TÜV SÜD America

Your ChallengesAutomakers and subassembly manufacturers have invested heavily to improve customer satisfaction and to position their brand as one of quality. Improvements in engine and suspension design have reduced driving noise, providing the consumer tranquil comfort, but irritating buzz, squeak and rattle sounds can devastate that consumer’s experience.

As a top contributor to customer dissatisfaction, Buzz, Squeak and Rattle (BSR) issues are well known and highly publicized culprits in automotive ratings. Consumer initial quality rankings are widely covered by the media. Identifying and removing Noise, Vibration and Harshness (NVH) root causes will result in greater customer satisfaction, increased brand loyalty and stronger quality reputation.

TÜV SÜD’s Equipment Solutions & Technology (EST) group designs and builds custom solutions for BSR, NVH and other testing. These systems are deployed at many automakers worldwide and include In-Ground, Modular Above Ground (MAG)

or Transportable Servo Electric Actuator (SEA) systems. To maximize the efficiency of test system operations the EST group also offers an OnSite staffing solution.

The Equipment Solutions & Technology group within TÜV SÜD revolutionized road simulation testing with the introduction of the silent and efficient servo electric road simulator. A complete solution to detect, diagnose and eliminate annoying sounds as part of design or production verification and to help solidify your best in class quality reputation.

Custom Automotive Testing SolutionsIdentify and Remove Buzz, Squeak and Rattle

Squeak and rattle issues

High warranty expense Costly rework & repairs at assembly Hard to fix at dealerships Annoy and frustrate customers Reduced consumer initial quality rankings

Prevent them with TÜV SÜD’s proven tools and services.

“The temperature controlled four poster has been the best investment made in a long time. We have been able to use it to be more proactive than ever before especially with the seasonally related problems.” - OEM Manager Product Quality Assurance

Proven Tools and Turn-key SolutionThese economical Four Posters are at the cutting edge of TÜV SÜD’s Servo Electric Actuator (SEA) technology and are far ahead of hydraulic or electro magnetic actuation. TÜV SÜD’s SEA system is superior in all performance metrics including force, velocity, acceleration, RMS error, NVH and energy consumption. Cost and waste are minimized with our SEA systems. Such an efficient testing solution for a moderate investment adds up to big savings for automakers and suppliers striving to produce superior products.

TÜV SÜD offers proven BSR prevention tools and methods that reduce vehicle rework and repair at the assembly plant, minimize dealership repairs, lower warranty expense and increase customer satisfaction. TÜV SÜD’s OnSite testing services team has partnered with top tier automakers for more than twenty years delivering testing services, root cause analysis, and resolutions. OnSite from TÜV SÜD is your one stop for BSR experts to implement product and process improvements as part of your complete solution. TÜV SÜD’s highly regarded third party expertise delivers a total solution package - custom testing equipment in conjunction with OnSite testing services. OnSite BSR experts add value at assembly plants and engineering centers, preventing BSR issues from reaching your customers today and in the future. Improve quality faster with custom test equipment coupled with OnSite testing services. Invest in the total solution from TÜV SÜD.

Why the TÜV SÜD EST Group?TÜV SÜD’s Equipment Solutions & Technology (EST) group is located in Holland, Michigan and has a wealth of experience supporting dozens of automotive customers. The Equipment Solutions Team works with many equipment manufacturers to provide the end user with custom systems integration in a package that delivers the performance they require. TÜV SÜD has acquired extensive system integration experience by delivering these systems worldwide using our international presence in all major markets to deliver local support and expertise.

By choosing TÜV SÜD, the customer partners with a financially stable global supplier serving industry for well over one hundred years. Our engineering and installation experience with multiple Four Posters, combined with a strong track record of collaboration with local facility managers, construction firms and contractors, yields on-time and within-budget installations for our customers. TÜV SÜD is fully committed to the long-term service support for all of the equipment we supply and we are able to accomplish this as a result of the deep involvement we have with our suppliers throughout the product development process.

