vehicle component testing considerations for extreme ...– iso 18437 – mil std 883 confidential...

Vehicle Component Testing Considerations for Extreme Winter Conditions An Expert Overview October 8, 2015

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www.smithersrapra.com CONFIDENTIAL 2

Today’s Presenters

Biographies

Todd Hain Moderator

Brent Gruber Director – Global Automotive

J.D. Power

Sean Connolly General Manager

Smithers Winter Test Facility

Jeff Andrasik Product Testing Manager

Smithers Rapra


• Consumer opinion on vehicle reliability by Brent Gruber

• Considerations for vehicle component durability in extreme winter conditions by Jeff Andrasik

• Smithers Winter Test Center facility overview and winter tire traction testing by Sean Connolly

Agenda

Agenda

© 2015 J.D. Power and Associates, McGraw Hill Financial. All Rights Reserved. CONFIDENTIAL & PROPRIETARY—For Internal Use.

Thursday, October 8, 2015

Brent Gruber Director, Global Automotive

Vehicle Components in Extreme Cold Conditions – Consumer Perspectives

5 © 2015 J.D. Power and Associates, McGraw Hill Financial. All Rights Reserved. CONFIDENTIAL & PROPRIETARY—For Internal Use.

J.D. Power Overview


Beijing

Munich

Singapore

Tokyo

Detroit Toronto

Shanghai

Bangkok

Westlake Village

São Paulo

Mexico City

Orange

J.D. Power Mission

Starting in 1981, J.D. Power established industry benchmarks in the United States as well as many other markets for product quality and customer satisfaction.

“To be the premier source of actionable voice of the customer insights that help our clients become more profitable”


J.D. Power Automotive Intelligence Overview


Most Important Reasons for Choosing Make/Model

Source: J.D. Power 2014 U.S. IQS StudySM

49%

47%

41%

40%

40%

38%

38%

37%

34%

Expected reliability

Exterior styling

Previous brand/model experience

Ride and handling

Reputation/reviews

Price/payment

Fuel economy/range

Safety

Quality of workmanship


Historical Example: Impact of Weather Conditions on the Experience

113

120

2013

2014

Northeast

109

108

2013

2014

South 124

125

2013

2014

West

110

116

2013

2014

Midwest


Increased problem rate:

• Window defrost • Exterior trim • Wind and road noise • TPMS • Traction/handling

“Polar vortex: Frigid Arctic air again grips Midwest, nears record cold”

- CS Monitor, January 2014

“'Polar vortex' to blast frigid air over much of US”

- Yahoo News, January 2014


Historical Example: Tire Problems and Driving Experience Satisfaction

Among Driving Experience problems, Abnormal suspension noises and Tire defects are significantly higher in 2014.


Driving Experience (Non-Brake) Problem Areas 2014 PP100

2013 PP100

Abnormal suspension noises 0.8 0.7

Tire defects 0.7 0.5

Steering system/wheel—too much play/loose 0.3 0.4

Steering system/wheel—abnormal noises 0.4 0.3

Steering system/wheel—not centered (misaligned) 0.4 0.3

Vehicle pulls excessively 0.4 0.3

Vehicle/Steering wheel vibrates excessively while driving 0.3 0.2

Steering system/wheel—excessively difficult to turn 0.1 0.1

Driving Experience (Non-Brake) Problems— Total (CQR) 3.3 3.0


Historical Example: Tire Problems and Driving Experience Satisfaction

When owners experience what they perceive to be a tire defect, satisfaction with the Driving Experience attributes are significantly lower than average, particularly Quietness over harsh bumps and Smoothness of vehicle’s ride.

