, Automotive topcoats
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Natural Weathering Tests
Outdoor Natural Exposures• Real-time natural degradation of materials
H h t i l li t diti• Harsh tropical climate conditions
• PSB Test site is part of the ATLAS, Florida (US) worldwide test sites
• Methods (ASTM, SAE)
Applications
Gloss d rabilit of a tomoti e topcoat
Natural Weathering Exposure
Automotive Components Testing
• Gloss durability of automotive topcoat
• Static exposure of polymeric parts and panels
Accelerated Weathering Tests
1. XENON ARC EXPOSURES
• Accelerated aging test of materials (up to 3 Suns)
• Loss of gloss (topcoat)
• Colour fading
• Polymer failure
2. SOLAR CLIMATIC CHAMBER
• Durability of large parts and automotive components
Applications
• Rubber materials and seals
Alpha accelerated weatherometer
Solar Climatic Chamber
Automotive Components Testing
• Finished product performance evaluation after test
• Performance of different product designs after test
• Selection of materials
• Rubber materials and seals
• Weather-strips
• Plastics and topcoats
• Leather seats (light fastness)
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Xenon /Carbon Arc Weatherometer
• Sample of Test condition:
Automotive Components Testing
Interior Trim
Salt Spray Test
Determine the resistance of metals, metallic and other protective coating to corrosive atmospheres by salt spray fog test.
Automotive Components Testing
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Salt Spray Test
Data Needed:
o Number of Hours of Salt Spray
o Condition of parts after Salt Spray Exposure
Evaluation:
o No change of the surface
o Corrosion of coating allowed but
not corrosion of the base material.
o Finished parts are to exhibit no
red rust worse than specificationred rust worse than specification
Automotive Components Testing
Scope of products:• all interior trim materials (except for the metal)
for automobiles.
Salt Fog Test
Purpose:Measuring the volatizing trend of organic constituents
of interior trim materials used for automobiles.
Evaluation:
Calculate the reflectance measured at 4 points of the glass plateCalculate the reflectance measured at 4 points of the glass plate
Automotive Components Testing
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• Scope:
Resistance to scratching on surfaces of plastic or other materials under standard conditions
RESISTANCE TO SCRATCHING
• Scratch fingers No. 1 7.0 N
2 6.0 N
3 4.5 N
4 3.0 N
5 2.0 N
• Evaluation:
Sky day light for examine all scratch lines according to a Rating Scale 1 to 5 (1 = no scratch line at all; 5 = severe scratch line).
Automotive Components Testing
• Scope:
Resistance to abrasion both interior and exterior plastic for automobile parts
RESISTANCE TO ABRASIONS
• Test method:
• Evaluation:
- No crack, deformation and discoloration of the test specimens.
- Crimping must remain on the surface
Automotive Components Testing
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ODOR FROM INTERIOR TRIM
• Scope:Determine the odor originating from
interior trim materials/components/
assemblies in the passenger or
luggage compartment
• Evaluation: odour Rating
1. No odour
2. Detectable, but not disturbing
3. Disturbing
4. Extremely disturbing
5. Obnoxious
6. Unbearable
Automotive Components Testing
Vibration
Scope of products:All completed automotive components
Purpose:evaluate the capability of part- evaluate the capability of part
event installed to the vehicle and are vibrated.
Evaluation:- No crack, breaks, deformation or such loose
fastener and caulking as to disturb internal components
Sample of condition:
Automotive Components Testing
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Vibration
Automotive Components Testing
Falling ball impact
Scope of Product:- Plastic part of automobiles
Automotive Components Testing
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Falling Ball Test
Automotive Components Testing
Falling Ball Test
• Data need:
- Drop High, impact location
Automotive Components Testing
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FLAMMABILITY
• Scope of products:Determine the flammability of interior trim materials used in the occupant compartment of vehicles
• Purpose:Determining the horizontal burn rate of materials at the air and be normally only applicable to interior trim materials of which any portion is within 13mm of the occupant compartment air space.
• Facilities:
Automotive Components Testing
FLAMMABILITY
Automotive Components Testing
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FLAMMABILITY
Automotive Components Testing
FLAMMABILITY
Purpose :
Determine the capacity of plastic, fabric material and insulator with fire testing to specifies the burning resistance.
Automotive Components Testing
Horizontal Flammability
Vertical Flammability
Evaluation:Burning rate = (burning distance/burning time)
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Peeling Test
Purpose:
Determine the peeling of interior trim and leather materials
Evaluation:
Evaluate load and reflection curve
Automotive Components Testing
IMPACT STRENGTH OF PLASTIC
Purpose :
Determine strength of plastic materials
Automotive Components Testing
Impact strength shall be the arithmetical mean of each test results and presented in kgf·cm/cm.
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IMPACT STRENGTH OF PLASTIC
Purpose :
Determine the impact resistance of plastic components by applying the impact to them under specified conditions
Automotive Components Testing
Evaluation:Examined with the naked eye. The component shall show no breakage or cracks.
FLEXURAL STRENGTH
Purpose :
Determine the strength and deformation characteristics of plastic test specimens when flexural loads are applied on plastic test
ispecimens
Evaluation:
Automotive Components Testing
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Hazardous substance test
Purpose :
It is the requirement for specifies the contain of Hazardous substances; Cd, Hg, Pb, Cr for each product i.e.
Cadmium (Cd): Switches, springs, connectors, housing for printed circuit boardsMercury (Hg):thermostats, sensors, relays in switches and discharge lampsLead (Pb):Soldering of printed circuit boards (PCB’s), glass for cathode
Automotive Components Testing
g p ( ), gray tubes and light bulbsHexavalent Chromium (Cr):metal coatings for corrosion protection and wear resistance
Hazardous substance test
Automotive Components Testing
Evaluation:- shall without the Hazardous substances, exempt some products which allow
by law or OEM’s requirements with small demand.
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End of section
Automotive Components Testing
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