Formula 1 for Quality direct from the Factory

Environmental Simulation Technology for Functional Testing and Safety in the Automotive Industry

Weiss Umwelttechnik GmbHSimulationsanlagen • Messtechnik

The Key to Quality and Safety

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The good reputation of a make of caris the culmination of a multitude ofadvantageous features and – verifiable– marks of quality.Throughout the world, the motoristplaces high demands on driving perfor-mance, comfort and safety.

And because vehicles more than anyother mass-produced product areexposed to changing environmentalinfluences, reliability, service life andoperational reliability play an extremelyimportant role because a vehiclepacked full with electronics, essentialmechanical components and efficienttechnology is susceptible to just asmany risks of failure.

We at Weiss possess the environmen-tal simulation technology for all thatconcerns the automobile: Standardtesting and special testing systems forcorrosion and weathering, for testingelectrical, electronic and mechanicalcomponents and systems of all sizesand design capacities for motors andemission tests.

If it is a question of ensuring that onlytested quality is produced in series,then contact Weiss Umwelttechnik.

We will give you extensive consulta-tion, undertake project planning andinstall testing systems which give youthe reliabiltiy and safety you require:Individual special solutions based onwell-tried components according tonational and international guidelinesand laws for environmental simulationtechnology in the manufacturing ofautomobiles.Environmental simulation technologywhich has been a fixed constituent ofquality management of many renown-ed manufacturers for many years.

EnvironmentalSimulationTechnology for Professionals.

Communication

Radio, board computer, mobile radiotelephone, control and information sys-tems . . .

Comfort

Heating, air conditioning, doorlock con-trol, cruise control . . .

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Durability

Lacquer, metals, plastics, rims . . .

Safety

ABS, electronic stability programme(ESP), steering mechanism, airbag,belt tensioning, light system . . .

Drive Technology

Engine and electronics, speed andexhaust control, gear and gear control,chassis . . .

Engine and Emission Tests

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Weiss SHEDChambers. . .

In addition to exhaust emissions causedby traffic, hydrocarbon vapours arealso emitted when refuelling tank sys-tems and by the vehicle itself.

Due to the globalisation of the auto-mobile industry, the strict regulations ofthe American Environmental ProtectionAuthorities EPA and CARB have foundworld-wide recognition in the specifica-tions defining the requirements of envi-ronmental simulation technology.

The SHED chambers of Weiss Um-welttechnik which can be temperatureconditioned comply with these require-ments.

Many leading automobile manufac-turers and renowned suppliers repeat-edly choose Weiss environmentalsimulation technology for very goodreasons. Not least because Weiss Umwelt-technik is one of the leading manufac-turers of testing systems world-wide.

RL SHED Chamber

The RL SHED chamber for determin-ing the emission of fuel evaporationduring driving. The system consists ofdriver instructor unit with ceilingmounted monitor, a dynamometer, vol-ume compensation with Tedlar foil ormovable ceiling, analyser, softwareand special airtight door.

Test chamber volume: 95 m3

Temperature range: +15 . . . +45 °CTemperature constancy: ±1 K

. . .Special Testing Systems

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ORVR SHEDChamber

These chambers are used for OnboardRefuelling Vapour Recovery testing(ORVR). A vehicle located in the cham-ber is refuelled from the outside viahermetic port holes in the chamber wall.The HC emissions generated in theprocess are determined and assessed.The fuel required is provided by a fuelconditioning system at the temperatureand volume flow rate required.

Test space volume: approx. 60 m3

Test temperature: +27 °C

VT SHED Chamber

VT SHED chambers for evaporativedetermination on motor vehicles inaccordance with EPA, CARB and EUregulations. A main feature is volumecompensation with tedlar bag or mov-able ceiling enabling temperatureprofiles to be performed with an her-metically sealed chamber without a dif-ferential pressure to ambient.

Test space volume: approx. 60 m3

Temperature range: +15 . . . +45 °C

Special Testing Systems...

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Climate TestChamber with 4-wheel-driveDynamometer andSunlight Simulation

These chambers are used for emissiontesting in accordance with Europeanand American regulations.

Besides the sunlight simulation systemfor SFTP tests these chambers areadditionally equipped with an air make-up unit, a wind speed fan and fuel tankheating by hot air blowing onto thetank surface.

Test space volume: approx. 502 m3

Temperature range: –20 . . . +50 °CClimate range: +10 . . . +35 °CHumidity range: 5.5 . . .15.5 gH2O/kg dry air, max. 75 % r.h.

