Auto Test

23/11/54
Automotive&Components Testing_Part 1
Automotive Components Testing

Presented By:
Mr. Chanachai Marangsri
Introduction
Objective of components testing:
The tests required to validate a product that will
simulate
i
l
the
h stresses and
d exposures related
l d to iits
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)
Continuous Conformance Tests maybe required during
normal production
23/11/54
Design Validation Flowchart
Mechanical Parts
M l
Metal
N
Non-metal
l
Strength
Natural Rubber
Synthesis Rubber
Tensile Stress
Viscosity
Weathering
Bending test
Stress & Strain
Grayy scale
Ozone
Torsion
Flammability
Rain
Salt Spray
Spring rate
Design Validation Flowchart

Electrical Characterization
Resistance to Electro Static
Discharge
Dielectric strength
Bulk current injection closed

loop
Insulation
Bulk current injection:

substitution method
Brief Voltages dip
Radiated immunity: Stripline

test
Power supply voltage

ripple
Conducted emission: current

probe method
Measurement of conducted
transient
Sinusoidal
vibration
Dust test
Humidity soak
Thermal shocks
Technical
Characterization
Spraying Water
Resistance to
storage
Thermal Characterization
Handling drop
Technical
characterization
Voltage offset se
Condensation
Ground offset test
Radiated emissions: Antenna

method
Switch off de-activation

test
Resistance to brief
supply failures
Transient immunity
Humidity
Cycles
Resistance to non usual

battery voltage
Radiated emissions: Stripline

test
Magnetic field emission
Durability
Cranking
Immunity to radiated field semianechoic
Conducted RF emission
Resistance to dynamic
shock
Slow increase & decrease of

supply voltage
Resistance to ground & positive
supply short circuit
23/11/54
Process Validation Flowchart

Durability
Dust test
Humidity
Cycles
Sinusoidal
vibration
Humidity soak
Thermal shocks
Technical
Characterization
Spraying Water
Resistance to
storage
Handling drop
Technical
characterization
h
t i ti
Condensation
Resistance to dynamic
shock
ASIA:
Headquarters
TV SD Asia Pacific Pte. Ltd.
Singapore
AMERICAS:
Headquarters
TV SD America Inc.
Danvers, Massachusetts
EUROPE:
Headquarters
TV SD AG
Munich, Germany
Continuous Conformance Flowchart
Durability
Thermal Shock
Humidity soak
23/11/54
List of components
Press Parts
List of components
Interior Trims
23/11/54
List of components
Engine component
List of components
23/11/54
Typical Test Parameters to Consider
Electrical Characteristics
Electromagnetic and Electrostatic Characteristics
Cli
Climatic
i S
Stresses
Mechanical Stresses
Solids/ Fluids Stresses
Chemical Stresses
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
etc.
etc
EMC Chambers
23/11/54
Electromagnetic Compatibility Tests

Automotive EMC Testing (Electronic Systems)
Electromagnetic Emission Measurements
(Radiated/Conducted)
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
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)
23/11/54
Component Testing
Climatic Stresses
This category includes tests to demonstrate compatibility with climatic stresses
such as temperature, humidity and solar radiation.
Temperature/ Humidity
Chambers
Xenon Arc
Weatherometer
Solar Climatic
Chamber
Combined Environmental
Chamber and Vibration
Tester
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.
Load Test
Door Handle Load Test
Spring Test
Car Seat Lateral

Vibration Test
Steering Wheel
Vibration Test
23/11/54
Component Testing
Solids / Fluids Stresses
This category includes tests to demonstrate component resistance to solids

andd flfluids
id suchh as ddust,t water
t andd rain.
i
Dust Test
Water
Submergence
Test
Rain Test
High Pressure Water

Spray 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.
Salt Spray Test
Salt Fog Test
Fluid Compatibility Test
23/11/54
Component Testing
Durability Test
This category includes tests to demonstrate the components durability, fatigue
strength and reliability.
Shock Absorber Endurance

Test
Master Brake
Cylinder Cyclic
Actuation Test
Car Horn
Endurance Test
Switch
Endurance Test
Environmental and Reliability Tests
Climatic Test
1. Operating Temperature/ Humidity
2. Storage Temperature/Humidity
3. Altitude Test
4. Thermal shock/cycling
5. Environmental Stress Screening
6. Biased Power Temperature Cycling
7. Ingress protection
10
23/11/54
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:
Abnormalities in configuration, size, appearance, color tone of
the sample surface properties
Example:
E
l a cycle
l off h
heat and
dh
humidity;
idi
11
23/11/54
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.
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
Electronic parts & components failure
Methods(ASTM ,ISO, SAE, MIL, JASO)
Applications
Dash-board, Rubber seals, Hoses, Plastic parts, Adhesives, Sun-block
Films and Accessories, Automotive topcoats
12
23/11/54
Natural Weathering Tests
Outdoor Natural Exposures
Real-time natural degradation of materials
H h ttropical
Harsh
i l climate
li t conditions
diti
PSB Test site is part of the ATLAS, Florida (US)

worldwide test sites
Methods (ASTM, SAE)
Applications
Natural Weathering Exposure
Gloss durability
d rabilit of automotive
a tomoti e 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
Finished product performance
evaluation after test
Performance of different product
designs after test
Selection of materials
Alpha accelerated
weatherometer
Solar Climatic
Chamber
Applications
Rubber materials and seals
Weather-strips
Plastics and topcoats
Leather seats (light fastness)
13
23/11/54
Xenon /Carbon Arc Weatherometer

