General Presentation - BOSMAL · 2018. 2. 16. · General Presentation 2018 JBS-199/2/2015 AQAP 2110:2009 B-21/2/2015 ... as well as residents at plants in the country and the CNH

45 years on the automotive market 20 years as an Accredited Testing Laboratory AB 128

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& ProductionServicesBOSMAL Automotive Research and Development Institute Ltd

for automotive industry

General Presentation2018

AQAP 2110:2009JBS-199/2/2015B-21/2/2015

Version dated 25.01.2018


TestsDesign

& ProductionServices

Decision of the Minister of Economy, BOSMAL was granted the status of research and development center

Decision of the Minister of Transport, Construction and Maritime EconomyBOSMAL has obtained the qualifications for type approval of vehicles

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Strategically located near several key European engine and vehicle manufacturing centers BOSMAL is a state-of-the-art testing and R&D facility providing comprehensive services in the area of engine and fuel technology, as well as other automotive technologies.

Year of foundation: 1972Scope of activities: complex design & testing services

for automotive industryLegal status: LtdArea of premises: 83 000 m2

Indoor area: 24 700 m2

Staff in Poland: about 380 employees (17 professors and/or doctors, 233 engineers and/or masters)

Staff in Italy: ca. 30 employeesLocation in Poland: Bielsko-Biała, northern part of the city,

in the neighborhood of 1 and S1/S52 crossroad BOSMAL in Poland

BOSMAL in Italy

BOSMAL in brief


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BOSMAL Automotive Researchand Development Institute Ltd

Sarni Stok 93Bielsko-Biała

Poland

BOSMAL ITALIA S.R.L.Via Bardonecchia 185

Torino, ItaliaVia Circonvallazione 186/23

Santena, TorinoItalia

Torino

Bielsko-Biała

Sigmaringen

Representation of BOSMAL in GermanyHandelsvertreter des Institutsfür Forschung und Entwicklung

von Fahrzeugtechnik BOSMAL GmbH in Deutschland

Am Schönenberg 4 Sigmaringen, Deutschland

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BOSMAL has several representations in Europe, as well as residents at plants in the country and the CNH Płock Customer Service.In addition, the Institute leading testing vehicles in various ground conditions and climate, has a fixed routes outside Poland - in Italy, Spain, Sweden, Ukraine and other European countries.

BOSMAL in Europe


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AUTONEUMBMWBORG WARNER TURBO SYSTEMSBORYSZEWBOSCHBREMBOCETIM-CERMATCNH INDUSTRIALCOOPER-STANDARDCORNAGLIADELPHIDENSOEATONELTEKENIEXXON MOBILFAURECIA

SOLARIS BUS & COACHSTATOILTAKONITEKNIA ZEMTENNECO AUTOMOTIVETHULETI POLANDTIBERMECTOFAS TURK OTOMOBILTOYOTA MOTOR TRELLEBORG SEALING SOLUTIONSUMICOREVALEOVISSCHER CARAVELLEVISTEONVOLKSWAGENZF TRW

FEDERAL MOGULFEVFIAT CHRYSLER AUTOMOBILESFORMPOLFREMACHGENERAL MOTORS HUTCHINSON INFINEUMISUZU MOTORS ITV DELTARJOHNSON CONTROL KIRCHHOFF LEAR CORPORATIONLUBRICANTS UKMAGNAMAGNETI MARELLIMAZDA

MECAPROMNANNI INDUSTRIESNEAPCO EUROPENEMAKNIDEC MOTORS & ACTUATORS NSK STEERING SYSTEMSPETRONASPRIMAPROSEATPEUGEOT CITROEN AUTOMOBILES SAPILKINGTON AUTOMOTIVE REMY AUTOMOTIVE SAINT GOBAINSEWS - CABINDSHELL SHILOH INDUSTRIESSISTEMA

BOSMAL actively came on stream in the Polish automotive sector in 1972, commencing its operation as engineering and testing-developing back-up facilityof the former FSM factory (Small Car Factory)in Bielsko-Biała.

Currently, we provide wide range of R&D services for companies from automotive branch, both domestic and from abroad.

High qualifications and many years of experienceof our staff ensure high level of performed services.

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BOSMAL in Europe


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POLAND

CZECH REPUBLIC

SLOVAKIA

HUNGARY

AUSTRIA

WRZEŚNIAVW

car assembly plant

TYCHYOPEL Poland

diesel engine plant

BIELSKO BIAŁAFCA Powertrain PolandDiesel /Gasoline engine

plants

ŽILINAKIA

car assembly plant

POZNAŃVW

car assembly plant

KOLINTOYOTA/PSA

car assembly plant

JELCZ LASKOWICETOYOTA

engine plant

MLADA BOLESLAVŠKODA

car assembly plant

TYCHYFCA Poland

car assembly plant

GERMANY

POLKOWICEVW

engine plant

TRNAVAPSA

car assembly plant

OSTRAVA HYUNDAI car assembly plant

GLIWICEOPEL Manufacturing Poland

car assembly plant

SZENTGOTTHARDOPEL

engine plant

GYÖRAUDI engine&car

assembly plant

ESZTERGOMSUZUKI

car assembly plant

BRATISLAVAVW

car assembly plant

KECSKEMETMERCEDES

car assembly plant

JAWORMERCEDES

engine plant(under construction)

WAŁBRZYCHTOYOTA

engine&gear box plant

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BOSMALBIELSKO-BIAŁA

The nearest car and engine manufacturers

BOSMAL in Europe


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& ProductionServicesBOSMAL - Business range