Climate TestChamber withDynamometer

These chambers are used for emissiontesting in accordance with Europeanand American regulations.

Test space volume: approx. 579 m3

Temperature range: –20 . . . +35 °CClimate range: +10 . . . +35 °CHumidity range: 5.5 . . .12 gH2O/kg dry air

. . .Special Testing Systems

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VT Mini SHEDChamber

VT Mini SHED Chambers are used forpermeation tests in fuel tanks or forHC emission tests in vehicle compo-nents carrying fuel.In addition to the explosion-proof testspace, the equipment comprises a vol-ume compensation device, an ana-lyser, lighting, a window, a refuellingport as well as purging and safetyequipment.

Test space volume: 2.6 m3

Temperature range: +15 . . . +80 °CTemperature constancy: ±1 K

Altitude SimulationChamber

The Altitude Simulation Chamber isused for measurement of performance,exhaust emission and fuel consump-tion of combustion engines at differentaltitudes.

Test space volume: approx. 138 m3

Temperature range: –40 . . . +50 °CPressure range: 715 . . .1100 mbarAltitude range: up to 3000 m above

sea level

Fuel ConditioningSystem

Fuel conditioning systems are used tocarry out ORVR refuelling in vehiclesin compliance with legal regulationsand to test vehicle tanks.In addition to the supply tank the maincomponents comprise various gasolinenozzles, active and passive gas vapourrecovery, pre-pay function, etc.

Tank volume: up to 200 lTemperature range: +5 . . . +45 °CVolume flow: up to 80 l/min.

Corrosion Testing

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Extreme Environmental Influences on Motor Vehicles. . .

Damp, cold, heat, de-icing salt, nox-ious gases and global radiation: Every-where and in all seasons, motorvehicles are subject to environmentalinfluences. The effectiveness of corro-sion preventive measures is a qualityfeature which plays a decisive role inthe automobile industry today when avehicle is purchased.

Walk-in Salt SprayTest Chambers

Walk-in salt spray test chambersfor performing corrosion tests as pere.g. DIN 50 021 and DIN 50 017.Also suitable for long-term tests.

Test space volume: 7.5 m3

Temperature range: AT. . . +50 °CTemperature constancy: ±2 K

Combined CorrosionTesting System

For vibration, climate and corrosiontesting of axles, half axles and parts of axles. The operating reliability testbench enables the combination of thetest parameters – temperature, humidi-ty, corrosion with NaCl, CaCl and MgClsolutions with simultaneous vibration inthe x, y and z axes.

Temperature range: – 40 . . . +130 °CClimate range: +15 . . . +90 °CHumidity range: 10 . . . 80 % r.h.Amplitude of the vibration system:max. ±150 mmTest space volume: 13.6 m3

The very combination of numerousenvironmental influences means thatvirtually all exposed vehile compo-nents are subject to high amounts ofpollution. On the other hand, thedemands on durability and for longerperiods of warranty are increasing. Thecontinuous inspection and optimisationof protective measures is thus impera-tive for assuring quality and competi-tive advantages.

Weiss Umwelttechnik has an extensiverange of systems and processes forimplementing short-term weatheringand corrosion tests, alternating climateand noxious gas tests in accordancewith generally valid standards or cus-tomer-specific test specifications.

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. . .Standard Testing Systems

Salt Spray/Alternating ClimateTesting Chamber

For performing corrosion tests andtesting the anti-corrosive resistance ofmotor vehicle lacquers under exposureto cyclically alternating conditions.

The salt spray chambers of the seriesSC/KWT are an outstanding examplefor profitability, wide application rangeand trendsetting environmental simula-tion technology.

They enable reproducible corrosiontests as per DIN, ISO, ASTM, DEF,MIL-STD and can be upgraded, if re-quired, to an alternating climate testingsystem with individually programmablelong-term cycles.

Well devised details such as the pro-gram editor for up to 100 testing pro-grams, the fully automatic recordingand display of the rainfall rate or thesturdy construction of absolutely corro-sion-resistant polyethylene are evi-dence of the above-average standardof Weiss Umwelttechnik testing sys-tems. An air conditionig unit – availableas option – allows test cycles with con-trolled air humidity, automatically alter-nating cycles with salt mist and con-densation.

Global UV Testing System(Type BAM)

For the reproducible weathering test ofpolymer materials e.g. plastics, coat-ings or car lacquers in the entire natur-al temperature and humidity range.

