99 389 Testing Machines And Systems For The Automotive .
BB 389.2.07.17Testing Machines and Systems for theAutomotive IndustryIntelligent Testing
1 ZwickRoell GroupContents1.1 Passion and expertise1.2 A trusted partner for testing in the automotive industry1.3 Mechanical tests on materials1.4 Joining technology in automotive engineeringPage34682 Motors, drives, and electrification2.1 Tests on electric motors and traction motors2.2 Tests on electric energy storage systems2.3 Tests on fuel cells2.4 Tests on engine components2.5 Tests on engine-related components2.6 Tests on the drive train1010101113143 Body3.1 Testing of sheet metal forming properties3.2 Fracture toughness testing3.3 Testing of surface waviness of the body exterior3.4 High-speed tensile testing3.5 Disk flexure testing3.6 Crash structure testing1515161616174 Chassis4.1 Spring testing4.2 Tests on wheels, tires, and rims4.3 Tests on the steering system1819205 Electronics and mechatronics5.1 Tests on switches5.2 Function tests on electromagnetic actuators21216 Seats, interior and safety components6.1 Static seat testing6.2 Testing of seat belts6.3 Testing of safety belts6.4 Testing of sealing sensors6.5 Testing of airbag connectors22232323237 Products7.1 Testing machines for quasi-static applications7.2 Dynamic testing machines7.3 System for testing at temperature and high temperatures7.4 Testing machines for multi-axial stress states7.5 Special testing systems and instruments7.6. testXpert III testing software7.7 Measurement and control electronics7.8 Modernizing and retrofitting testing machines24262829303234368 Services8.1 Materials and Components Testing Laboratory8.2 Applications technology8.3 Overview of services2373838
1. ZwickRoell GroupZwickRoell Group1.1 ZwickRoell—Passionand expertiseOur company philosophy is foundedon a passionate commitment toour customers. We work hard toensure customer satisfaction byhaving over a third of our employeesengaged in service and support.Fig. 1: Innovation Center at ZwickRoell's headquarters in Ulm, GermanyApplicationsAs a family-owned company witha tradition stretching back 160years, we place great value onhonesty and fairness. Over the yearsan ethos of close collaborationbased on mutual trust between ourpartners, suppliers, and customershas evolved—something that we allvalue highly.Always at your serviceThe right solutionsOver 1100 workers are employed at our headquartersin Ulm, Germany. Many of them have been with us foryears—decades even. Their knowledge, ability and commitment are what lies behind the worldwide success ofthe ZwickRoell Group.Whether for static materials testing or the various formsof fatigue testing—we have the right solutions. We offerproducts for hardness testing as well as instruments forimpact testing and for melt index determination.We are present in over 50 countries around the world.ProductsThe basis of a successful partnership: innovative employees as well as innovative products.And for that rare occasion when we don’t have a solution that fits, our experts will find one—from the smallestadaptation to a fully automated testing system or a testbench for special tasks.3
1.2 ZwickRoell—A trusted partner for testing in the automotive industryReliable test results inR&D, quality control, andproductionAccurate and reliable testresults are an importantfoundation in all developmentstages of automobiles andcomponents. Testing solutions from ZwickRoell deliveraccurate, repeatable, reproducible, and traceable testresults.Quality managementThe standard for quality management systemsof organizations in the automotive industry, IATF 16949,is key for processes in theautomotive industry.ZwickRoell testing instruments support suppliersand vehicle manufacturers inimplementing standard requirements in testing.A trusted partner for vehiclemanufacturers and suppliers forover 70 yearsZwickRoell began delivering testingsystems to the automotive industry inthe 1950's and since then has gainedthe trust of international OEMs, suppliers, research institutes, engineeringand testing service providers as well ascertification organizations.organiz4E-Mobility and lightweight construction—Let us help lead you into the futureThe automotive industry is in the midst of changes and faces major challenges driven by the necessity to reduce emissions, which can only beachieved through electrification and consistentlightweight construction. ZwickRoell offers innovative and flexible testing solutions that are theresult of close cooperation between research andindustry.Testing solutions from materials to completecomponentsMost vehicle components must be designed for mechanical loading over the service life of the vehicleand reliably fulfill the component requirements.ZwickRoell testing systems support this requirementfrom the reliable determination of material characteristics through the functional checking of components.