User Comment

ACTUATOR IMPROVEMENTS:TÜV SÜD Servo Electric vs. Electro Magnetic

4 times higher continuous force capacity Modular design for reconfiguration and

servicing ease High efficiency through optimized use of magnetic flux Longer life fixed wiring and cooling systems design Liquid cooled = 25 times more efficient heat dissipation Higher accuracy = more repeatable testing

with higher frequency content Quieter, virtually silent operation. No high-pitch

commutation noise Direct cooling of external, fixed coils = higher force

capacity / longer life

Improved temperature monitoring via built-in, integrated thermocouples

Discrete, non-contact infrared ‘spot’ sensors Improved bearing design = longer life with greater side

load capacity Offset load management = no overheating problems Digital control = smoother, quieter, more efficient Eliminates failure modes associated with “flying leads” Higher resolution encoder = better control accuracy Regeneration = higher energy efficiency Compatibility with global power supplies. Direct

connection to 380-480vac 3 PH without additional cost for step-down transformers

TÜV SÜD America 10 Centennial Drive, Peabody, MA 01960 United States(800) 888-0123 info@tuvam.com www.tuv-sud-america.com

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Four Poster Comparison Table - Electric vs. Hydraulic

Choose certainty. Add value.TÜV SÜD is a premium quality, safety and sustainabilitysolutions provider that specializes in testing, inspection,auditing, certification, training and knowledge services.Represented in over 800 locations worldwide, we holdaccreditations in Europe, the Americas, the MiddleEast, Asia and Africa. By delivering objective solutionsto our customers, we add tangible value to businesses,consumers and the environment.

Parameter Servo-Electric Servo-Hydraulic NotesPeak Force CapacityFpk

6,250 lb,27.8 kN

5.5 -6.3 klb,24.5 -28kN

Other Peak Force configurations available forboth Electric and Hydraulic versions.

Continuous or Static ForceFstat or Fcont

3,650 lb16.2kN

5.5 -6.3 klb,24.5 -28kN

Static or Continuous Force required to supportVehicle Weight plus the average Forcesrequired during operation.

Max Speed at Max ForceVmax, Fmax

75.5 in/sec1.92m/sec

N/A Pressure drop in Servo-Hydraulics based on oilflow proportional to velocity.

Max Speed at Reduced Force Vmax, Fn

166 in/sec4.2 m/sec

63 in/sec1.6 m/sec

Vmax for Servo-Hydraulics based on dual15gpm servovalves with accumulation

Typical FrequencyResponse at -3dB, Fn

149 Hz 40 Hz Servo-Hydraulic Response based on MoogG761 response, ignoring hydraulic resonance

Energy Consumption ,Continuous usage , /hr

7kW 84kW Servo-Hydraulic 40gpm@3000psi + coolingServo-Electric uses <20% of Energy

Energy Consumption,50% Duty Cycle , /hr

4kW 77kW Servo-Electric uses very little power when idle.

System PerformanceAffected by: Accumulator pressure Servovalve wear Flow restrictions Hydraulic resonances Fluid Dynamics Oil Contamination Pressure Losses

NoNoNoNoNoNoNo

YesYesYesYesYesYesYes

Servo-Electric system performance unaffectedby many physical parameters that limit Servo -Hydraulic systems.

Servo-Electric systems do not require retuningbased on specimen variations or waveformcontent (same PID values for ALL conditions)

System Accuracy, % RMS Error – typical file playback

1% 10-30% Accuracy for Servo-Hydraulics depends greatlyon tuning and waveform content.

Consumables Filters Seals Accumulators Servovalves Hydraulic Oil Hydraulic Hoses Cooling water & conditioning

Does Not Apply Repair/ReplaceAnnually

Annual maintenance costs for Servo-Electricsystems are virtually elimated.

Built-In Performance Monitoringand Diagnostics

Disp Limits Supply Power Voltage

and Phase Current (force) limits Peak Velocity

and Accel control Dynamic FollowingError Inertial Compensation Motor Temps Motor Cabling Displacement Feedback Energy Usage

Disp Limits Following error not effective due to poor dynamic response

Servo-Electric solution provides easier setupand usage, as well as extended built -indiagnostic functions for identifying andcorrecting problems when they do occur.

Regenerative Energy Yes No Regen returns captured energy back to theelectric power system for greater efficiencies.