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7/25/2019 Automotive Components Testing
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utomotive&Components Testing_Part 1
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Automotive Components Testing
Presented By:
Mr. Chanachai Marangsri
Automotive Components Testing
Introduction
Ob jective of components testing:
• The tests req uired to val idat e a prod uct t hat will
s m u ate t e s t res ses an exp osu res re at e to t s
int end ed environm ent. (ISO 900 1)
• Tests are requ ired to be carr ied ou t in the Design
Valida tion (DV) st age an d th en in t he Process Valid ation
(PV) st age. (ISO900 1 an d TS/ ISO 16 94 9)
Automotive Components Testing
• Cont inuous Conformance Tes ts m aybe required d ur ing
norm al produ c t ion
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Process Validation Flowchart
Electrical Characterization
Thermal Characterization Dust test
ASIA:
HeadquartersTÜV SÜD Asia Pacific Pte. Ltd.Singapore
Durability HumidityCycles
Humidity soak TechnicalCharacterization
Sinusoidalvibration
Thermal shocks Spraying Water
Thermal Characterization Handling drop
Resistance tostorage
Technical
AMERICAS:
HeadquartersTÜV SÜD America Inc.Danvers, Massachusetts
EUROPE:
HeadquartersTÜV SÜD AGMunich, Germany
c arac e r z a on
Condensation
Resistance to dynamicshock
Electrical Characterization
Automotive Components Testing
Continuous Conformance Flowchart
Electrical Characterization
Du rabi lity Th erm al Sh ock Humid ity 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
• Electroma gnetic and Electrosta tic Characteristics
• C imatic Stresses
• Mechanical Stresses
• Solids/ Fluids Stresses
• Chem ical Stress es
Automotive Components Testing
• Flammability
Testing - Solutions
Electro Magnetic Compatibility
• This category includes tests to demonstrate EMC such as Magnetic Emissionsand Immunity, Electromagnetic Susceptibility, Conducted Disturbance Immunity
.
Automotive Components Testing
EMC Chambers
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Electromagnetic Compatibility Tests
Electromagnetic Emission Measurements(Radiated/ Conducted)
Harmo nics Emission and Volta e Fluctuation
Automot ive EMC Testing (Electronic Systems)
Testing
Electromagnetic Susceptibility Measurements(Radio Receivers)
Electrostatic Discharge Immuni ty Testing
RF Radiated Immunity Testing
Electrical Fast Transient / Burst Immuni tyTesting
Automotive Components Testing
Voltage Surge Imm unity Testing
Conducted Distur bance Immuni ty Testing
Magnetic Emissions and Imm unit y
Mains Voltage Variations/ Interrupti onsImmunity Testing
Electromagnetic Compatibility Tests
Automot ive EMC Testing (Electronic Systems) – available standards for EMC
CISPR 25
Radiated Emi ssions
Conducted Emissions
ISO 7637- 1 / - 2 / - 3 ISO 7637 - 1Definiti ons & General Considerations.
ISO 763 7- 2 (12 V & 24V Supp ly Lines) Test Pulses
1a, 1b, 2, 3a, 3b, 4, 5a, 5b.
ISO 7637 - 3 (Other Lines) Test Pulses 3a, 3b vi a
Coupling Clamp.
Applications
Engine Controll ed Module
Car audio system
Electr ical Contro l Unite (ECU)
Automotive Components Testing
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Component Testing
Climatic Stresses
• This category includes tests to demonstrate compatibility with climatic stressessuch as temperature, humidity and solar radiation.
Xenon ArcWeatherometer
Solar ClimaticChamber
Combined EnvironmentalChamber and Vibration
Tester
Temperature/ HumidityChambers
Automotive Components Testing
Component Testing
Mechanical Stresses
• This category includes tests to withstand effects of mechanical stresses suchas vibration, load test, mechanical shock and package/ handling drop.
Automotive Components Testing
Steering WheelVibration Test
Car Seat LateralVibration 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 solidsan u s suc as us , wa er an ra n .
Automotive Components Testing
Dust Test Rain Test High Pressure WaterSpray Test
WaterSubmergence
Test
Component Testing
Chemical Stresses
This category includes tests t o demon strate com ponent resistance
to corrosive environm ent caused by th e presence of certain gases
and f luids - such as gasoline/ engine oil for und er-hood locations
and coffee/ cola for cabin comp artmen t locations.
Automotive Components Testing
Salt Sp ray Tes t Sa lt Fog Tes t Fluid Comp atibility 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 HornEndurance Test
Shock Absorber EnduranceTest
SwitchEndurance Test
Master BrakeCylinder CyclicActuation Test
Environmental and Reliability Tests
Climatic Test
1 . Oper a t ing Temper a tu r e / Hum id i ty
2 . Sto r age Temper a tu r e /Humid ity
3 . Alt it u d e Te s t
4 . T her ma l shock/ cyc ling
Automotive Components Testing
5. Environm enta l St ress Screening
6. Biased Power Tem pera ture Cycling
7 . Ingr ess p ro t ect ion
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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:
Abnorm alities in configuration, siz e, app earan ce, color tone of
the sam ple surface properties
Examp e: a cycle of heat and hum idity;
Automotive Components Testing
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Thermal Shock
Product scope:
o Inter ior or exterior parts on organic-coated p rodu ct (painted )
Purpose:
o Determine th e change at low
and high temp erature cycles
and visua l ins ec t ion
– No visible distortion, change of color, discoloration, deform ation,tears, cracks, peeling off , tack, hardn ess cha nge etc.
– No loosen ing of f as tener , cau lk ing and so on .