ZwickRoell GroupApplicationsIntelligent testing solutions—The right product for any applicationZwickRoell's wide range of testing machines is modularly designed and can be optimally adaptedto your testing requirements. This enables us to offer various testing solutions for standard-compliant tests via universal testing machines for a number of test tasks to fully automated complextesting systems. All ZwickRoell testing systems deliver reliable test results, easy operation, andhigh availability.From drive systems to electronics—Testing solutions for all segmentsWe not only provide testing systems for fundamental challenges such as the use of materialsand joining technology, we offer comprehensive testing solutions for all relevant vehicle segments, from engines to the chassis, body, interior, and safety, to electronics/mechatronics.We work closely with our customers in the development electrical drives and battery technologies.ProductsWorldwide expert networkWe support our customers in allcountries in which vehicles and components are manufactured. Our qualified team of experts participates incontinuous training in order to provideour customers around the world withoptimal consultation and support.5
1.3 Mechanical tests onmaterialsCompliance with strict statutoryemission limit values requires thatthe automotive industry make vehicles more efficient and environmentally friendly. This will be achievedthrough drastic weight reductions,improved combustion technologyand exhaust gas treatment, as wellas through the use of alternativedrives. Despite more stringent requirements for safety, efficiency, andcomfort, it is considerably easierfor manufacturers to produce eachnew generation of vehicles. At thesame time, this requires newer orimproved materials as well as intelligent material compounds that allowbetter properties at lower specificweights in their area of application. In addition, weight reductionis systematically implemented in allcomponents of a vehicle, which isrequired for optimal material utilization.grips, test fixtures and environmental simulations. As a result thetesting system can be adapted tomodified or future test tasks. Youcan find additional details in ourbrochures or on our website.Reliable determination of mechanical characteristics plays a vital rolehere. By using diverse test methodsthe various material properties aredetermined as realistically as possible. Our universal testing systemscan generally be expanded withmeasurement sensors, specimenTests on metals6Tensile testSheet metal testingHigh-temperature testingHardness testingCharpy impact testBiaxial testHigh-speed testFracture mechanics
Tensile testing3-point flexure testingCompression testingHardness testingImpact testInstrumented puncturetestExtrusion testingFatigue testingZwickRoell GroupTesting of plastics and componentsTests on soft foamsTensile tests on elastomersAbrasion tests on rubberTensile tests on threadsTensile tests on textilefabricsGlass testsTensile shear tests onwood jointsTests on cablesProductsApplicationsTests from other application areas7
1.4 Joining technology inautomotive engineeringIn vehicles, various joining methodsare used that all have to be characterized mechanically.gain popularity in the automotiveindustry. Modern adhesive materialsfulfill the requirements of lightweightconstruction optimally, since theyoffer high joining quality at a lowweight and can be implementedflexibly.The focus lies on a crash-safe design of components, while ensuringthe required service life. In additionstiffness is a key criterion for designing components in the body shell aswell as in the chassis.Fig. 1: Static tensile test on screwsFig. 2: Fatigue tests on threaded connectionswith the VibrophoreRemovable threaded connectionsare used in a range of applicationswithin vehicle manufacturing andincreasingly in safety critical applications. The quality requirements thatmust be met in tensile and fatiguetesting are correspondingly high forscrews.In the chassis, linear connections(welded joints) are used overwhelmingly where the focus is on the service life of the component or joiningconnection. Linear, pointed and flatconnections as well as a combination of the individual connectionsare used in vehicle body shells.Adhesive bonding has become apopular method for reliably joiningvarious materials and continues to8
The data calculated during testing(quasi-static tensile tests, fatiguestrength tests, and dynamic impacttests) is used for quality assuranceand as input for simulating servicelife and crash behavior.tallic materials presents challengesto the manufacturer that can onlybe solved by using various joiningmethods. All joining methods combined require that you ensure thestiffness of the compound and itsload-bearing capacity in application.When using component-like specimens, these can also be used asvalidation for service life or crashmodels. The combination of variousmaterials is becoming increasinglyimportant in lightweight construction. Joining metallic and non-me-ZwickRoell GroupThe mechanical properties of thejoining connections must be determined under quasi-static as well asunder fatigue and impact dynamicloading.ApplicationsFig. 5: Push out test for riveted jointsFig. 3: Shear tests on riveted jointsFig. 6: Peel tests on structural adhesive bondsFig. 2: Slotted specimen for adhesive bondingof two fiber composites in shear testFig. 4: Laser welded sheet metal specimenafter tensile test with failure outside the welding locationFig. 7: Peel tests on adhesive stripsProductsFig. 1: Point welded specimen9
