Vehicle Level Test

MARMARA ÜNİVERSİTESİ
TEKNOLOJİ FAKÜLTESİ
Taşıt Test Tekniği
-Temel Bilgiler-
HAZIRLAYAN:
Yrd. Doç. Dr. Abdullah DEMİR
TESTLER
Prototype parts can be validated
using test rigs. Although the
ultimate goal of a test rig is to
simulate real-world conditions, it is
not always possible to reproduce
the component’s actual operating
loads and environment.
It is extremely time-intensive and
expensive to validate parts and
systems using test rigs. Testing
costs can account for up to 30% of
total development costs.
Each validation test usually
requires a different type of test rig
(equipment costs).
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
TESTLER
In addition, multiple prototypes
(component
costs)
must
be
constructed. Finally, well-educated
test engineers (personnel costs) are
also required to create testing plans,
run tests, evaluate results, and
write reports. The amount of time
required to manufacture prototypes
and run tests must also be
considered.
It is also common for tests to be
interrupted frequently due to
premature component failure (the
quality of prototypes is never the
same as that of series production
components) or failed module tests.
In this case, the test must be started a
new.
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
TESTLER
Validation tests only provide
information about whether the
components fulfill function and
durability requirements. These
tests do not provide information
about whether the components
are optimized for weight. It
should also be noted that the
test conditions (load spectra,
load
frequencies,
force
application
points,
environmental
conditions,
influences of untested systems
and components, etc.) are only
an estimation of the actual
operating conditions.
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
TESTLER
The first step in the validation process is to
ensure that the prototype satisfies the specified
functional requirements and package conditions.
Next, the durability of the prototype is tested
using static and dynamic loads, both at room
temperature and under extreme environmental
conditions. Misuse tests are also conducted in
which the prototype is subjected to extreme loads
and conditions. In summary, a number of tests
must be conducted using a variety of different test
rigs and facilities [6]:
 visual examination and package space
validation
 function tests
 wear tests
 misuse tests
 environmental simulations and corrosion
tests
 durability tests.
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
TESTLER
For a number of
chassis
components,
workgroup
requirements specifications are
available
which
have
been
developed by a consortium of
different (German) OEMs and
suppliers and are accepted by all
parties. In addition to these
requirements specifications, each
OEM has their own testing
specifications, which often vary
widely. For validation runs
conducted on test rigs, the
results of system-level, subsystemlevel, and component-level tests
may vary.
Each of these different levels
requires different test fixtures and
procedures.
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
TESTLER
The results of these various tests are
also weighted differently:
Whole-Vehicle Tests are the most
significant tests with regard to the
vehicle’s function. This type of
testing is not always possible due to
cost and time factors as well as
complexity.
System-Level
Tests
offer
comprehensive results for the
system being tested, but are often
very complex and time consuming,
which prevents them from being
repeated frequently enough to
obtain statistically relevant data. As
a result, system tests should instead
be carried out as iterative simulation
experiments.
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
TESTLER
Subsystem Tests are less significant
due to the fact that they are focused
only on a small number of
components. Subsystem tests are
considerably less complicated than
system tests and can be more
statistically meaningful. They can be
carried out using block loads, as
single-step experiments, or as iterative
simulation experiments.
Component Tests are only focused on
a single part. The results are therefore
less significant for the system as a
whole, but can be of considerable use
for
component
designers.
The
usefulness of the results depends on
the type of experiment conducted