TESTS DESIGN & PRODUCTION

SERVICES

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Vehicles testing

Tests of engines and exhaust treatment systems

Exhaust emissions testing

Materials testing

Heat exchangers testing

Tests of automotive parts and assemblies

Electrotechnical and electronic tests, photometric measurements

Metrological measurements

Type Approval

Technical opinions and analyses, opinions on innovations

Parts and subassemblies failureanalysis

Confirmation of conformity vehicle with manufacturer requirements

Technical documentation translation

Vehicle workshop and RegionalVehicle Inspection Station

Certificates

Complex design services

Design, CAD/CAM/CAE, engineering calculations, prototyping

and manufacturing,

Manufacturing of tooling, workshop aids, gauges, special machines

Engineering support of production

Electric car - BOSMAL 500 E, conversion of cars from fuel-driven

to electric, tests


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• Assessment of functionality of cars, parts, units, automotive accessories and consumables

• Tests of steering ability and stability of passengercars

• Tests of durability and reliability of EOBD systems• Tests of traction systems, e.g. ABS, ASR• Tests on sliding vehicle• Tests on ascending vehicle• Temperature distribution in certain systems

(brake, exhaust, engine cooling and lubrication, heating)

• Tightnes tests of vehicles• Mileage tests, durability-fatigue tests of parts,

units, assemblies and complete cars

TrucksPassenger vehicles BusesDurability-fatigue, functional and mileagetests of cars with LPG/CNG, DIESELand gasoline engines

BOSMAL - Vehicle road testing

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• Urban• Heavy urban• Mountain• Motorway• Off-road• Mixed

Testing tracks/roads:

• Reliability Growth tests • Fleet - EOBD tests • miscellaneous

Hot/ special climate:• Torino (Santena) - Italy• Modena (San Giovanni) - Italy• Livigno - Italy• Granada - SpainTemperate climate:• Bielsko-Biała - Poland • Slovakia• SerbiaCold climate:• Sweden

Durability-fatigue, functional and mileage tests of cars with LPG/CNG, DIESEL and gasoline engines

Road tests on advanced testing race tracks (Italy, Czech Republic, Germany, Sweden)

BOSMAL - Vehicle road testing

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Vehicle testing - AVL M.O.V.E. Portable Emission Measurement System (PEMS)

• Exhaust gas emissions tests on vehicles in the real driving conditions (‘RDE’) using Portable Emissions Measurement Systems (PEMS)

• Ranging from large heavy-duty engines to the smallest light-duty vehicles and, recently, to non-road mobile machinery

• The currently available PEMS analyzers measure gaseous exhaust components (CO2, CO, HC, NOx) and particulate number (PN)

PEMS test under real operating conditions

BOSMAL - Vehicle testing

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Temperature range: -45°C... +75°CEntrance gate : width: 360 cm

height: 278 cm

Rain chamber for vehicles (from each direction - of the sides, from the front and from the top) for tightness test performing

3700 (w) x 3150 (l) x 3500 (h)

Vehicles tests in Temperature chamber Vehicles tests in Rain chamber


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7100 (w) x 8700 (l) x 3150 (h)


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Tests for vehicle approval (homologation)


Regional Vehicle Inspection Station

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18 meters long

Entrance of vehicle workshopand Regional Vehicle Inspection Station


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BOSMAL engine test cells are equipped with the industry-leading testing devices of Horiba-Schenck and AVL

• Quality and COP tests• Support in qualification of parts from new suppliers• Support in product development

Bio-fuels tanks

Engine emissions measuring system HORIBA MEXA 7000

• Base engine development (Euro 6, Euro 6d)• Combustion analysis• Engine mapping and calibration• Engine vibration measurements• Engine noise measurements• Engine component temperature measurements• Durability and special tests• Aftertreatment systems optimisation (TWC, DOC, DPF, SCR, LNT, GPF)• Engine parts and assemblies qualification• Support in launching new engines into production• Development of engines for alternative (special) fuels and for new

markets

Engine development:

Engine testing:

Fuel and lubrication oil testing:

• Alternative fuel and fuel additives development• Biofuels testing• Lubrication oil validation test

BOSMAL - Engine testing

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Automotive Engines• Light Duty• Medium Duty• Heavy Duty Off Road Engines Marine Recreational Engines

High Performance and Motocycle Engines Industrial Engines Hybrid Powertrains

• Engine development activities• Engine validation and endurance tests• Engine thermal and special tests• Lube oil and fuel tests• Aftertreatment aging and development

tests• Engine calibration activities• Emission measurements and optimization• Conformity of production tests• Homologation tests


Our limits of engine testings are: max. power – 500 kW; max. torque – 3000 NmBOSMAL can test 6 groups of engines.

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Engine testing laboratory20 engine test cells:• 15 equipped with SCHENCK and HORIBA eddy-current dynamometers W130 to W470 types • 5 equipped with fully dynamic dynos AVL APA 202, AVL DynoExact and HORIBA DYNAS3 LI250

Gasoline, diesel, biofuels (different liquid fuels in pararell to each test cell), LPG and CNG


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Test cells with LPG installation

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Test cells with CNG installation

Dynamic dyno

Heavy Duty Test cellsMedium Dutydynamic dyno

for adaptionto dynamic dyno

Development test benches


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Engine emissions measuring system HORIBA MEXA ONE

AVL DynoExact504/5 Px500 KW

3000 Nm

Emission system for emission measurement of engine exhaust gases

from the combustion engine

Equipment for measuring number and diameters of particles present in the exhaust gases of combustion engines, with an exhaust gas diluter

TSI 3090 Size Distribution Spectrometer

Dynamic engine test stand For heavy duty hybrid gaseous and particulate exhaust emissions testing as a part of Centre of Competence for automotive propulsion system development


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AVL Smart Sampler


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Types of fuel used for tests:• gasoline• diesel• gasoline with ethanol• bio-diesel• LPG• CNG

Diesel tanks (inc. bio-diesel)

CNG compressor

Gasoline tanks

In addition, part of the fuel is stored in underground tanks

LPG tanks

Fuel distribution system

Tests of cars and engines fueled with LPG/CNG, DIESEL, gasoline, biofuels


Petrol Station

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• Conformity of Production (COP) and other quality tests• Homologation/Certification• Emission tests for vehicle fleet program• Fuel consumption/fuel economy tests

