Automotive Components Testing

Automotive&Components Testing_Part 1
Automotive Components Testing

Presented By:
Mr. Chanachai Marangsri
Introduction
Objective of components testing:
Th e t es t s r eq u ir ed t o va lid a t e a p r o d u ct t h a t will
s im
i u la
l t e t h e s t r es s es an d exp o s u r es r ela
l t ed
d t o it
i s
in t en d ed en vir on m en t . (ISO 9 0 0 1 )
Tes t s a r e r eq u ir ed t o b e ca r r ied ou t in t h e Des ign
Valid a t io n (DV) s t a ge a n d t h en in t h e Pr o ces s Va lid a t ion
(PV) s t a ge. (ISO9 0 0 1 a n d TS/ ISO 1 6 9 4 9 )
Co n t in u ou s Co n fo r m a n ce Tes t s m a yb e r eq u ir ed d u r in g
n or m al p r o d u ct io n
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
Gray
y 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
Radiated emissions: Antenna
method
Radiated emissions: Stripline
test
Magnetic field emission
Transient immunity
Durability
Humidity
Cycles
Dust test
Humidity soak
Technical
Characterization
Cranking
Immunity to radiated field semianechoic
Conducted RF emission
Thermal Characterization
Sinusoidal
vibration
Thermal shocks
Spraying Water
Resistance to
storage
Resistance to non usual

battery voltage
Handling drop
Technical
characterization
Voltage offset se
Condensation
Ground offset test
Resistance to dynamic
shock
Switch off de-activation

test
Resistance to brief
supply failures
Slow increase & decrease of
supply voltage
Resistance to ground & positive
supply short circuit
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
List of components
Press Parts
List of components
Interior Trims
List of components
Engine component
List of components
Typical Test Parameters to Consider
Elect rical Ch a ract eris t ics
Elect ro m a gn et ic an d Elect ro s t at ic Ch ara ct eris t ics
Cli a t ic
Clim
i St
S res s es
Mech an ica l St ress es
So lid s / Flu id s St res ses
Ch em ical St ress es
Du rab ilit y Tes t
Fla m m a bilit y
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
Electromagnetic Compatibility Tests

Aut omotive EMC Test ing (Electronic Systems)
Elect rom agnetic Em ission Measurem ent s
(Radiat ed/ Conduct ed)
Harm onics Em ission and Volt age Fluct uat
uation
ion
Test ing
Elect rom agnet ic Suscept ibilit y Measurem ent s
(Radio Receivers)
Elect rost at ic Discharge Im m unit y Test ing
RF Radiat ed Im m unit y Test ing
Elect rical Fast Transient / Burst Im m unit y
Test ing
Volt age Surge Im m unit y Test ing
Conduct ed Dist urbance Im m unit y Test ing
Magnet ic Em issions and Im m unit y
Mains Volt age Variat ions/ Int errupt ions
Im m unit y Test ing
Electromagnetic Compatibility Tests

Automotive EMC Test ing (Electronic Systems)
available standards for EMC
CISPR 25
Radiat ed Em issions
Conduct ed Em issions
ISO 7637- 1/ - 2/ - 3
ISO 7637- 1Def init ions & General Considerat ions.
ISO 7637- 2 (12V & 24V Supply Lines) Test Pulses
1a, 1b, 2, 3a, 3b, 4, 5a, 5b.
ISO 7637- 3 (Ot her Lines) Test Pulses 3a, 3b via
Coupling Clam p.
Applications
Engine Cont rolled Module
Car audio syst em
Elect rical Cont rol Unit e (ECU)
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
Component Testing
Solids / Fluids Stresses
This category includes tests to demonstrate component resistance to solids