– No deformat ion result ing in funct ional dis turbance of internal
component .
Automotive Components Testing
Accelerated Weathering Tests
Accelerated Weathering
1. 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
Automotive Components Testing
Methods(ASTM ,ISO, SAE, MIL, JASO)
Applications
Dash- board, Rubber seals, Hoses, Plastic p arts, Adhesives, Sun- block
Film s and Accessories, Automot ive topcoats
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Natural Weathering Tests
Outd oor Natural Exposu res
Real-t ime n atural d egradat ion o f m ateria ls
ars t rop ca c m ate con t on s
PSB Test site is pa rt of t he ATLAS, Florid a (US)
worldwide test sites
Meth od s (ASTM, SAE)
Applications Natural Weathering Exposure
Automotive Components Testing
o ss u ra t y o a ut om ot ve t op coat
Stat ic exposu re of polymer ic part s and pan els
Accelerated Weathering Tests
1. XENON ARC EXPOSURES
Accelerated aging test of m aterials
(up to 3 Suns)
Loss o f gloss (topcoat )
Colour fading
Polymer failure
2. SOLAR CLIMATIC CHAMBER
Durability of large parts and
automotive componentsApplications
Alpha accelerated weatherometer
Solar ClimaticChamber
Automotive Components Testing
Finished produ ct performan ceevaluation after test
Performance of d i fferent prod uctdes igns af ter tes t
Selection of materials
Weather-strips
Plastics and topcoats
Leath er seats (l ight fastne ss)
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Xenon / Carbon Arc Weatherometer
Sample of Test condition:
Automotive Components Testing
Int erior Trim
Salt Spray Test
Determine the res is tance o f met als , met allic and ot her pr ot ect ive coat ing t o
corr osive at mos pher es b y salt s pra y f og t est .
Automotive Components Testing
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Salt Spray Test
Data Needed:
o Num ber of Hours of Salt Spray
o Condition of p arts after Salt Spray Exposur e
Evaluation:
o No change of the surface
o Corrosion of coating allowed b ut
not corros ion of the b ase m ater ial .
o Finished parts are to exhibit no
Automotive Components Testing
Scope of products:
all interior tr im m aterials (except for th e met al)
for aut omobi les .
Salt Fog Test
Purpose:
Measuring the volatizing trend of organic constituents of interior trim materials used for automobiles.
Evaluation:
Calcu lat e th e reflect an ce m easu red at 4 oin ts of th e lass late
Automotive Components Testing
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Scope:
Resis tance to scratching on su rfaces of plas t ic or other materia ls under s tandard
condi t ions
RESISTANCE TO SCRATCHING
Scratch f ingers 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 exam ine all scratch lines accor ding t o a Rating Scale 1 t o 5 (1 =
no scratch line at all; 5 = severe scratch line).
Automotive Components Testing
Scope:
Resis tance to abras ion both interior and exterior plas t ic for autom obile part s
RESISTANCE TO ABRASIONS
Test m ethod:
Evaluation:
- No crack, deformat ion an d discolorat ion of the tes t specimens .
- Cr imping mu s t remain on the sur face
Automotive Components Testing
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ODOR FROM INTERIOR TRIM
Scope:
Determine the od or or iginat ing f rom
inter ior t r im m ater ials/ compo nents /
assemblies in the passenger or
luggage comp ar tmen t
Evaluation: o d o u r Ra t in g
1. No odo ur
2. Detectable, but not d isturbing
3. Disturb ing
4. Extrem ely disturbing
5. Obnoxious
6. Unbearable
Automotive Components Testing
Vibration
Scope of products:
All completed autom otive compon ents
Purpose:
-
event installed to t he vehicle and are vibrated .
Evalu
ation:
- No crack, breaks, deform ation or su ch loose
fas tener and caulking as to d is turb internal componen ts
S am ple o f cond it ion:
Automotive Components Testing
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Vibration
Automotive Components Testing
Falling ball impact
Scope of Product:
- Plas t ic par t of aut omobi les
Automotive Components Testing
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Falling Ball Test
Automotive Components Testing
Falling Ball Test
Data need:
- Drop High, impa ct location
Automotive Components Testing
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FLAMMABILITY
Scope of products:
Determine the f lamm ability of interior tr im m aterials u sed in t he
occupant com partm ent of vehicles
Purpose:
Determining the horizon tal burn rate of mat erials at the air and
be nor m ally only app licable to interior trim m aterials of which
any portion is within 13mm of the occupan t compart men t air
space.
Facilities:
Automotive Components Testing
FLAMMABILITY
Automotive Components Testing
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FLAMMABILITY
Automotive Components Testing
FLAMMABILITY
Purpose :
Determ ine the capa city of plastic, fabric mate rial 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 m aterials
Evaluation:
Evaluat e load an d reflection curve
Automotive Components Testing
IMPACT STRENGTH OF PLASTIC
Purpose :
Determine strength of plastic materials
Automotive Components Testing
Imp act strength shall be the arithm etical mean of each test
resu lts 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 specif ied conditions
Automotive Components Testing
Evaluation:
Examined with the naked eye. The component shall show no breakage or cracks.
FLEXURAL STRENGTH
Purpose :
Determine the stren gth an d d eformation characteristics of plastic
test s pecimen s when f lexural loads are app lied on plastic test
s p ec m e n s
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 boards
Mercury (Hg):
thermostats, sensors, relays in switches and discharge lamps
Lead (Pb):
Solderin of rinted circuit boards PCB’s lass for cathode
Automotive Components Testing
ray tubes and light bulbs
Hexavalent 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