▪ Conventional and alternative fuel testing• Development tests

▪ Engine calibration▪ Aftertreatment system testing (DOC, DPF, TWC, SCR, LNT, GPF)

Scope of research works in the range of emission testing

BOSMAL - Exhaust emission testing

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Exhaust emissions laboratory - Climatic chamber

• Temperature control over the range -35°C to +60°C• Control accuracy (temperature tolerance): ±1,0°C (under static conditions, with zero heat load); ±1,2°C

(during emissions tests); ±2°C (during performance tests)• Control over the humidity value during emissions tests: from 5,5 to 15,0 grams of water per kilogram

of dry air at temperatures ranging from +20 to +35°C• Variation in humidity level: ≤ 5%• Temperature gradient (with the chamber empty): 0,5°C per minute during warm-up and cool-down

phases

Testing possibilities in BOSMAL’s climatic chamber:• Emission Tests (European: NEDC & WLTC, Japanese: JC08, US-EPA: US06, SC03, FTP75, HFET)• New vehicles development• Special tests:

▪ Hot & Cold start test▪ Driveability & shifing test▪ Defrost test▪ Electronic control units applications▪ Engine mapping▪ Fuel heating tests

BOSMAL - Exhaust emission testing

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10100 (w) x 14300 (l) x 4300 (h)


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Chemical Laboratory

Metallographic Laboratory

Plastics, Rubber & Coatings Laboratory

• Identification• Concentration

• Metallic materials evaluation

• Cleanliness determination

• Properties of materials• Ageing

Materials testing failure analysis

BOSMAL - Materials testing

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• Material composition analysis (metals, alloys of metals)

• Non metallic materials constitution and composition analysis (rubber, plastics, solvents, paints, fuels and lubricants)

• Chemical and physicochemical tests

• Galvanized and organic (paints), coatings examination (corrosion tests), thickness, scratch (adhesion)

• Material resistance to light and climatic environment (ageing tests)

• Cleanliness of parts and components inclusions and contamination analysis regarding its compositions and constitutions

• Materials VOC (Volatile Organic Compounds) analyses

• Emission testing of hydrocarbons and halocarbons

• Tests of petroleum products: fuels, oils, lubricants, coolants for radiators, brake fluids, anaerobic adhesives, sealing compounds, other materials


DSC Q2000

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Air quality testing within the vehicle

Gas chromatograph Agilent 7890A with mass detector Agilent 5975C and MARKES Micro Chamber/ Thermal Extractor (u-CTE) and UNITY 2 MARKES thermodesorber

Material composition analysis (metals, alloys of metals)

Plasma emission spectrophotometerPerkin Elmer Optima 4300 DV

Emission testing of hydrocarbons and halocarbons

Air conditioning systems components. Vehicle interior materials


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Strength tests of metals and metal alloys

Mechanical and technological properties of rubber and plastics like:tensile strength, tear strength, elongation, compression stress, static hysteresis of compression, rigidity 3-points method and fatigue test. Vickers, Brinell, Rockwell, Knoop hardness measurements of metals, and hardness measurements with use of modified methods: ball indentation hardness measurements of plastic and rubber materials

Microstructure tests of metals and metal alloys

• 0bservation of material-graphic structures• Crystallite analysis• Analysis of graphite release• Analysis of non-metallic inclusions• Measurement of layers’ depth

Non metallic materials constitution and composition analysis (rubber, plastics, solvents, paints, lubricants)

Gas chromatograph Agilent 7890A with mass detector Agilent 5975C and MARKES Micro Chamber/ Thermal Extractor (u-CTE) and UNITY 2 MARKES thermodesorber


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Material analyses by infrared spectrometry (FTIR)

Infrared spectrometerThermo Scientific NICOLET 6700

Spectrofotometer VIS Hach Lange DR 3800

VIS (Visible Spectroscopy) analyses (concentration, absorbance, transmittance, kineticand spectra in absorbance, % transmittance, multiwavelength measurements) of e.g. formaldehyde

Materials VOC (Volatile Organic Compounds) analyses

• Fogging device • Increased cooling/heating power• Air mass flow controller• Additional sensor of temperature and humidity• Reinforced test space container• Sampling distribution tree


WEISS/VOETSCH WKE 1000

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• Scanning Electron Microscope (SEM) EVO 25 MA Zeiss, with variable vacuum, with EDS, BSD i EBSD detectors• Fluorescent X-ray Spectrometer with wavelength dispersion (WDXRF) model Rigaku Primus II with rhodium lamp• XENO WEATHER-OMETER CI 4000 Atlas for materials testing resistance to light exposure• Salt spray - humidity cycles S1000M-TR Liebish chamber• Environmental Chamber EGNX 28-12 CWLE ESPEC (temperature range: -70°C to +180°C RH10 to 98%,

the rate of cooling and heating up to 12°C/min)• Gas-chromatograph Agilent 7890A• Liquid Chromatograph Agilent 1260 Infinity HPLC• WEISS/VOETSCH WKE 1000 for VOC (Volatile Organic Compounds)

Exemplary new equipment of the material testing laboratory


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• Active sampling on TD tubes• Active sampling on solvent extractable sorbents• Active bag sampling• Passive sampling - Radiello• Solid Phase Microextraction (SPME)

Car cabin air testing


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According to:

• PN-EN ISO 11357-1:2009• ISO 11357-2:1999• ISO 11357-3:1999• ISO 11357-6:2008• PN-EN ISO 11358:2004• ASTM D 3418-03

• Determination of glass transition temperature

• Determination of melting and crystallizationtemperature and enthalpy

• Determination of Oxygen induction time

• Determination of transition temperature, enthalpyof fusion and crystallization of polymers.