(single-step experiments, block loads,
or iterative simulation experiments.
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
TESTLER
Meaningful knowledge of the system and its
components can only be obtained by examining
experimental results for all of the following levels:
 component tests (statistically relevant)
 subsystem tests (statistically relevant)
 system-level tests (greater significance)
 vehicle-level misuse tests
 condensed
vehicle
endurance
tests
(correlation to system tests)
 vehicle endurance tests conducted on actual
roads (simulation of rough customer use).
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
TESTLER
Whole-Vehicle Validation
Vehicles can also be used to validate components and systems. Releaselevel vehicles are generally used for final validation and tuning. Preproduction vehicles are subsequently used for final quality assurance
checks. These tests can be carried out
 on test rigs
 on actual roadways (each OEM has its own specially-chosen
representative durability testing routes)
 on test tracks (owned or rented by OEMs or suppliers) and proving
grounds with restricted public access such as Lommel (in Belgium,
Ford), IDIADA (Spain), Miramars (France), MIRA and Millbrook
(UK), the Southwest Research Institute and Southern and Michigan
Proving Grounds (USA), or in Germany the Nürburgring Nordschleife,
Neustadt, Ehra-Lessien (VW), Dudenhofen (Opel), Aschheim (BMW),
Boxberg (Bosch), and Papenburg
 under extreme conditions, e.g. Arctic Falls AB in northern
Scandinavia or Smirthers Winter Test Center (winter testing), Nevada
Automotive Test Center, Death Valley (USA) (summer testing), on
mountain passes in the Alps (Großglockner), or even in deserts in Asia
or Africa.
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
TESTLER
Whole-Vehicle Validation
Whole-vehicle tests under various
conditions are used to investigate
and evaluate the overall function of
the vehicle, the interactions and
mutual influences of the individual
systems, and the behavior of all
components,
materials,
and
substances. These tests also provide
information about the overall driving
experience, the suitability of the
vehicle for long-distance use and
operation on poorly maintained
roads, handling and behavior at the
stability limit, and behavior under
extreme
conditions.
Technical
specifications and parameters (fuel
consumption,
acceleration,
top
speed, etc.) can also be measured.
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
TESTLER
Whole-Vehicle
Validation
(Cont.)
The following chassis-relevant
operating
parameters
are
evaluated during whole-vehicle
testing:
Driving: steady-state operation,
acceleration, passing, backing,
towing, uphill operation, driving
up ramps, off-road operation,
performance on poorly-maintained
roadways, emergency operation
Handling: cornering, crosswind
response behavior, slalom, ISO
lane changing, μ-split behavior
Braking:
constant
braking
(downhill operation), normal
braking deceleration, emergency
braking, μ-split and μ-jump
braking.
Taşıtın
kullanım
performansı;
sürücünün girdilerine taşıtın verdiği
tepkiyi gösterir. Taşıtın kullanılması
(kontrol/kumanda
yeteneği),
taşıtsürücü kombinasyonunun kapsamlı bir
ölçüsüdür. Sürücü ve taşıt, kapalı
döngülü bir sistemdir. Bunun anlamı;
sürücü
taşıtın
yönünü
ya
da
pozisyonunu/konumunu
izler
ve
arzulanan
hareket
için
gerekli
müdahaleyi yapar.
Note: Handling - the efforts of the
driver necessary to maintain the
course and the speed and to control
the vehicle safely.
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
TESTLER
Üretim Aşamasındaki Testler:
• Tasarım Doğrulama
• Dayanım Testleri
• Fonksiyon Testleri
• Yol ve Araç Testleri
In most cases, just 24 months are
planned for the series development
(design and testing) phase. This stage
of
product
development
involves
designing
components,
performing
strength calculations and functional
optimizations, and ensuring that timeline
goals and cost targets are met. No major
changes are allowed during this phase, as
planning is already underway for
production
facilities
and
tooling
(industrialization).
Test: Bir kimsenin, bir topluluğun doğal
veya sonradan kazanılmış yeteneklerini,
bilgi ve becerilerini ölçmeye ve anlamaya
yarayan sınama. / TDK
TESTLER
Okuma Parçası:
Yeni tip taşıt ve motorların testleri:
Yeni tip taşıt ve motorların testleri; imalatçıların gelecekte piyasaya
çıkarmayı planladıkları motor ve taşıtların anma değerlerini dizayn
değişikliklerinin performansa etkilerini belirlemek için yapılan
testlerdir.
Standart metot ve kabul testleri:
Standart metot ve kabul testleri; genellikle imalat sonrasında, motor ve
taşıtların beklenen çıkış değerlerini verip vermediğini ya da
güvenilirliğini test etmek için uygulanırlar.
Araştırma testleri:
Araştırma testleri; bilimsel araştırmalar için yapılan testlerdir. Bu testler
motor ve taşıtta cereyan eden karmaşık olayların nedenlerini
araştırmak, ortaya çıkarmak, açıklayıcı teoriler geliştirerek bu teorilerin
geçerliliğini denemek için yapılan testlerdir.
Alıştırma testleri:
Alıştırma testleri; motor ya da taşıtın önce başka bir güç kaynağı ile
tahrik edilmesi ve ardından motorun kendi gücü ile bir test düzeninde,
taşıtın bir test alanında belirli sürelerde çalıştırılarak alıştırılması ve
gözlemlerin yapılması şeklindeki testlerdir.
TESTLER – Okuma Parçası
1. Yeni üretilen otomobillerin
testleri
Komple
• Kalite amaçlı
• Prototip
Ekipman
Tüketici Bilgilendirme Testleri:
1.
2.
3.
4.
5.
Acceleration
Braking
Skidpad
Slalom
Comparison Test Pricing Points
2. Tüketici testleri
• Komple
• Ekipman
Diğer tüketici testleri
• Yürüyen aksam kalite testi
• Geyik testi
• Slalom testi
• µ-split fren testi
vs.
Not: A skidpad or skidpan is a large paved area used to test a car's lateral acceleration.
TAŞIT MODELİ
Integration of subsystems in a
full vehicle model
Edited by David A. Crolla, Automotive Engineering
Powertrain, Chassis System and Vehicle Body,First
edition,2009 Elsevier
Reading Text:
Introduction vehicle testing required.
 Safety and Regulation testing
 Durability testing
 Vehicle function testing
Test method and facility
• Crash test (Euro NCAP)
• Wind tunnel test
• Noise vibration harness test(NVH)
• Squeak and rattle test
• Hot cold and humility test
• Water leak test
• Air leak test
• Engine test
• Chassis and suspension test
• Electrical module test
• Brake test
• Steering test
• Body in white test
• Interior testing
• Fuel system test
• Lighting system test
Vehicle and component parts testing, SUT 25 NOV 2012
Reading Text:
Introduction vehicle component testing standard
 UNECE
 SAE
 JASO
 ISO
Test method and facility
• Wheel and tire
• Drive shaft and spinning shaft
• Shock absorber
• Dynamic sealing
• Movable and fixed Glass
• Seat and Seat belt
• Hard trim and soft trim
• Body attachment
• Engine component
• Chassis and suspension component
• Electrical module component
• Brake component
• Steering component
• Body in white and sheet metal component
• Interior component
• Fuel system component
• Lighting system component
Vehicle and component parts testing, SUT 25 NOV 2012
JASO: Japanese Automotive Standards Organization
READING TEXT:
UNECE: European New Car Assessment Programme with a realistic and independent
assessment of the safety performance
SAE international: Society of Automotive Engineers, is a US-based organization for
engineering professionals in the aerospace, automotive, and commercial vehicle
industries. The Society coordinates the development of technical standards based on
best practices identified and described by SAE committees and task forces comprising
engineering professionals in the relevant fields.
JASO: Japanese Automotive Standards Organization, is an organization that sets
automotive standards in Japan.
ISO: International Standards ensure that products and services are safe, reliable and
of good quality. For business, they are strategic tools that reduce costs by minimizing
waste and errors and increasing productivity. They help companies to access new
markets, level the playing field for developing countries and facilitate free and fair
global trade.
Why need testing for vehicle level
and component part level?
•
Accident
•
Durability
•
Perform vehicle function intent
Vehicle and component parts testing, SUT 25 NOV 2012
Why need testing for vehicle level
and component part level?
•
Accident
•
Durability
•
Perform vehicle function intent
Vehicle and component parts testing, SUT 25 NOV 2012
Vehicle Level Test
 End of line testing
 Off line testing
 Evaluation lab testing
 Product development
testing
Vehicle and component parts testing, SUT 25 NOV 2012
Vehicle Level Test