The simultaneous effect of UV radia-tion, temperature, humidity, (acid) rainand their diurnal variations are deci-sive factors for the premature ageingof polymer materials. The global UVtesting system, Type UV200 was devel-oped in cooperation with the FederalAgency for Materials Testing andenables real-life simulation of weather-ing effects in a working range of– 20 . . . + 80 °C and up to 95 % relativehumidity.

Radiation is in accordance with the rel-evant regulations in the wavelengthrange of 290 nm to 450 nm so that thereaction to sensitive materials can betested.

The unit has a program memory for100 programs plus an integrated moni-toring system which provides informa-tion on operating faults and recordsthe machine operating times and num-ber of which actuations of individualcomponents.

Appropriate interfaces and configura-tion modules are available for docu-menting and for integrating in hosttesting systems.

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Endurance Strength Testing

Cold-Heat ClimateTest Chamber withRoad Simulator andSunlight Simulation

For multiple component testing of com-plete vehicle bodies under realisticoperational stress in combination withthe environmental influences of tem-perature, humidity and solar radiation.

Test space volume: 480 m3

Temperature range: – 40 . . . + 90 °CClimate range: +10. . . + 80 °C Dewpoint temperature range:+ 5 . . . + 59 °C*

*limited by sunlight simulation

Endurance StrengthTest Stand

The Endurance Strength Test is perform-ed by fixing specimens onto a 2 x 2 mtest bench in the temperature testchamber. This is dynamically stressedunder temperature influences via hy-draulic servo actuators. Conditionedair is supplied into the test chamberthrough ducts from a remote condition-ing system.

Test space: 15 m3

Temperature range: – 40 . . . +150 °C

© IABG 2004

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. . .Special Testing Systems

Cold-Heat ClimateTest Chamber withMultiaxis VibrationTable

For temperature and climate condition-ing of specimens fixed on a multiaxisvibration table which provides transla-tive and rotary motion in three axes.To compensate for the table motion andthe associated volumatic change of thetest space and also to isolate the vibra-tion from the conditioning system spe-cial flexible insulating walls are used.

Test space volume: 14 m3

Temperature range: – 30 . . . + 90 °CClimate range: + 20 . . . + 60 °C*Dewpoint temperature range:+10 . . . + 55 °C*

Cold-Heat ClimateTest Chamber witha 4 Poster Systemand SunlightSimulation

These chambers are used for com-bined tests with road conditions andenvironmental influences such as tem-perature, humidity and sunlight (Squeakand Rattle Tests).

Test space volume: 304 m3

Temperature range: – 40 . . . + 80 °CClimate range: + 5 . . . + 80 °C*Humidity range: 20 . . . 80 % r.h.

*limited by sunlight simulation

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Electronics Testing

Testing Electricaland ElectronicComponents

Today electronics dominate almost allsectors of automobile manufacture:Safety equipment, comfort features,motor function – from exhaust controlto ignition, everything is electronicallycontrolled.

Whether ABS, ESP or antiskid device,mobile radio telephone, board comput-er, air conditioning system or doorlockcontrol: sensors, microcomputers and otherelectronic components ensure safety,reduce environmental pollution andincrease driving comfort.

The automobile as a high-tech deviceequipped with components from theelectronics industry, some of which arehighly sensitive can only function asreliably as its electrical and electroniccomponents.

Not only dust, spray and splash waterbut also extreme temperature fluctua-tions have a lasting effect on the oper-ational reliability and service life ofthese components.

The wide product range of WeissUmwelttechnik with its standard or tai-lor-made testing systems contains allrelevant parameters and their real-to-life combination of same:From a system for IP protection testingto a drive-in cold chamber for perform-ing cold start test.

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Temperature ShockTest Chamber TS130

Temperature and Climate Test Chambers Series WT/WK

For temperature tests of –70 °C . . .+180 °C and climate tests of +10 °C . . .+ 95 °C and a relative humidity of10 . . . 98 % in accordance with relevanttesting standards, e.g. DIN, ISO, MIL,IEC, DEF, EN or ASTM. The test chambers of the WT/WKseries with graphics-compatible touchpanel and 32 bit processor haveundergone completely new develop-ment as regards comfortable handlingand reliable functioning even underextreme conditions. Outstanding fea-tures are the powerful, even tempera-ture conditioning, input via touch panelor notebook, service-friendly modularconstruction, documentation and eval-uation per graphics plus the compati-bility with all Weiss software products.

Standard test space volumes from190 l to 1540 l with and without panora-ma window are available.