Thermal analysis

DSC Q2000 Differential scanning calorimeter and TGA Q500 Thermogravimeter


DSC Q2000

TGA Q500

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Wavelength and full spectral detection

Precise identification, quantification and purity analysis at trace levels

HPLC (High-performance liquid chromatography)

Liquid chromatography

PALL Component Cleanliness


Pall Cabinet

1260 Infinity VariableWavelength Detector

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• liquid• glass• bottles• stickers• carpets

• plastic • fabric• wood• foam• paint

Tests resistance of:

Material resistance to light and climatic environment (ageing tests)


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Various climatic chambers

Tests of ageing, heat cycles, enviromental trials, low and high temperature resistance of materials and components


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Corrosive resistance of large components:• NSS• ASS• CASS • SWAAT

Corrosion resistance of materials, coatings and components


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• assessment of the quality of engine fuels, oils and lubricants, • assessment of the quality of technological oils• qualification tests of engine and transmission oils, depending on their

operational conditions• assessment of quality of temporary corrosion protection agents used

in preservation of automotive components• assessment of quality of auto-cosmetics• assessment of quality of automotive coolants• assessment of properties of brake fluids• tests of anaerobic adhesives and sealing compounds used in vehicles

Tests of petroleum products


Items tested:• fuels• oils• lubricants• coolants for radiators• brake fluids• anaerobic adhesives• sealing compounds• other materials

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Tests of:• Coolers• Heater cores• Intercoolers• Condensers• Fans + shrouds

Tests according to the standards of:

• Environmental• Temperature• Ageing• Corrosion resistance• Internal corrosion of coolers EGR and CAC• Internal corrosion / erosion• Pressure cycles (oil + glycol)• Thermal shock• Deep thermal shock (glycol)• Pressure cycles (air)• Heat efficiency• Erosion• Freon emission• Vibration• Acoustic• Thermovision

• BMW• FIAT• Ford• GM• Jaguar• Mazda

• Mercedes• Mazda• Nissan• PSA• Renault• Toyota• others

The scope of heat exchangers tests:

BOSMAL - Heat exchangers testing

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• Burst test (ambient and hot)• Chip resistance test• Impact test • Pin test (the forces of pin break)• Chemical resistance/ageing of plastics• Cleanness (according to DIN 8964-2)• Geometrical measurements• Calcium chloride test• And others for a special Client’s request

Additionally BOSMAL performs:

BOSMAL - Heat exchangers testing

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The range of tests:• Durability test of gears, mechanisms and gearbox’s bearings on individual gears

and motorway cycle• Endurance and dynamic tests of various types of manual and dual-clutch (DCT) gearboxes

used in transverse 4x2 drive systems• Simulation the functions of the gearbox in the vehicle• Simulation of combustion or hybrid engine operation• Simulation of road load conditions• Simulation of driver behaviors

Driving motor capabilities:• Permanent magnet synchronous motor• Rotor moment of inertia: jrot = 0,121 kgm² ± 5%• Water cooled• Max. torque 800 Nm (1000 Nm in overload mode)• Max. speed 10000 rpm

Braking motors capabilities:• Asynchronous AC type• Rotor moment of inertia: jrot = 3,87 kgm² ± 5%• Air cooled• Max. torque 3200 Nm (4700 Nm in overload mode)• Max. speed 3000 rpm

The test bench will be equipped with the REILHOFERdelta-ANALYSER diagnostic system of wear and damages of the automated dual-clutch and manual gearboxes.

The REILHOFER diagnostic system is based on the vibrations assessment.

The system compares gearbox wear at the beginning of the test with the recorded during the test. The system ensures the detection of the gearbox wear/damage and point its location (e.g. damage of the teeth of the 3rd gear on the driven wheel and indicate the wear/damage progress history). The system of gearbox wear/damage detection works automatically, continuously and will be integrated with the test bench control system to stop the test, in case of damage or exceeding set emergency levels.

Vibration diagnostics

Dynamic gearbox test stand for manual and automatic (also dual-clutch)

BOSMAL - Tests of automotive parts and assemblies

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The test stand control software features:• Fully automatic operation cycle, customizable to test standard requirements

and/or the client's specific demands• Data acquisition of the complete test at a sample rate of 1 Hz• High resolution data acquisition of the last 5 minutes of the test at a sample rate of 100 Hz• Adjustable torque change rate during loading and unloading• Adjustable rpm change rate during acceleration and deceleration• Adjustable differentiation between half-shafts rpms• Adjustable safety limits:

▪ Input/output rpm▪ Input/output torque▪ Oil temperature

• Reilhofer system of vibration evaluation

Motors Parameters:

Driving motor:• Type: SCHORCH LN8250M-A• Speed: 6000 rpm• Torque: 400 Nm up to 5240 rpm/ 300 Nm at 6000 rpm

Loading motors:• Type: LEROY SOMER LSK 2804 CSM 03• Speed: 2000 rpm• Torque: 2500 Nm up to 780 rpm/ 400 Nm at 2000 rpm

Durability tests of manual gearboxes


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Automotive Brake Performance Dynamometer LINK

• Max. motor power: 186 kW (250 HP)• Max. braking torque: 5650 Nm• Max. speed: 2500 rpm• Max. brake pressure: 200 bar• Range of simulated inertia: 5 - 250 kgm2


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Durability and fatigue tests

• Durability tests of various parts and assemblies, e.g. two-dimensional loads - rotation and force control

• Fatigue tests of assemblies, e.g. radiators, cooling fans, fuel tanks• Fatigue test of the shock absorbers• Squeak and rattles tests• Fatigue tests of components and systems loaded with Power Spectrum

Density (PSD) signals• Assemblies of the airplanes, wing connections, and many more to meet

the requirements of our Customers

Vibration tests

Static and dynamic torsion tests of various parts

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Strain gauge measurements

• Main aim of strain research:• Comparison of real values with calculations• Assurance of fatigue tests repeatability on various

test stands and in different laboratories• Determining the root cause of too early cracks• Indirect measurements of forces in mechanical

systemStrain gauge - rosette

Strain measurementsof construction

Durability test - two-dimensional loads (rotation and force control)



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The measurements of noise and vibration are performed during road testing, in anechoic chamber and on special test stands.