Sample of Test condition:
Interior Trim
Salt Spray Test

Determine the resistance of metals, metallic and other protective coating to
corrosive atmospheres by salt spray fog test.
14
23/11/54
Salt Spray Test

Data Needed:
o
o
Number of Hours of Salt Spray

Condition of parts after Salt Spray Exposure
Evaluation:
No change of the surface
Corrosion of coating allowed but
not corrosion of the base material.
o Finished parts are to exhibit no
red rust worse than specification
o
o
Salt Fog Test

Scope of products:
all interior trim materials (except for the metal)
for automobiles.
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 plate
15
23/11/54
RESISTANCE TO SCRATCHING
Scope:
Resistance to scratching on surfaces of plastic or other materials under standard
conditions
Scratch fingers
No. 1
2
3
4
5
7.0
6.0
4.5
3.0
2.0
N
N
N
N
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).
RESISTANCE TO ABRASIONS
Scope:
Resistance to abrasion both interior and exterior plastic for automobile parts
Test method:
Evaluation:
- No crack, deformation and discoloration of the test specimens.
- Crimping must remain on the surface
16
23/11/54
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
Vibration
Scope of products:
All completed automotive components
Purpose:
- 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:
17
23/11/54
Vibration
Falling ball impact
Scope of Product:
- Plastic part of automobiles
18
23/11/54
Falling Ball Test
Falling Ball Test
Data need:
- Drop High, impact location
19
23/11/54
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:
FLAMMABILITY
20
23/11/54
FLAMMABILITY
FLAMMABILITY
Purpose :
Determine the capacity of plastic, fabric material and insulator with
fire testing to specifies the burning resistance.
Horizontal Flammability
Vertical Flammability
Evaluation:
Burning rate = (burning distance/burning time)
21
23/11/54
Peeling Test
Purpose:
Determine the peeling of interior trim
and leather materials
Evaluation:
Evaluate load and reflection curve
IMPACT STRENGTH OF PLASTIC
Purpose :
Determine strength of plastic materials
Impact strength shall be the arithmetical mean of each test

results and presented in kgfcm/cm.
22
23/11/54
IMPACT STRENGTH OF PLASTIC
Purpose :
Determine the impact resistance of plastic components by applying the impact to
them under specified conditions
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
specimens
i
Evaluation:
23
23/11/54
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):
Solderingg of printed
p
circuit boards (PCBs),
(
), gglass 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 OEMs requirements with small demand.
24
23/11/54
End of section
25

Auto Test

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Auto Test

Hochgeladen von

Copyright:

Verfügbare Formate

23/11/54

Automotive Components Testing

Automotive Components Testing

Design Validation Flowchart

Stress & Strain

Design Validation Flowchart

Bulk current injection closed

Bulk current injection:

Brief Voltages dip

Radiated immunity: Stripline

Power supply voltage

Conducted emission: current

Ground offset test

Radiated emissions: Antenna

Switch off de-activation

Resistance to non usual

Radiated emissions: Stripline

Immunity to radiated field semianechoic

Slow increase & decrease of

Automotive Components Testing

Process Validation Flowchart

Continuous Conformance Flowchart

Automotive Components Testing

Automotive Components Testing

Automotive Components Testing

Automotive Components Testing

Automotive Components Testing

Typical Test Parameters to Consider

Electromagnetic and Electrostatic Characteristics

Solids/ Fluids Stresses

Automotive Components Testing

Electro Magnetic Compatibility

Automotive Components Testing

Electromagnetic Compatibility Tests

Electromagnetic Compatibility Tests

ISO 7637-1/ -2/-3

ISO 7637-1Definitions & General Considerations.

Engine Controlled Module

Automotive Components Testing

This category includes tests to withstand effects of mechanical stresses such

Door Handle Load Test

Car Seat Lateral

Automotive Components Testing

This category includes tests to demonstrate component resistance to solids

High Pressure Water

Automotive Components Testing

Salt Spray Test

Salt Fog Test

Fluid Compatibility Test

Automotive Components Testing

Shock Absorber Endurance

Automotive Components Testing

Environmental and Reliability Tests

Automotive Components Testing

Temperature and Humidity Test

Automotive Components Testing

Interior or exterior parts on organic-coated product (painted)

Determine the change at low

Automotive Components Testing

Accelerated Weathering Tests

2. Controlled Temperature and Humidity

Natural Weathering Tests

Outdoor Natural Exposures

Real-time natural degradation of materials