Testing

Based on experience in calculation, meaningful and correct tests should be defined and carried out.

 

Our main field of activity is in the field of dynamic component testing. A modern four-poster system with very good dynamics is at your disposal. Furthermore, we use a 4-D component test bench as well as a HEXAPOD under climate to ensure the best possible implementation.

Services

The flexible test bench, which is used on a hydraulic shaker or stamp system and is patent-pending, enables realistic tests to be carried out on components in the overall car system. Our invention is used to investigate the interaction of a body and a component to be tested, such as doors, flaps, HV storage, and front end and rear end.

 

It all started with the FSB Type 1, which was developed exclusively for convertible roof systems. With the continued use of the basic modular concept, Type 2 made it possible to depict limousines, station wagons, and SUVs. With the FSB Type 3 for off-road vehicles with a ladder frame, the replacement vehicles became more and more realistic in terms of the position of the support structure. The tuning options for the static and dynamic properties are also more diverse. Types 4 and 5 represent the latest generations of battery-powered vehicles and those with combustion engines. Type 6 was specially developed for electric trucks.

Explanation of the fundamental idea using the Cabrio FSB Type 1

The development of the body and development of the roof system are usually happening independently of each other. Due to that, suppliers and OEMs (vehicle manufacturers) often mainly focus on their own system. This causes a lack of concentration on the connection area of both opponents often leading to deficiencies in the BIW-roof connection

Body supplied by the manufacturer (OEM)

Karosserie geliefert vom Hersteller (OEM)

Interaction

Dach geliefert von Zulieferer

Roof supplied by subcontractor

Moreover, mostly the dynamic design takes place in a rigid environment (“rigid block” or body cutouts), which leads to a falsification of the results. Natural-frequencies against rigid constrains are usually in the range of 20-30 Hz and normally they collapse with global modes, which lay much deeper. Due to that, different data has a different output despite doing the same stimulation on the component (e.g. by measuring the roof – main bearing).

The body of a convertible is recreated as a lead frame with adjustable elements. This recreation is our Flexible Shaker Type 1, short = FSB1, which is designed especially for convertible-related components.

Convertibles as well as all other vehicle types (sedans, station wagons, etc.) can be tested with the FSB2 test bench. However, this is more complex than the FSB1, since not only the natural frequency can be set accordingly, but also the individual deflection shape of the car.

Substitute vehicle for off-road vehicles with a ladder frame and cell mounted on rubber elements

With the FSB 4, all of the components described above can be mapped with a supporting HV storage unit.
The FSB 5 is related to the FSB 5, but the floor assembly is designed for combustion engines.

Ersatzfahrzeug für elektrisierte LKW’s.

 

Bilder folgen…

Shaker frames for component testing.

 

Examples:

  • Shaker frame for spoiler systems with dynamically tuned replacement tailgate
  • Shaker frame for spoiler systems with dynamically tuned replacement tailgate (additional: sealing systems on the body)
Spoilergestell 2
  • Rigid spoiler frame

Workshop with a lathe, milling machine (conventional and CNC), drill press, hacksaw, welder, etc.

Complete vehicle tests can be carried out with a total weight of up to 6 tons, a maximum height of 2.50 meters and a wheelbase of 1.80-3.80 meters. We can also support you in the area of ​​component testing (sunroof, doors, durability,…), as well as in modal analysis on the entire vehicle and components.

  • Seismic mass 95t
  • Air suspension with additional volume (0.8 Hz natural frequency)
  • Trafficability max. 8 t
  • Foiled windows
  • Code secured doors

Cylinder

Zylinder
  • System pressure 280 bar
  • Servo-hydraulic 40 kN cylinder
  • Hydrostatic bearing
  • Shear force reinforced; 80mm piston rod
  • 250 mm working stroke
  • 2 Moog 761 63 l servo valves
  • Pressure accumulator 3.5 l

Wheel discs

Radteller 1
Radteller 2
  • high-strength aluminum
  • wheel diameter 20″
  • Wheel width 340mm
  • Weight 11kg
  • high frequency capable
  • high-strength aluminum
  • wheel diameter 20″
  • Wheel width 225mm
  • Weight 7kg
  • high frequency capable
  • noise-optimized
  • steel
  • wheel diameter 20″
  • wheel width 350 mm
  • Weight 37kg
  • heavy overload capacity
Radteller 1
  • hochfestes Aluminium
  • Raddurchmesser 20″
  • Radbreite 340 mm
  • Gewicht 11 kg
  • hochfrequenzfähig
Radteller 2
  • hochfestes Aluminium
  • Raddurchmesser 20″
  • Radbreite 225 mm
  • Gewicht 7 kg
  • hochfrequenzfähig
  • geräuschoptimiert
  • Stahl
  • Raddurchmesser 20″
  • Radbreite 350 mm
  • Gewicht 37 kg
  • hochlastfähig