NVH

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• Sinusoidal vibrations (e.g. according to IEC 60068-2-6)• Random vibrations (e.g. according to IEC 60068-2-64)• Mechanical shocks (e.g. according to IEC 60068-2-27)

Vibration system

Range of the tests:

• Inside dimensions: 1500x1500x1500 mm (volume 3,4 m3)• Temperature range with vibration system: -40... +160°C• Temperature range for stand-alone operation: -75... +180°C• Relative humidity 10… 98% - at temperatures: +10… +90°C• Temperature change rate: 10°C/min (also with heat dissipation inside)

Parameters of the Climatic chamber

Unholtz-Dickie Vibration System integrated with Climats Climatic Chamber

The test stand is used for sinusoidal and random vibration tests as well as for mechanical shocks along three excitation axes (X, Y, Z).The tests can be performed at room temperature or inside the climatic chamber.

Fan system noise – test in anechoic chamber

Environmental and industrial noise

• Measurements of noise on test stands• Measurements of external noise of vehicles, according to ECE• Measurements of noise level of internal noise of vehicles• Measurements of noise level of horns in automotive vehicles• Measurements of acoustic power

Measurements and analysis of vibration of machinery and vehicles• Spectrum analysis of vibrations• Analysis of linear and torsional vibrations• Contact-free measurements and analysis of torsional vibrations of shafts

Dynamics testing of machinery and vehicles• Determination of impedance and mechanical mobility• Modal analysis

Internal noise test



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• Control of elements and subassemblies operation• Tests of resistance of appliances to environmental

factors (e.g. cold weather, dry hot air and damp, hot air, temperature changes)

• Recording of parameters at time of applianceoperation (electric current, voltage, temperatures, rotational speed, etc.)

• Durability tests• Determination of defects’ causes and of faulty

systems operation

Tests of car’s electric and electronic accessories

Tests of resistance to environmental factors

• Environmental tests in climatic and temperaturechambers and in furnaces

• Tests of resistance to rain, dust and high pressure washing

BOSMAL - Electrotechnical and electronic tests

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• Light intensity, luminance, illumination• Colour of light, nearest colour temperature, colour indicator• Spectrometric measurements (photometric and radiometric)• CIL reflection coefficient, surface density of reflection coefficient• Coefficients of reflection, transmission, and luminance• Haze

• Colour in relation to a template• Colour change (DE) following testing of resistance

to atmospheric conditions• Coefficients of reflection, transmission and luminance• Degree of white and degree of yellowish tinge• Other

• Color measurements of reflective materials• Color measurements of transparent materials• Measurements in reflective geometry d/8 and 45/0• Measurements in direct and total transmission

Photometric measurements

Colour measurements

Spectrophotometric measurements of colour

BOSMAL - Photometry

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• Linear and angular dimensions• Measurements of shape and position deviations• Presentation of surface topography• Surface roughness assessment

High precision geometrical measurements(contact and contact-free)

BOSMAL - Metrological measurements

• DEA GLOBAL PERFORMANCE (12.30.10) with measurement and inspection software PC-DMIS™ CAD++ On-line with DCT CATIA V5 and DCT UNIGRAPHICS

• DEA GLOBAL STATUS (09.15.08)• HexMet-OPTIV CLASSIC 321GL tp

Measuring machines:

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DEA GLOBAL STATUS

DEA GLOBAL PERFORMANCE1200 X 3000 X 1000 mm

OPTIV CLASSIC 321GLTP


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& ProductionServicesBOSMAL - Other tests

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Complex design services - the range of offered services

BOSMAL - Design & Production

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Turnkey systems

Design Assumptions

Engineering Calculations

Designing

Modeling

Production

Verification in Tests

Setting into Production


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Design, prototyping and manufacturing

Design

• 3D models• 2D documentation• Conversion

Simulation /Calculation

• Analysis of issue:• Linear• Nonlinear• Dynamic• Own frequency• Coupled field

Prototyping

• Control & laboratory gauges (JIGS)• Vibration holders• Checking fixtures• Attributive gauges

Manufacturing

• Milling• Turning• Grinding• WEDM• CMM validation

Complex development of testing instrumentsfor components used in the automotive industry

Strength analysis

Programming advanced CAM systemand CNC machining

• Dassault System CATIA V• Siemens NX• Autodesk INVENTOR• Autodesk AutoCAD• Dassault System Simulia Abaqus,

CATIA Generative Structual Analysis• Solid EDGE• SIEMENS NX CAM, Edge CAM• Creo

CAD/CAM/CAE


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Production of tooling, workshop aids and gauges

Tools and gauges - design & manufacturing for automotive lightning industry - examples:

• Photometry supports• 3D lamp supports• Vibration test supports• 3D Lens support• Housing quality gauge• Precise car body gauge


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Design, prototyping and manufacturing


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Non contact, optical measuring device for gaskets


Impregnationinstalationof fabrics - MI-10

Design, prototyping and manufacturing - examples

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Prototyping and manufacturing

Parameters of 5-axis vertical machining center:- table: 2720 x 820 mm - rotary table D = 800 mm, rotation 360° (max load: 3000 kg) travels: - X -axis = 2550 mm

- Y-axis = 1000 mm- Z-axis = 1000 mm

- positioning accuracy: + / - 0,008 mm- repeatability: + / - 0,005 mm- tilting head rotation range: + / - 105°

Parameters of 3-axis vertical machining center:- table: 1200 x 480 mm (max. load: 1300 kg)- travels: - X = 1050 mm

- Y = 540 mm- Z = 550 mm

- positioning accuracy: + / - 0,01 mm- repeatability: + / - 0,003 mm

5-axis vertical machining center

3-axis vertical machining center


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- Rotation: 50 - 4 000 rpm- Max. working lengh : 900 mm

