components testing sut

Automotive&Components Testing_Part 1 23/11/54

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Automotive Components Testing

Presented By:Mr. Chanachai Marangsri


Introduction

Objective of components testing:

• The tests required to validate a product that will i l h d l d isimulate the stresses and exposures related to its

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


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Design Validation Flowchart

Mechanical Parts

M l N lMetal Non-metal

Strength

Tensile Stress

Bending test

Natural Rubber Synthesis Rubber

Viscosity

Stress & Strain

Weathering

Gray scale


Bending test

Torsion

Salt Spray

Ozone

Rain

Spring rate

y

Flammability

Design Validation Flowchart

Electrical Characterization

Resistance to Electro Static Discharge

Bulk current injection closed loop

Bulk current injection:

Dielectric strength

Insulation Durability Humidity Cycles

Humidity soak Technical Characterization

Thermal Characterization Dust test

Immunity to radiated field semi-anechoic

Brief Voltages dip

Bulk current injection: substitution method Cranking

Sinusoidal vibration

Thermal shocks Spraying Water

Radiated immunity: Stripline test

Conducted RF emission

Conducted emission: current probe method

Measurement of conducted transient

Power supply voltage ripple

Resistance to non usual battery voltage

Voltage offset se

Ground offset test

Thermal Characterization Handling drop

Resistance to storage

Technical characterization

Condensation


Radiated emissions: Antenna method

Radiated emissions: Stripline test

Magnetic field emission

Transient immunity

Switch off de-activation test

Resistance to brief supply failures

Slow increase & decrease of supply voltage

Resistance to ground & positive supply short circuit

Resistance to dynamic shock



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Process Validation Flowchart


Thermal Characterization Dust test

ASIA:HeadquartersTÜV SÜD Asia Pacific Pte. Ltd. Singapore

Durability Humidity Cycles

Humidity soak Technical Characterization

Sinusoidal vibration

Thermal shocks Spraying Water

Thermal Characterization Handling drop

Resistance to storage

Technical h t i ti

AMERICAS:HeadquartersTÜV SÜD America Inc. Danvers, Massachusetts

EUROPE:HeadquartersTÜV SÜD AG Munich, Germany

characterization

Condensation

Resistance to dynamic shock



Continuous Conformance Flowchart


Durability Thermal Shock Humidity 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

• Electromagnetic and Electrostatic Characteristics

Cli i S• Climatic Stresses

• Mechanical Stresses

• Solids/ Fluids Stresses

• Chemical Stresses

• Durability Test


• 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 etcetc.


EMC Chambers


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Electromagnetic Compatibility Tests

• Electromagnetic Emission Measurements (Radiated/Conducted)

• Harmonics Emission and Voltage Fluctuation

Automotive EMC Testing (Electronic Systems)

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)



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Component Testing

Climatic Stresses

• This category includes tests to demonstrate compatibility with climatic stresses such as temperature, humidity and solar radiation.

Xenon Arc Weatherometer

Solar Climatic Chamber

Combined Environmental Chamber and Vibration

Tester

Temperature/ Humidity Chambers


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.


Steering Wheel Vibration Test

Car Seat Lateral Vibration 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 solids d fl id h d t t d iand fluids such as dust, water and rain.


Dust Test Rain Test High Pressure Water Spray Test

Water Submergence

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


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Component Testing

Durability Test

• This category includes tests to demonstrate the components’ durability, fatigue strength and reliability.


Car Horn Endurance Test

Shock Absorber Endurance Test

Switch Endurance Test

Master Brake Cylinder Cyclic Actuation 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


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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:Abnormalities in configuration, size, appearance, color tone of the sample surface properties

E l l f h d h idi• Example: a cycle of heat and humidity;

•Automotive Components Testing


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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 Weathering1. 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


• Electronic parts & components failure • Methods(ASTM ,ISO, SAE, MIL, JASO)

ApplicationsDash-board, Rubber seals, Hoses, Plastic parts, Adhesives, Sun-block Films and Accessories, Automotive topcoats


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Natural Weathering Tests

Outdoor Natural Exposures• Real-time natural degradation of materials

H h t i l li t diti• Harsh tropical climate conditions

• PSB Test site is part of the ATLAS, Florida (US) worldwide test sites

• Methods (ASTM, SAE)

Applications

Gloss d rabilit of a tomoti e topcoat

Natural Weathering Exposure


• Gloss durability of automotive 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

Applications

• Rubber materials and seals

Alpha accelerated weatherometer

Solar Climatic Chamber


• Finished product performance evaluation after test

• Performance of different product designs after test

• Selection of materials

• Rubber materials and seals

• Weather-strips

• Plastics and topcoats

• Leather seats (light fastness)


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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.



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Salt Spray Test

Data Needed:

o Number of Hours of Salt Spray

o Condition of parts after Salt Spray Exposure

Evaluation:

o No change of the surface

o Corrosion of coating allowed but

not corrosion of the base material.

o Finished parts are to exhibit no

red rust worse than specificationred rust worse than specification


Scope of products:• all interior trim materials (except for the metal)

for automobiles.

Salt Fog Test

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 plateCalculate the reflectance measured at 4 points of the glass plate



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• Scope:

Resistance to scratching on surfaces of plastic or other materials under standard conditions

RESISTANCE TO SCRATCHING

• Scratch fingers 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 examine all scratch lines according to a Rating Scale 1 to 5 (1 = no scratch line at all; 5 = severe scratch line).


• Scope:

Resistance to abrasion both interior and exterior plastic for automobile parts

RESISTANCE TO ABRASIONS

• Test method:

• Evaluation:

- No crack, deformation and discoloration of the test specimens.

- Crimping must remain on the surface



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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- 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:



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Vibration


Falling ball impact

Scope of Product:- Plastic part of automobiles



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Falling Ball Test


Falling Ball Test

• Data need:

- Drop High, impact location



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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



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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)


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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 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 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

ispecimens

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 boardsMercury (Hg):thermostats, sensors, relays in switches and discharge lampsLead (Pb):Soldering of printed circuit boards (PCB’s), glass for cathode


g p ( ), gray tubes and light bulbsHexavalent 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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components testing sut

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