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

Spray Test
Component Testing
Chemical Stresses
Th is cat egory in clu d es t es t s t o d em on st ra t e com p o n en t res is t a n ce
t o corro sive en viron m en t cau sed by t h e p res en ce of cert a in gas es
an d flu id s - s u ch as ga so lin e/ en gin e o il for u n d er-h oo d lo cat io n s
a n d coffee/ cola for cab in co m p art m en t locat ion s.
Sa lt Sp r a y Tes t
Sa lt Fo g Tes t
Flu id Co m p a t ib ilit y Te s t
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 . Op er at in g Tem p er a t u r e/ Hu m id it y
2 . St or a ge Tem p er a t u r e/ Hu m id it y
3 . Alt it u d e Tes t
4 . Th er m al s h o ck / cyclin g
5 . En vir o n m en t a l St r es s Scr een in g
6 . Bias ed Power Tem p er at u r e Cyclin g
7 . In gr es s p r o t ect io n
10
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:
Ab n orm alit ies in con figu rat io n , siz e, a p p eara n ce, co lo r t on e o f
t h e s am p le s u rfa ce p ro p er t ies
E m p le:
Exa
l a cycle
l off h ea t an d h u m id iit y;
11
Thermal Shock
Product scope:
o
In t er ior or ext er ior p a rt s on or ga n ic-coa t ed p r od u ct (p a in t ed )
Purpose:
o
Det er m in e t h e ch a n ge a t low
a n d h igh t em p era t u r e cycles
a n d vis u a l in s p ect ion ;
No vis ible d is t or t ion , ch a n ge of color, d is color a t ion , d efor m at ion ,
t ea r s , cr acks , p eelin g off, t ack, h a rd n es s ch a n ge et c.
No loos en in g of fa s t en er, ca u lkin g a n d s o on .
No d eform at ion r es u lt in g in fu n ct ion al d is t u rb an ce of in t er n al
com p on en t .
Accelerated Weathering Tests
Accelerated Weat hering

1. UV Ex posures (UV- A and B)
Polym er Durabilit y
Body paint work
Rubber Weat herst rips & Adhesives
2. Controlled Temperat ure and Humidit y

Conditions
Durabilit y of aut om ot ive int erior m at erials
Therm al shock resistance
Elect ronic part s & com ponent s failure
Electronic
Met hods(ASTM ,ISO, SAE, MIL, JASO)
Applications
Dash- board, Rubber seals, Hoses, Plastic parts, Adhesives, Sun- block
Film s and Accessories, Autom otive topcoats
12
Natural Weathering Tests
Ou t d oor Nat u r al Exp os u r es

Re a l-t im e n a t u r a l d egr a d a t io n o f m a t er ia ls
H r s h t r o p ical
Ha
i l clim
li a t e co n d it iio n s
PSB Te s t s it e is p a r t o f t h e ATLAS, Flo r id a (US)
wo rld wid e t es t s it es
Met h o d s (ASTM, SAE)
Ap p lica t ion s
Na t u r a l Wea t h er in g Exp o s u r e
Glo s s d u rraabbilit
ilit y of a u t om ot ive
i e t op coa t
St a t ic exp os u r e of p olym er ic p ar t s a n d p an els
Accelerated Weathering Tests

1 . XENON ARC EXPOSURES
Acceler at ed a gin g t es t of m a t er ia ls
(u p t o 3 Su n s )
Los s of glos s (t op coat )
Colou r fad in g
Po lym er failu r e
2 . SOLAR CLIMATIC CHAMBER

Du r ab ilit y of lar ge p ar t s an d
a u t om ot ive com p on en t s
Fin is h ed p r od u ct p erfo rm a n ce
eva lu at io n aft er t es t
Pe rform a n ce of d iffer en t p r od u ct
d es ign s aft er t es t
Alpha accelerated
weatherometer
Solar Climatic
Chamber
Ap p licat io n s
Ru b
bbber
er m at er ials
ia ls a n d s ea
eals
ls
Wea t h er-s t rip s
Pla s t ics an d t op coa t s
Lea t h er s eat s (ligh t fas t n es s )
Select io n of m a t er ia ls
13
Xenon /Carbon Arc Weatherometer

Sample of Test condition:
In t er io r Tr im
Salt Spray Test

De t erm in e t h e res is t a n ce of metals, metallic and other protective coating to
corrosive atmospheres by salt spray fog test.
14
Salt Spray Test

Data Needed:
o
o
Nu m ber of Hou rs of Sa lt Sp r ay
Co n d it ion of p a rt s aft er Salt Sp r ay Exp os u r e
Evaluation:
No ch an ge of t h e s u r fa ce
Co rr os ion of coat in g allo wed bu t
n o t cor ros ion of t h e b as e m at er ia l.
o Fin is h ed p ar t s a re t o exh ib it n o
r e d rru
u s t wors
wor s e t h aan
n s p ecificat ion
o
o
Salt Fog Test