Source: J.D. Power 2014 U.S. APEAL StudySM

Driving Experience Satisfaction Attributes

Yes – Tire Defects

Satisfaction Rating

No – Tire Defects

Satisfaction Rating

Industry AVG

Satisfaction Rating

Quietness over harsh bumps 6.95 7.80 7.79

Vehicle ground clearance 7.15 8.01 8.01

Insulation of the cabin from wind and road noise 7.20 7.85 7.84

Smoothness of vehicle's ride 7.25 8.23 8.22

Vehicle stability in adverse conditions 7.51 8.28 8.27

Handling on curves/winding roads 7.75 8.28 8.27

Vehicle maneuverability at parking lot speeds 7.78 8.31 8.30

Braking responsiveness/effort 7.86 8.36 8.36

Steering responsiveness at moderate/high speeds 7.96 8.42 8.42

Overall rating of the vehicle's driving dynamics 7.60 8.34 8.33


Historical Example: Problem Impact on Vehicle Loyalty Among customers who reported one or more problems

31% 17% 17% 16% 14% 13% 12% 11%

23%

28%

19%

28% 25% 26%

32% 29%

0%

10%

20%

30%

40%

0%

10%

20%

30%

40%

Engine/Transmission

ACEN DrivingExperience

HVAC Seat FCD Exterior Interior

% D

efin

itely

Will

Rep

urch

ase

Vehi

cle

Mak

e

% In

dica

ting

A Ve

ry S

erio

us P

robl

em

% Respondents Indicating "A very serious problem" % Definitely Will Repurchase Vehicle Make

Among all component categories, owners who experienced one or more “very serious” Driving Experience problem(s) have the lowest likelihood that they’ll repurchase the same vehicle make. For this group, tire defects are the most problematic aspect of Driving Experience.



Ice and Snow Traction is a Top Problem

2.7

2.9

3.4

4.9

5.2

5.9

7.6

7.9

8.8

11.9

0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0

Poor Traction/Grip When Accelerating From a Stop

Vibration

Uneven Wear

Rough Ride

Poor Traction/Grip on Wet Roads

Poor Traction/Grip on Snow-Covered/Icy Roads

Fast Tread Wear

Slow Leaks

Excessive Road Noise

Road Hazard/Puncture (Hole, Curb, Nail, Glass, etc.)

PP100

Top-10 Tire Problems

Source: J.D. Power 2015 U.S. OE Tire StudySM

Northeast Midwest South West

9.4 9.7 2.5 4.5

In the Northeast and Midwest, poor tire

traction and handling on ice and snow becomes the #2 problem overall


Thank You

Brent Gruber Director, Global Automotive [email protected] 248.680.6430

Jeff Andrasik Product Testing Manager Senior Testing Engineer

Component Testing – Cold Weather Implications


• Components – Brittleness / stiffness – Expansion and contraction causing

leakage – Rupture – Fluid viscosity

• Electronics – Back up cameras, radar, etc. – Electrical connections and wiring – Sensors

• Snow ingestion • Condensation build-up resulting in rust • Corrosion due to salt water exposure

Common Failure Modes – Extreme Cold / Winter

Common Failures


Could also include: – Belts – Lights – Interior components / accessories

Components and Related Test Methods

Test Methods

Common Components Affected Related Test Methods

Hoses SAE J2044, ASTM D380, SAE J343

Seals ASTM D1414

Electronics ISO 16750, MIL STD 883

Fuel / fluid lines SAE J2044, SAE J2045

Tires ASTM F1805, UNECE R117


Test Techniques to Replicate Real World Conditions

Test Methods

Fluid Exposure Pressure

Vibration Mechanical Shock

Temperature


Temperature Cycling / Thermal Shock

Temperature Cycling / Thermal Shock

• Used to evaluate the behavior of the product when exposed to varying temperature extremes.

• An environmental chamber, capable of cycling temperature, is used during this test.