. . .Standard Testing Systems

For producing thermal stresses onelectronic components, units and sys-tems for environmental stress screen-ing and performance tests according tonational and international standards.

The turn-key temperature shock testchamber TS 130 offers high performancetemperature changing (sufficient for 10 kg integrated circuits as specified inMIL-STD) at a working range of– 80 °C . . . + 220 °C. At a transfer timeof approx. 10 sec., test specimens of20 kg (optional 50 kg) can be subjectto temperature change in time-opti-mised operation.The TS 130 can be operated either asa self-sufficient simulation device orintegrated in automated testing andproduction systems.

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Special Testing Systems. . .

Spray and SplashWater TestingEquipment SWT

For performing reproducible tests fortesting of the protection of housings/enclosures against ingress of waterduring development and quality con-trol. The spray and splash water testequipment is manufactured as a turn-key version for protection system tests(IP code). In conjunction with a timer,the test cycle can be automated with asettable test time of 3 sec. to 30 h.Thanks to the integrated circulationequipment, water consumption can bereduced to a minimum.

Dust TestingEquipment andSystems

For protection code testing (IP-code) ina dust-laden atmosphere according toIEC and DIN regulations.

The systems can be equipped with anunderpressure device so that the dustnot only settles on the entire specimenbut can also ingress into the specimen.

Test space volume: 1 m3

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. . .Special Testing Systems

Cold-Heat Test Tunnel

Cold-Heat Test Tunnels are used forproduction-integrated testing of com-ponents for e.g. automotive electronics(such as airbag systems, engine man-agement systems and transmissioncontrol).

Test Tunnels for temperature tests areequipped with a conveyor belt and testheads.

Main components are:

cold zone:temperature range down to – 45 °C

hot zone:temperature range + 95 . . . +145 °C

cooling zone

loading, transport and unloading system

test heads

Cold-Heat Test Chamber

With rotating device and contactingsystem for fully automatic temperaturetesting and performance testing ofelectronic control units.

Test space volume: 1000 lWorking range: – 40 . . . +150 °CTemperature constancy: ±1 K

Combined Testing Processes

There’s no suchthing as “it can’t be done”. . .

. . . is the motto of Weiss.

Test specifications which distinguishthe brand quality by defining their ownstandards repeatedly present a chal-lenge to the engineers at Weiss Um-welttechnik.

Combined environmental testing pro-cesses on parts and complete systemscome closest to real-life field tests.Whether mechanical vibration loads,thermal or chemical stress factors, dur-ing manufacture, for quality monitoringor when driving:mechanical components in such highlysensitive safety systems as the airbagdemand a high degree of care whenundergoing a performance test.

Especially for testing systems for theautomotive industry.

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. . .Standard Testing Systems

Quick TemperatureChange by means of Stress ScreeningSystems

Environmental stress screening sys-tems series WT/WK can improve thereliability of technical products. Faultsources are detected and can be elimi-nated at the earliest stage of develop-ment.

Test space volume: 180 . . .1300 lTemperature range: –70 . . . +180 °CClimate range: +10 . . . + 95 °CHumidity range: 10 . . . 98 % r.h.Temperature change rates: 5/10/15 °C/min.

Cold-Heat andClimate TestChambers withVibration SystemWT/V and WK/V

These chambers are used for testingof e.g. components used in the enginecompartment of a vehicle under theinfluence of a combination of variousparameters such as vibration, temper-ature or temperature changes andhumidity.With the blank floor element (no vibra-tor port) these chambers can be usedas temperature and climate test cham-bers and also as stress screening sys-tems.

Temperature range: – 40 . . . +180 °CClimate range: +10 . . . + 95 °CHumidity range: 10 . . . 95 % r.h. (1)

(1) with the blank floor element (no vibrator port)

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Special Testing Systems. . .

Airbag TestingSystem forResearch andQuality Assurance

The system comprises the tempera-ture conditioning chamber, a slidingtest frame with runners, automaticallyclosing gate and switch cabinet withcontrol system. The testing system isfor testing the performance of airbagsat extreme temperatures.

Test space volume: 25 m3

Temperature range: – 40 . . . +120 °CTemperature constancy: ±1 K

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. . .Special Testing Systems

Ozone Climate Test Chamber

For testing organic materials and rub-ber elasticised materials.Ozone causes such materials tobecome prematurely brittle, hair cracksappear on the surface. The compo-nents age prematurely and/or aredestroyed.