Appearance inspection

Water leak test

Brake test
Vehicle and component parts testing, SUT 25 NOV 2012
Vehicle Level Test
•
•
Vehicle and component parts testing, SUT 25 NOV 2012
Noise vibration harness test (NVH)
Air leak test
•
•
•
•
•
•
•
•
•
Genel Akustik Ölçümleri - IEC 651
Taşıt iç ve dış gürültü ölçümleri
İletim yolu analizi (TPA)
Motor titreşim ve gürültü ölçümleri
Pass By ve Egzoz Testi Ölçümleri ISO 362 70/157
Ses gücü ölçümleri – ISO 3740 serisi
Ses kalitesi ölçümleri - ISO 532B
Yarı anekoik oda test ölçümleri - ISO
3745
Akustik haritalama
NVH: Noise, vibration,
Harshness: Sertlik/şiddet
and
harshness
Four-post test rig (ZF Sachs)
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
Vehicle Level Test
•
•
Vehicle and component parts testing, SUT 25 NOV 2012
Crash test (Euro NCAP)
Squeak and rattle test
An example crash test requirement profile
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
K&C Analizleri
Paralel tekerlek deplasmanı
Zıt tekerlek deplasmanı
Tek tekerlek deplasmanı
Direksiyon Çevrimi
Statik yük
Çalışma şartları simülasyonu
KC ya da K&C:
Kinematics&Compliance
OTAM
The elastokinematic behavior of each axle has a major
influence on the vehicle’s overall handling and dynamic
behavior. The main elastokinematic parameters include
toe, camber, caster, wheel center displacements,
etc.
Elastokinematic properties are measured using a
kinematics and compliance test rig (K&C rig). This type of
test rig allows kinematic and elastokinematic parameters
to be differentiated from one another .
K&C rig (IKA, RWTH Aachen)
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
Vehicle Level Test
•
•
Wind tunnel test
Hot cold and
humility test
Vehicle and component parts testing, SUT 25 NOV 2012
Vehicle Level Test





Engine test
Chassis and suspension test
Steering test
Lighting system test
Electrical module test
Vehicle and component parts testing, SUT 25 NOV 2012
•
•
•
•
•
•
•
•
•
•
Taşıt Emisyonları:
Tip I Emisyon Testi - 70/220 EEC
Tip II Karbon monoksit emisyon testi 70/220 EEC
Tip III Karter doğrulama testi- 70/220
EEC
Tip IV Buharlaşmalı Emisyon testi –
70/220 EEC
Tip VI Soğuk ortamda (-7 ⁰C)
karbonmonoksit ve egzoz emisyonları
testi– 70/220 EEC
Katalizör öncesi- katalizör sonrası
direkt emisyon ölçümü ve EGR emisyon
testi
Sabit hızda emisyon testi
Yeni çevrim oluşturma ve emisyon testi
Alternatif yakıtlar emisyon testleri
Yağ, yakıt katkısı emisyon testleri
gibi…
OTAM
Not: EEC - European Economic Community
Vehicle Component Level Test
1.
Dynamic sealing
2.
Movable and fixed Glass
3.
Hard trim and soft trim
4.
Body attachment
5.
Electrical module component
6.
Body in white and sheet metal
component
7.
Interior component
8.
Lighting system component
Vehicle and component parts testing, SUT 25 NOV 2012
Vehicle and component parts testing, SUT 25 NOV 2012
Vehicle and component parts testing, SUT 25 NOV 2012
Vehicle Component Level Test
•
•
•
Wheel and tire
Shock absorber
Brake component
Vehicle and component parts testing, SUT 25 NOV 2012
Aquaplaning test run (longitudinal direction)
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
Test rig setup for durability testing
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
High-performance test rig at TÜV-Süd used for tire characteristic measurements,
power loss analyses, and temperature analyses (max speed 350 km/h)
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
Vehicle-mounted test rig (rolling test rig)
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
Test rig for rolling resistance measurements [Source: TÜV-Süd]
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
Vehicle Component Level Test
•
•
Vehicle and component parts testing, SUT 25 NOV 2012
Seat and Seat
belt
Fuel system
component
Vehicle Component Level Test
•
•
Vehicle and component parts testing, SUT 25 NOV 2012
Drive shaft and spinning shaft
Steering component
Ball stud durability test rig
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
Vehicle Component Level Test


Chassis and suspension
component
Steering component
Vehicle and component parts testing, SUT 25 NOV 2012
Three-axis control arm test rig
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011
Spring compression test rig
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011

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