• Common test protocols: – MIL STD 202H – MIL STD 883 – SAE J2657 – ISO 16750


Vibration Combined with Temperature

Vibration Tests

• Temperature-controlled vibration evaluations are used to simulate how a component is affected when flexed or shaken under specific climatic conditions

• Utilize vibration and thermal test chambers to simulate extreme cold (or hot) temperatures

• Common test protocols: – DEF STAN 00-35 – ISO 16750


Mechanical Shock and Temperature

Mechanical Shock and Temperature

• Used to evaluate the durability or fragility of a product

• Utilize shock and vibration test

systems

• Common test protocols: – ISO 18437 – MIL STD 883


Pressure Testing

Pressure Testing

There are 3 common pressure tests used to verify the product and its assemblies comply to a specified pressure range:

– Static (aka Leak Checks or Proof Tests) – Requires you to apply pressure up to MWAP to verify the product will not rupture and does not leak.

– Impulse – Designed to produce a high pressure / low pressure effect on the assembly to simulate power being turned on and off.

– Burst – Requires a constant increase in pressure inside a product assembly (such as a hose) until failure occurs. This determines the Safety Factor Ratio.


Fluid Exposure Testing

Fluid Exposure

Fluid exposure testing is usually done on the finished material. Studies are performed to confirm that the material / product can withstand prolonged exposure with the fluid.

Typical Testing Protocol for fluid exposure - ASTM D471


Considerations for Test Setup

Test Setup Considerations

Setup Variable Consideration Orientation Should the part be arranged the same way

that it sits during operation?

Flow What is the flow rate on the pump? Direction of flow can affect performance

Torque What is the torque on the tightening of the fittings, clamps, etc.?

Abrasion While in service, is abrasion a factor?


Test Setup Considerations

Setup Variable Consideration Leaks Are leaks occurring at certain temperatures or

pressures?

Motion Should the part be moving during operation? Are other elements around it moving? Should they be moving?

Fluid exposure What are the specifications on the type of fluid(s) that are used during operation?

Considerations for Test Setup (continued…)


Testing in a controlled laboratory environment can be effective however... • Extreme conditions could introduce other variables that in-lab

testing does not replicate.

• On-vehicle testing is a good way to uncover those other variables.

• May consider conducting a material benchmarking study as a way to evaluate:

– Changing variables (pressure, temperature…) – Changing components

Other Considerations Beyond the Spec

Other Considerations

Sean Connolly General Manager, Smithers Winter Test Center

Winter On-Vehicle Testing – Tire & Vehicle System Testing Implications


First in Class Winter Test Facility Upper Peninsula, Michigan USA

Smithers Winter Test Center


Smithers Winter Test Center (Brimley, Michigan)


Smithers 700-acre facility offers a variety of courses and surfaces for standard and custom test evaluations. Custom surfaces include

– Snow fields, Ice pads, Snow handling courses, Deep snow areas

Split mu (coefficient) surfaces – Slopes – 10%, 15%, 20%, 30% split mu for traction control

– Circles – multiple ice and snow circles

– Straights – alternating mu and split mu surfaces` Smithers Expertise:

– 40 years of test development, course prep and maintenance




Why do we need all the different surfaces for testing? Facility Uses:

– Subjective and data driven vehicle evaluations

– Vehicle safety systems

• Electronic Stability Control (ESC)

– Antilock Braking Systems (ABS)

• Advanced Driver Assistance Systems (ADAS)

– Sensors

– Cameras

– Autonomous Vehicles




Facility Uses Continued.. – Powertrain/Drivetrain systems

• Engine, transmission, and axles

– Winter durability and reliability testing

• Cold-start testing

• Batteries, oil, transmission, other fluids

• Snow ingestion

– Not just limited to passenger vehicles

• Military, OTR mining, construction equipment, ATV

• Commercial products

– Snow blowers


Tire testing on passenger vehicles and trucks

Winter Tire Test Methods and Requirements

Published snow traction standards: – ASTM F1805 Driving Traction Test

– ECE R117 C1-C2 Braking Test

– ― ECE R117 C3 (Truck) Driving test


F1805 Driving Traction Test – Procedure


Straight line test on snow or ice with load: • Requires a modified vehicle

• Groom surface (CTI Index of 70-80)

• Temperature

– Ambient below 3°C (38°F)

– With a surface temperature of -15°C (5°F) Min -4°C (25°F) max

• Load is 74% of the tire rated load

• Test speed = 8 km/h (5 mph)


F1805 Driving Traction Test – Procedure continued..