Component Testing

  • Own design
  • 6 INOVA hydraulic cylinders a 30kN
  • Reinforced lateral force with 80mm piston rod
  • Cylinder stroke +/- 50mm
  • INOVA regulation EU3000 up to 10kHz
  • Frequency range from 1Hz to 200Hz
  • Max. acceleration empty in X>10g, Y>9g and Z>15g
  • Max. acceleration loaded depending on the test piece mass
  • High strength aluminum
  • Natural frequency >300Hz
  • Thread M16 x 2 with Helicoil
  • Hole grid 100mm x 100mm
  • Dimensions 1170mm x 1070mm (L x B)
  • Clamping surface expandable via adapter
  • Max. table displacements:
    +/- 84mm in X
    +/- 92mm in Y
    +/- 62mm in Z
  • Max. table rotations:
    +/- 8.9° in Rx
    +/- 6.5° in Ry
    +/- 8.7° in Rz

Climate Chamber

  • Manufacturer CTS / Hechingen
  • Volume 17 m³
    Dimensions (LxBxH) 3.05 m x 2.6 m x 2.1 m
  • Temperature range -30°C to +85°C
  • Humidity range 10% to 95%
  • Dew point range +5°C to +78°C
  • Heating 0.5K/min from -30°C to +70°C
  • Cooling 0.5K/min from +80°C to -20°C
  • Acoustic panels for noise analysis can be used if necessary

Hexapod

  • 6 INOVA hydraulic cylinders a 30kN
  • Reinforced lateral force with 80mm piston rod
  • Cylinder stroke +/- 50mm
  • INOVA regulation EU3000 up to 10kHz
  • Frequency range from 1Hz to 200Hz
  • Max. acceleration empty in X>10g, Y>9g and Z>15g
  • Max. acceleration loaded depending on the test piece mass
  •  

Table

  • High strength aluminum
  • Natural frequency >300Hz
  • Thread M16 x 2 with Helicoil
  • Hole grid 100mm x 100mm
  • Dimensions 1170mm x 1070mm (L x B)
  • Clamping surface expandable via adapter
  • Max. table displacements:
    +/- 84mm in X
    +/- 92mm in Y
    +/- 62mm in Z
  • Max. table rotations:
    +/- 8.9° in Rx
    +/- 6.5° in Ry
    +/- 8.7° in Rz

Climate chamber

  • Manufacturer CTS / Hechingen
  • Volume 17 m³
    Dimensions (LxBxH) 3.05 m x 2.6 m x 2.1 m
  • Temperature range -30°C to +85°C
  • Humidity range 10% to 95%
  • Dew point range +5°C to +78°C
  • Heating 0.5K/min from -30°C to +70°C
  • Cooling 0.5K/min from +80°C to -20°C
  • Acoustic panels for noise analysis can be used if necessary
  • 3 cylinders with 15 kN (each 1 Moog 761 63 l servo valve
  • Sully flexible swinging table for consoles, struts, etc.
  • Seismic mass 15 t
  • Air suspension with additional volume (1.2 Hz natural frequency)
Measurement signals for signal iteration / Measurements on OEM test tracks

Endurance runs to determine the service life of components:

 

e.g. roofs, holders, complete vehicles.

Force-controlled testing of convertible top component (using a force sensor)

OMA and IMA for the entire vehicle and components

INOVA EU 3000

  • 10 kHz control clock rate
  • Up to 4 independent control tasks in parallel
  • 16 freely configurable analog inputs
  • Control of paths, acceleration, forces, or other external variables
INOVA EU 3000

Mobile measuring systems from LMS + IMC

 

  • 32 channels + 48 channels (expandable)
  • 24 x ICP 3-axles, 2 of which weigh 0.8 grams
  • 1 x ICP 1-axis with 0.5 grams
  • 4 x DC 1 axis
Induktiver Wegaufnehmer
Inductive displacement sensor
Seilzug Wegaufnehmer
Cable pull – displacement sensor
Beschleunigungssensor
Acceleration sensor
Kraftmessdose
Force sensor

Dytran 5850B Impulse Hammer

Modalhammer

Calibration of test objects.

3D-Messarm