- X travel 787 mm- Y travel 508 mm- Z travel 520 mm- Table size: 1372 x 355 mm- Max. table load: 600 kg- Rotation: 50 - 5000 rpm

Table size: 1 000 x 500 mm- Max. Table load : 400 kg- X travel 750 mm- Z travel 500 mm- Y travel 500 mm- Max. rotation: 9000 rpm

- X travel 1524 mm- Y travel 596 mm- Z travel 610 mm- Table size: 1930 x 355 mm- Max. table load: 850 kg- Rotation: 50-5000 rpm

- X travel 600 mm- Y travel 400 mm- Z travel 310 mm - Max. workpiece dimension 1050 x 820 x 305 mm- Max. table load: 1500 kg

Vertical milling machine NC SMX 3500 Vertical milling machine NC SMX 5000

Vertical milling machine CNC MCV 750 QUICK Lathe NC SLX 355

Wire EDM - MITSUBISHI MV2400S Tubular


Prototyping and manufacturing

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R&D/ Quality DepartmentsActivity area/ responsibilities (mechanical and electronics engineers):• Residents for engines• Engineering support for car asssembly plant• Residents for E&E systems• Residents for body and interiors• Residents for engine systems

Production parts approval process

Carried out PPAP :• All engine components with level 3 PPAP• Level 4 and 5 PPAP is performed on suppliers place, with the presence of Supplier Quality Engineer, and Product Engineering The internal PPAP sample assembly is made of new components in the full production cycle.

Exhaust emission laboratory - management

Analysis of defects in vehicle’s components (aftermarket)

Quality verification of spare parts/accessories introduced into sales in Poland (aftermarket)

Calibration and R&D acctivities in engine & exhaust emission laboratories.

BOSMAL - Engineering support of production

Engineering support in phase of setting into R&D/ curent production/ residents activity

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& ProductionServicesBOSMAL - New initiatives

Electric car - BOSMAL 500E

Parameters: • three-phase synchronous electric motor PMSM type

▪ max. power: 57 kW ▪ max. torque: 220 Nm

• battery: Li-ion type (ca. 15 kWh)• single-speed transmission• range acc. to NEDC: ca. 100 km • maximum speed: 120 km/h• charging time: 6 h (single-phase) or 3 h (three-phase)• vehicle weight: 1100 kg

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Electric Vehicles Research – services we offer:

• determination of chassis dynamometer coefficients using the coast down method (based on determination of vehicle road load by the coast down method)

• determination of the electric range of vehicles powered by an electric powertrain according to UN ECE Regulation No. 101 (measurement carried out at temperature between +20°C and +30°C)

• determination of the electric range of vehicles powered by an electric powertrain at various (non-standard) ambient temperatures (between -30°C and +60°C)

• measurement of electrical energy consumption according to UN ECE Regulation No. 101 (measurement carried out at temperature between +20°C and +30°C)

• measurement of electrical energy consumption at various (non-standard) ambient temperatures (between -30°C and +60°C)

• determination of power at the tyres of vehicles powered by an electric powertrain

A different measurement procedure can be used, following consultation with the customer.

BOSMAL - New initiatives

BOSMAL’s research capabilities in the field of electric vehicles

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• road tests of functionality and durability under various traffic and climate conditions,• measurements of geometric dimensions,• evaluations of cars in terms of security,• evaluation of traction performance (maximum speed, acceleration capacity

from a standstill or from a specific starting speed),• evaluation of operating properties (vehicle range on different routes, with various

driving styles, at sub-zero temperatures),• tests of the influence of ambient temperature (low, ambient, high) on the efficiency

of the electrical energy storage system, its processing system, the mechanical efficiency of the transmission, and the range and performance of the entire drivetrain,

• evaluation of steerability and stability of the vehicle on the road,• brake assist and steering system assessment and their activation without assist,• assessment of ventilation and heating systems’ efficiency,• tests of battery charging time,• evaluation of the amount of batteries power failure while the vehicle is stopped

at negative and positive ambient temperatures,• measurements of temperatures of motor and batteries parts while the vehicle

is in motion,• test result evaluations,• other tests and R&D activities.

Other services BOSMAL offers in respect to research on electric vehicles

Vehicles tests in Rain chamber

Vehicles testsin Temperature chamber


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• selection of drive components and supplementary units for electric vehicles (motor with a frequency inverter, battery, charging system, voltage inverters, components of electric supplementary units – heating elements, air conditioning compressor),

• preparation of algorithms of vehicle components control system with the electric drive and steering system integration with participation of the suppliers of main components, such as the motor and battery unit,

• harness design and modifications to the harness of the base vehicle (in the case of conversion),

• arrangement and mounting of powertrain components and supplementary units in the electric vehicle,

• complex tests for the purposes of EC type-approval (small series production).

BOSMAL offers conversion of cars from fuel-driven to electric An example of conversion


TestsDesign

& ProductionServicesBOSMAL - Type Approval

According to the decision No TD-5i-027-17(4)/13 of Polish Ministry of Transport, Construction and Maritime Economy of 14th October 2013, BOSMAL Automotive Research and Development Institute Ltd is entitled to perform the following actions:

1. in scope of approval:a) performing EC-type approval tests of vehicles or category M, N, O or T vehicle type approval tests,b) performing the approval tests of parts or equipment for category M, N, O or T vehicles,c) performing approval tests related to the installation process of gas retrofit systems adapting vehicles of category M or N to use gaseous fuels,d) performing:• Conformity of Production of vehicle, parts or equipment for category M, N, O or T vehicles,• Conformity of Production of installation of gas retrofit systems adapting vehicles of category M or N to use gaseous fuels,2. in scope of Individual Vehicle Approval of category M or N vehicles: performing the tests confirming the fulfillment of relevant acts of law requirements or technical features, leading to introducing the vehicle into the road traffic,3. in scope of EC Individual Vehicle Approval: performing the tests confirming the fulfillment of relevant acts of law requirements or technical features, leading to introducing the vehicle into the road traffic.