• Test tire is part of a group

– SRTT control tire

– Test tire

– Test sequence= C1,T1,T2, C1

• Free spinning to controlled accelerated rate

• Test ends with the tire spinning 4x speed vehicle is traveling

• Engine returns to idle

• Test consist of a minimum of 10 spins per tire

• Test repeats

• Tested over 3 different days


F1805 Driving Traction Test – Vehicle


• Self-contained test vehicle modified to run the F1805 test • Drives at 5 mph (8 km/h)

• Applies increasing driving torque to test wheel (other wheels braked)

• Test wheel measures:

– Vertical force

– Traction force

– Spinning speed

• Dedicated computer

program/instrumentation


F1805 Driving Traction Test – Vehicle


• Dedicated vehicle modified for a wide range of loads and tire sizes:

– Tire loads from 650 to 1,600 pounds

– Rim diameters from 13” to 22”

• Encoders to measure vehicle/wheel speeds

• Two-axis load cell

• Automatic throttle control

• On-board jacks for tire change

• Adjustable suspension for leveling

• Removable weights

• No fenders


F1805 Driving Traction Test – Mountain Snowflake


• Mountain Snowflake requires tires to perform at >110% of SRTT

• True snow tires can be 130-150%

• Many all-season tires won’t make it

• Most LT tires won’t make it


ECE R117 Braking Test - Procedure


• Vehicle deceleration test

• Standard production vehicle

• Groom surface (CTI Index of 75-85)

• Temperature – Ambient between -15°C (5°F) and -2°C (28°F)

– With a surface temperature between -15°C (5°F) and 4°C (39°F)

• Load – 60%-90% of the tire rated load for C1 tires

– 60%-100% of the tire rated load for C2 tires

• Test speed = 9-24 km/h (6-15 mph)


ECE R117 Braking Test – Procedure continued..


• Test tire is part of a group

– SRTT control tire

– Test tire

– Test sequence= C1,T1,C1 or C1,T1.T2,C1

• Vehicle runs up to designated speed, car shifts into neutral, brakes

are applied (Engage ABS)

• Stable deceleration to less than 8km/h (12 mph)

• Test consist of a minimum of 6 test

• Test repeats

• Tested over 2 different days


ECE R117 Braking Test - Vehicle


Test vehicle: Standard Production Vehicle

• Uses vehicle’s ABS

• Instrumentation to measure speed

and deceleration rate

• All four positions must have test

tires (F1805 requires one tire)

• Test tire deceleration is compared

against SRTT deceleration


R117 Braking Test vs. ASTM F1805


R117 Braking Test ASTM F1805

Measured Parameter Vehicle Deceleration Driving Force / Load

Snow CTI Index 75 - 85 70 - 80

Load C1: 60-90% rated C2: 60-100% rated

74% rated

Inflation C1: 35 psi for all tires C2: Depends on load

Depends on rated pressure

# events / test 6 10 / 8

# repeats 2 3 or more

Mountain Snowflake criterion

C1: 107% of SRTT14 C2: 102% of SRTT16C

110% of SRTT14

Test speed 6 – 15 mph 5 mph

% Slip <20% 40 - 300%


Related Traction Testing Webinar

Click to download audio file for “Winter Tire Traction Test Methods and

Requirements” webinar

https://smithersinformation.webex.com/smithersinformation/lsr.php?RCID=dee7c8e1feaf7108e20c6dd723d05bb1

Questions?


J.D. Power

Brent Gruber Director, Global Automotive [email protected] 248.680.6430

Smithers Rapra 425 West Market Street Akron, OH 44303 USA www.smithersrapra.com

Jeff Andrasik Product Testing Manager Senior Test Engineer 330.762.7441 [email protected]

Sean Connolly General Manager Smithers Winter Test Center 330.762.7441 [email protected]

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