Automotive Components Testing

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


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)


• 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



Continuous Conformance Flowchart


Du rabi lity Th erm al Sh ock Humid ity soak

Thermal Characterization

Thermal Characterization






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List of components

Press Parts


List of components

Interior Trims





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List of components

Engine component


List of components





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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


• Flammability

Testing - Solutions

Electro Magnetic Compatibility

• This category includes tests to demonstrate EMC such as Magnetic Emissionsand Immunity, Electromagnetic Susceptibility, Conducted Disturbance Immunity

.


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


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)





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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


Component Testing

Mechanical Stresses

• This category includes tests to withstand effects of mechanical stresses suchas vibration, load test, mechanical shock and package/ handling drop.


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 .


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.


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.


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


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


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;





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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 .


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


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


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


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:


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 .





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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


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





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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).


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





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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


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:





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Vibration


Falling ball impact

Scope of Product:

- Plas t ic par t of aut omobi les





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Falling Ball Test


Falling Ball Test

Data need:

- Drop High, impa ct location





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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:


FLAMMABILITY





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FLAMMABILITY


FLAMMABILITY

Purpose :

Determ ine the capa city of plastic, fabric mate rial and insulator with

fire testing to specifies the burning resistance.


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


IMPACT STRENGTH OF PLASTIC

Purpose :

Determine strength of plastic materials


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


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:





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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


ray tubes and light bulbs

Hexavalent Chromium (Cr):

metal coatings for corrosion protection and wear resistance

Hazardous substance test


Evaluation:

- shall without the Hazardous substances, exempt some products which allow

by law or OEM’s requirements with small demand.




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Automotive Components Testing