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• for motor vehicles and their trailers (M, N, O): 70/157/EEC, 70/221/EEC (A2), 70/222/EEC, 71/320/EEC, 76/114/EEC, 76/756/EEC, 76/757/EEC, 76/758/EEC, 76/759/EEC, 76/760/EEC, 77/538/EEC, 77/539/EEC, 77/540/EEC, 80/1269/EEC, 89/297/EEC, 91/226/EEC, 92/21/EEC, 92/22/EEC, 94/20/EC (A.V.1, A.V.2), 95/28/EC, 97/27/EC, 2001/85/EC, 2003/97/EC, 2005/55/EC, 715/2007, 595/2009, 672/2010, 1003/2010, 19/2011, 109/2011, 458/2011, 130/2012, 1230/2012.

• for agricultural tractors (T): 76/432/EEC, 2009/60/EC (A1,1), 2009/60/EC (A1,2), 2009/144/EC (A1), 2009/144/EC (A2), 2009/144/EC (A3 exc. A3A p.8.1.3.3).

• for vehicles in categories: M, N, O and T according to UN ECE Regulations: No 3, No 4, No 6, No 7, No 13, No 13H, No 23, No 24, No 27 (exc. A5 p. 10), No 38, No 39, No 43 (exc. A3 p.: 3.2, 6.1-6.3), No 46 (exc. p. 6.2 i A10), No 48, No 49, No 51, No 55 (A5.1; A5.2; A7), No 58, No 59, No 61, No 68, No 69, No 70, No 73, No 77, No 83, No 85, No 87, No 90, No 91, No 101, No 102 (S.I.5, S.II.13), No 103, No 104, No 107, No 115, No 118, No 119.

Scope of authorization to carry out type approval tests of the equipment or parts of category M, N, O, T vehicles - according to the Decision of the Director of Transportation Technical Supervision No. TDT.H-1030-24310-5/17 of 20.09.2017 (short list):

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1. For motor vehicles and their trailers (M,N,O): • 70/157/EEC Permissible sound level• 70/221/EEC (A2) Rear protective devices• 70/222/EEC Rear registration plate space• 71/320/EEC Braking• 76/114/EEC Statutory plates• 76/756/EEC Installation of lighting and light signaling devices• 76/757/EEC Retro reflectors• 76/758/EEC End-outline, front-position (side), rear-position (side), stop, side marker, daytime

running lamps• 76/759/EEC Direction indicators• 76/760/EEC Rear registration plate lamps• 77/538/EEC Rear fog lamps• 77/539/EEC Reversing lamps• 77/540/EEC Parking lamps• 80/1269/EEC Measurement of engine power• 89/297/EEC Lateral protection• 91/226/EEC, 109/2011 Spray-suppression systems• 92/21/EEC, 1230/2012, 97/27/EC Masses and dimension• 92/22/EEC Safety glazing• 94/20/EC (A.V.1, A.V.2) Couplings (COUPLING BALLS AND TOWING BRACKETS, COUPLING

HEADS• 95/28/EC Flammability• 97/27/EC Masses and dimensions• 2001/85/EC Buses and coaches• 2003/97/EC Indirect vision device• 2005/55/EC Emissions (Euro IV and V) heavy duty vehicles• 715/2007 Emissions (Euro 5 and 6) light duty vehicles/ access to information• 595/2009 Emissions (Euro VI) heavy duty vehicles/ access to information• 672/2010 Windscreen defrosting and demisting systems• 1003/2010 Space for mounting and fixing rear registration plates• 19/2011 Manufacturer’s statutory plate and vehicle identification number• 109/2011 Spray suppression systems• 458/2011 Installation of tyres• 130/2012 Vehicle access and manoeuvrability• 1230/2012 Masses and dimensions2. For agricultural tractors (T): • 76/432/EEC Breaking devices• 2009/60/EC maximum design speed of and load platforms(A1,1 maximum design speed,

A1,2 load platforms)• 2009/144/EC Certain components and characteristics (A1 Dimensions and towable masses, A2

Speed governor and protection of drive components, projections and wheels, A3 Windscreen and other glazing Equipment (exc A3A p.8.1.3.3 Resistance-to-radiation test))

3. For vehicles in categories: M, N, O and T according to UN ECE Regulations:• No 3 Retro-reflecting devices for power-driven vehicles and their trailers• No 4 Illumination of rear-registration plates of power-driven vehicles and their trailers• No 6 Direction indicators for power-driven vehicles and their trailers• No 7 Front and rear position lamps, stop-lamps and end-outline marker lamps for motor vehicles and their trailers• No 13 Braking of vehicles and trailers• No 13 H Braking of passenger cars• No 23 Reversing lights for power-driven vehicles and their trailers• No 24 Visible pollutants, measurement of power of C.I. engines (Diesel smoke)• No 27 (exc. A5 p.10) Advance warning triangles exc. Test of stability against wind• No 38 Rear fog lamps for power-driven vehicles and their trailers• No 39 Speedometer equipment including its installation• No 43 (exc. A3 p.: 3.2, 6.1-6.3) Safety glazing materials and their installation on vehicles exc. Headform test with deceleration measurement,

Resistance-to-radiation test• No 46 (exc. p.6.2, A10) Devices for indirect vision and their installation exc. Devices for indirect vision other than mirrors, Calculation of the

detection distance for CMS of Classes V and VI• No 48 Installation of lighting and light-signaling devices on motor vehicles• No 49 measures to against the emission of gaseous and particulate pollutants • No 51 Noise emissions• No 55 (A5.1; A5.2; A7) Mechanical coupling components of combinations of vehicles - Coupling balls and towing brackets, Coupling heads,