Scope of products:
all in t erior t rim m at eria ls (excep t fo r t h e m et a l)
for a u t om ob iles .
Purpose:
Measuring the volatizing trend of organic constituents
of interior trim materials used for automobiles.
Evaluation:
Ca lcu lat e t h e reflect an ce m eas
Calcu
ea su
u red at
a t 4 p o in t s o
off t h e gla s s p lat
la t e
15
RESISTANCE TO SCRATCHING
Scope:
Re s is t a n ce t o s cr a t ch in g o n s u r fa ce s o f p la s t ic o r o t h e r m a t e ria ls u n d er s t a n d a rd
co n d it io n s
Scratch fingers
No . 1
2
3
4
5
7 .0
6 .0
4 .5
3 .0
2 .0
N
N
N
N
N
Evaluation:
Sk y d a y ligh t fo r exa m in e a ll s cr a t ch lin e s a cco r d in g t o a Ra t in g Sca le 1 t o 5 (1 =
n o s cr a t ch lin e a t a ll; 5 = s ever e s cr a t ch lin e ).
RESISTANCE TO ABRASIONS
Scope:
Re s is t a n ce t o a b r a s io n b o t h in t er io r a n d ext er io r p la s t ic fo r a u t o m o b ile p a r t s
Tes t m et h od :
Evaluation:
- No cr a ck , d e fo r m a t io n a n d d is co lo r a t io n o f t h e t e s t s p ecim en s .
- Cr im p in g m u s t r e m a in o n t h e s u r fa ce
16
ODOR FROM INTERIOR TRIM

Scope:
De t er m in e t h e od or or igin a t in g fr om
in t erior t r im m at er ia ls / com p o n en t s /
a s s em blies in t h e p as s en ger or
lu ggage co m p a rt m en t
Evaluation: o d o u r Ra t in g
1 . No o d ou r
2 . Det ect a b le, b u t n ot d is t u r bin g
3 . Dis t u rb in g
4 . Ext r em ely d is t u r bin g
5 . Ob n oxio u s
6 . Un bea ra b le
Vibration
Scope of products:
All com p let ed a u t om ot ive co m p on en t s
Purpose:
- evalu
eva lu a t e t h e ca
capp aab
b ilit y of p aarrtt
even t in s t a lled t o t h e veh icle a n d a re vib ra t ed .
Evaluation:
- No cr ack, b rea ks , d efor m a t ion or s u ch loos e
fas t en er an d cau lkin g a s t o d is t u rb in t ern a l com p on en t s
Sample of condition:
17
Vibration
Falling ball impact
Scope of Product:
- Plas t ic p a rt of a u t om ob iles
18
Falling Ball Test
Falling Ball Test
Da t a n eed :
- Dro p High , im p a ct lo cat io n
19
FLAMMABILITY
Scope of products:
Det erm in e t h e fla m m ab ilit y of in t erior t rim m at erials u s ed in t h e
o ccu p a n t com p art m en t o f veh icles
Purpose:
Det erm in in g t h e h o riz o n t al bu rn r at e o f m a t erials a t t h e a ir a n d
b e n orm ally o n ly ap p licab le t o in t erior t rim m at erials o f wh ich
a n y p ort io n is wit h in 1 3m m of t h e o ccu p an t co m p art m en t a ir
s p ace.
Facilities:
FLAMMABILITY
20
FLAMMABILITY
FLAMMABILITY
Purpose :
Det er m in e t h e cap a cit y of p la s t ic, fa b ric m a t eria l a n d in s u lat or wit h
fir e t e st in g t o sp ecifies t h e b u rn in g res is t a n ce.
Horizontal Flammability
Vertical Flammability
Evaluation:
Burning rate = (burning distance/burning time)
21
Peeling Test
Purpose:
Det erm in e t h e p eelin g of in t erior t rim
a n d leat h er m a t eria ls
Evaluation:
Eva lu a t e loa d an d reflect io n cu rve
IMPACT STRENGTH OF PLASTIC
Purpose :
Det er m in e s t ren gt h o f p las t ic m at erials
Im p act st ren gt h sh all b e t h e arit h m et ical m ea n of ea ch t est

r es u lt s a n d p res en t ed in kgf cm / cm .
22
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 :
Det er m in e t h e s t ren gt h an d d eform at io n ch a ract erist ics of p las t ic
t es t s p ecim en s wh en flexu ral lo ad s are a p p lied on p la s t ic t es t
s p ecim
i en s
Evaluation:
23
Hazardous substance test
Purpose :
It is t h e req u irem en t fo r sp ecifie s t h e con t a in o f 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):
Soldering
g of printed
p
circuit boards ((PCBs),
), g
glass 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
End of section
25

Automotive Components Testing

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Automotive&Components Testing_Part 1