Temperature range: 10 . . . + 40 °CHumidity range: . . . 65 % r.h.Ozone concentration: According to standards DIN, JIS, ISO,ASTM

Climate Test Cham-ber with Noxious GasEquipment Type BSB

For the systematic testing of the corro-sive effect of noxious gases in theatmosphere. The test chamber isequipped with a climate test space anda removable interior chamber for nox-ious gas testing (air/jacket temperatureconditioning). The users have a climatetest chamber of high value at their dis-posal which can also be used for per-forming tests without noxious gas.Temperature range: +15 . . . + 80 °CHumidity range: 40 . . . 75 % r.h.Exposure to noxious gas with: SO2, H2S, NO2, CI2, O3

Cooling Cycle-Test Stand

For testing and measuring the perfor-mance of complete vehicle air condi-tioning systems (CO2 and R134a). Dueto the transcritical working conditions,the CO2 is cooled in a coaxial heatexchanger. It is also possible to mea-sure the torque at the compressor andthe refrigerant mass flow.

Test space volume: 2 x 500 lTemperature range in the compressortest space: AT. . . +150 °CTemperature range in the evaporatortest space: AT. . . + 50 °CTemperature constancy: ±1 K

Weiss Umwelttechnik Ges.m.b.H.A-1230 Wien � Ober-Laaer Strasse 316Tel. (01) 6 16 66 97 � Fax (01) 6 16 66 97-13eMail: wien.wuw@schunk-group.com

Weiss Technik Belgium B.V.B.A.B-1770 LiedekerkeNijverheidszone � Begijnenmeers 63Tel. (0 53) 68 10 10 � Fax (0 53) 68 10 20eMail: sales@weisstechnik.be

Weiss Technik AGCH-8802 Kilchberg � Böndlerstrasse 29Tel. (01) 7 16 10 66 � Fax (01) 7 16 10 76eMail: info@weiss-technik.ch

Weiss Technik France E.U.R.L.F-78955 Carrières sous Poissy 283, route d’AndrésyF-78304 Poissy Cedex � B.P. 4015Tel. (1) 34 01 11 00 � Fax (1) 39 27 37 84eMail: info@weissfr.com

Weiss Environmental Technology Inc.Menomonee Falls, WI 53051, USAW146 N9300 Held DriveTel. (2 62) 2 53-87 30 � Fax (2 62) 2 55-13 91eMail: info@schunkgraphite.com

Weiss-Vötsch Environmental TestingInstruments (Taicang) Co. Ltd. No 102, Changsheng Road Taicang Economy Development AreaJiangsu Province, 215400, P.R.C.Tel. (05 12) 534 43 11-0 � Fax (05 12) 534 43 11-1

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Subsidiaries

Representatives world-wide see www.wut.com or www.weiss.info

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Weiss Technik Ltd.GB-Marlow � Buckinghamshire SL7 1NXWillowbank House � 84 Station RoadTel. (0 14 94) 43 43 24 � Fax (0 14 94) 43 43 25eMail: info@weisstechnik.co.uk

Weiss Technik Italia S.r.l.I-20013 Magenta (Mi) � Via Murri, 22 – 28Tel. (02) 97 29 16 16 � Fax (02) 97 29 16 18eMail: info@weissitalia.it

Weiss Enet Industrietechniek B.V.NL-4004 JP Tiel � Morsestraat 8Tel. (03 44) 67 04 00 � Fax (03 44) 67 04 05eMail: info@weissenet.nl

Test Technology for Professionals. Test the Best . . .

A complete line of standard systems isavailable offering test space volumesranging from approx. 60 l to 1,500 l, aworking range from –75 . . . +180 °Cand relative humidity values rangingfrom 10 . . . 98 % r.h.

We also offer an extensive line offield-proven test systems specially for simulating exposure to weather,temperature shock, corrosion andlong-time tests for application inresearch, development, quality controland production.

Of course, Weiss – as one of the lead-ing producers of environmental simula-tion systems world-wide – offers theentire spectrum of high-tech testsystems starting from a series of cost-effective test systems up to custo-mised walk-in chambers and in-linesystems.

If it’s know-how, service and reliabilitythat you are looking for – contactWeiss Umwelttechnik.

Weiss Umwelttechnik GmbHSimulationsanlagen • Messtechnik35447 Reiskirchen-Lindenstruth / Germany � Greizer Str. 41– 49Telephone (0 64 08) 84-0 �Telefax (0 64 08) 84-87 10www.weiss.info • www.wut.com � eMail: info@wut.com