Installation and special requirements• No 58 Rear underrun protective devices (RUPDs) and their installation; rear underrun protection (RUP)• No 59 Replacement silencing systems• No 61 Commercial vehicles with regard to their external projections forward of the cab’s rear panel• No 68 Measurement of the maximum speed, including electric vehicles• No 69 Rear marking plates for slow-moving vehicles• No 70 Rear marking plates for heavy and long vehicles• No 73 Lateral protection of goods vehicles• No 77 Parking lamps for power-driven vehicles• No 83 Emissions of M1 and N1 vehicles• No 85 Measurement of the net power and the 30 min. power• No 87 Daytime running lamps for power-driven vehicles• No 90 Replacement braking parts• No 91 Side-marker lamps for motor vehicles and their trailers• No 101 CO2 emission/fuel consumption• No 102 (S.I.5, S.II.13) Close-coupling device (CCD); fitting of an approved type of CCD - Specifications, Requirements concerning the fitting of an

approved CCD• No 103 Replacement pollution control devices• No 104 Retro-reflective markings• No 107 M 2 and M 3 vehicles• No 115 LPG and CNG retrofit systems• No 118 Burning behaviour of materials used in the interior construction of certain categories of motor vehicles• No 119 Cornering lamps

Detailed scope of authorization to carry out type approval tests of the equipment or parts of category M, N, O, T vehicles - according to the Decision of the Director of Transportation Technical Supervision No. TDT.H-1030-24310-5/17 of 20.09.2017:


TestsDesign

& ProductionServicesBOSMAL - Certificates

TÜV Certificate

On Testing of Automotive Componentsfulfilling the criteria of the standard DIN-PN-EN 45001 and ISO/IEC Guide 25:1990

AQAP 2110:2009 CertificateQuality Management System

In the following scope of activities:Research, laboratory testing, development and implementation, engineering services, technical consulting, training, design, development, manufacture, distribution and service in the field of transport and their equipment,And in conformance with the standards STANAG 4107

Accreditation Certificate of Testing Laboratory No. AB 128

BOSMAL meets requirements of the PN-EN ISO/IEC 17025:2005 standard.Accredited activity is defined in the Scope of Accreditation No. AB 128

Certificate of ApprovalNo. 40222010 L

On conducting tests a range listed enclosure for: certification body TDT-CERTfulfilling the criteria of the standard PN-EN ISO/IEC 17025:2005

TEST WORK SUPPLIERCERTIFICATE

4 022 2010 L

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AQAP 2110:2009


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IQNet and PCBC Certificate

Integrated Management System

No. PL - B - 21/2/2015In the following field of activities:design, piece and small lot production of automotivecomponents, vehicles' equipment, stands and testing-manufacturing toolsSystem fulfills the requirements of the following standardOHSAS 18001:2007

Certificate of IntegratedManagement SystemQuality * OH&S * Environment

No. JBS - 199/2/2015 System in the following scope of activities:design, piece and small lot production of automotivecomponents, vehicles' equipment, stands and testing-manufacturing toolsis in conformance with the standardsPN-EN ISO 9001:2009, PN-EN ISO 14001:2005and PN-N-18001:2004

Certificate of Management SystemOH&S

No. B - 21/2/2015 System in the following scope of activities:design, piece and small lot production of automotivecomponents, vehicles' equipment, stands and testing-manufacturing toolsis in conformance with the standardOHSAS 18001:2007

IQNet and PCBC Certificate

Integrated Management System

No. PL - JBS - 199/2/2015In the following field of activities:design, piece and small lot production of automotivecomponents, vehicles' equipment, stands and testing-manufacturing toolsSystem fulfills the requirements of the following standardsPN-EN ISO 9001:2009, PN-EN ISO 14001:2005

JBS – 199/2/2015

B-21/2/2015JBS – 199/2/2015

B-21/2/2015

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Fiat Chrysler AutomobilesTests in range of qualitative qualification

of parts and assemblies to final assembly in Fiat Auto Poland

TÜV Rheinland / BerlinTests for compliance with demands of EEC Directives/ECE Regulations

International Technical Development CenterTests of parts and assemblies

in range of evaluation of OPEL/GM suppliers

• CNH• DELPHI• ENI• EXXON MOBIL• FIAT CHRYSLER

AUTOMOBILES• GENERAL MOTORS • LUBRICANTS UK LTD• MAGNETI MARELLI• SHELL• STATOIL• TI POLAND• UMICORE• VALEO• VISTEON

VOLVO CarCorporation

Federal Office for the Environment

FOEN

VOLKSWAGENGroup

Recommendations References Laboratory Accreditations

Membership

Polish Scientific Society of Combustion Engines

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& ProductionServicesThank you for your attention. We invite your co-operation.

BOSMAL Automotive Research and Development Institute Ltd

(Instytut Badań i Rozwoju Motoryzacji BOSMAL Sp. z o.o.Istituto Automobilistico di Ricerche e Sviluppo BOSMAL S.r.l.

Institut für Forschung und Entwicklung von Fahrzeugtechnik BOSMAL GmbH)

Sarni Stok 9343-300 Bielsko-Biała

Poland

Tel.: +48 33 81 30 539www.bosmal.com.pl, [email protected]

BOSMAL ITALIA S.R.L.

Via Bardonecchia 18510141 Torino, Italia

Via Circonvallazione 186/2310026 Santena – Torino, Italia

Tel.: +39 (0) 11 194 45 052, +39 329 479 66 68www.bosmal.it

[email protected]

Representation of BOSMAL in Germany

Dr. Gerardo CarelliHandelsvertreter des Instituts für Forschung

und Entwicklung von Fahrzeugtechnik BOSMAL GmbH in Deutschland

Am Schönenberg 4 72488 Sigmaringen, Deutschland

Tel.: +49 7571 13 647Mobile: +49 1523 273 7294, +39 335 6220 999

[email protected]

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Documents

General Presentation - BOSMAL · 2018. 2. 16. · General Presentation 2018 JBS-199/2/2015 AQAP 2110:2009 B-21/2/2015 ... as well as residents at plants in the country and the CNH