2 Motors, drives, andelectrificationDrive assemblies are the focus ofdevelopment efforts to provide efficient mobility with reduced emissions. Downsizing plays a largerole in achieving the demandingworldwide regulatory goals. Onthe one hand combustion enginesare becoming smaller and lighter,but on the other hand they arealso becoming more elaborate andcomplex due to additional enginefeatures such as supercharging,operating parameter optimization,and the increasing combination withelectric drives presenting challengesto the composite materials used.Testing technology from ZwickRoelldelivers reliable test results for supporting this development process.2.1 Tests on electrical drivesTo achieve a high degree of efficiency with electric traction motors,unconventional paths are oftentaken: complex sheet metal stampings, thinner sheet metal, and highperformance magnets for permanent excitation. ZwickRoell testingmachines are used to measurepush-out forces of adhered permanent magnets for example to ensurea secure fit. In addition, assemblyand disassembly forces of electricmotor components are determined10Fig. 1: Traction motor testingFig. 2: Testing the bond strength of electrode layers for lithium ion batteriesin order to more precisely pinpointcauses of failure.transport regulations for high energystorage systems. Machine control,acceleration of the testing machineand its data acquisition rate mustbe designed for these quick processes.2.2 Tests on electric energystorage systemsThe lithium ion battery is currentlythe most popular option for energystorage for electric drives in vehicleconstruction. Its complex designrequires high process safety during manufacturing and assemblyin the complete battery system. Inthis manner, the widest range ofmechanical tests are performed oncells, battery modules and evencomplete battery systems. Due tothe high energy density, the batteries must withstand mechanicalloading up to a triggered shortcircuit, in order to prevent a hazardto the vehicle occupants. In addition, strict test standards must beadhered to in order to meet the2.3 Tests on fuel cellsFuel cells offer another interesting alternative to fossil fuels andcombustion engines by convertinghydrogen into energy for electricdrives. In addition to undergoingload tests for individual cell layersor the determination of stackabilityof individual fuel cell modules, thematerials for pressurized hydrogenstorage must withstand pressuresof up to 1200 bar. Plus the materials used must be inspected for anypossible negative influences fromhydrogen, such as embrittlement.
2.4 Tests on enginecomponentsApplicationsZwickRoell's Vibrophore with special forked specimen grips allowsto achieve a high testing frequencyof up to 250 Hz and an extremelyhigh specimen throughput. Due toto the comparatively low energyconsumption operating costs arecorrespondingly low.ZwickRoell GroupConnecting rod testingThe load collective acting on connecting rods requires a designand materials that meet the highdemands placed on it, such as afatigue limit of approx. N 5 x 106cycles. The connecting rod can bedivided into three loading rangesand for testing both eyes mustbe tested under real conditions,i.e. with play and in a temperaturerange of 90 to 120 C surroundedby oil.Fig. 1: Fatigue tests on connecting rodsProductsTesting of crankshaftsFor fatigue testing on crankshafts,you can use the Vibrophore or aservo-hydraulic testing machine. Todetermine the S-N curve, individualsegments are fatigued through flexural loading in which the mountingtable and tools are arranged so thatall of the crankshaft's segments canbe checked by reclamping them.A fatigue limit of approximately N 3 x 106 cycles is assumed here.Force-controlled sinusoidal cyclesare performed according to thestaircase method. Fatigue testingvia torsional loading can also beperformed using the same machine.Fig. 2: Crankshaft segment under dynamic loading in a Vibrophore11
Testing of assembledcamshaftsThe nature of camshaft operationrequires that they withstand high,continuous torsional loads. Torsiontesting machines can be used forproduction-related quality control.The torque acting on a camshaftat which component connectionsbegin to loosen is determined.Camshaft sections are gripped horizontally in the machine and a torqueload of up to 1000 Nm is increasingly applied. Especially interestingis the elastic and plastic deformation of the camshaft components.ZwickRoell's optical laser extensometer measures the rotationalangle without making contact.Fig. 3: Torsion tests on camshaftsAdditional tests on engine componentsFig. 1: Fatigue tests on the engine blockFig. 4: Valve spring testingFig. 6: Testing the coefficient of friction ofDLC coated fuel injectorsFig. 2: Fatigue tests on engine chainsFig. 5: Hardness testing on valvesFig. 7: High temperature testing on enginecomponents12
Due to their location, these elements are often subject to strongthermal loads as well as vibrations.If not properly designed, these components can fail prematurely. Operational fatigue strength testing basedon the actual expected loading isnecessary for adequate protection.Testing of exhaust systemsExhaust systems are highlystressed, complex components thatare subject to thermal loads, jolts,and vibrations, as well as corrosivemedia. These systems include alarge number of sensitive components such as catalytic converters,measurement sensors, and elec-tronics, which must be designedand checked for these requirements. ZwickRoell offers a widerange of testing solutions. In theexample, biaxial tests are performedon a complete exhaust system in aservo-hydraulic testing system.ZwickRoell Group2.5 Testing of engine-relatedcomponentsApplicationsTesting of engine mountsElastomer mounts fulfill a range offunctions in the engine area andchassis. They serve as joints andassist in equalization and vibrationisolation and damping. Various testmethods are used to characterizeand test active and passive mounts.Fig. 2: Fatigue tests on exhaust systemsProductsTesting of catalytic convertermatsBrittle ceramic catalytic converterbodies must be stored safely in theexhaust system for the entire duration of the service life. Determiningthe stiffness and coefficient of friction at temperature is extremely important for the bearing mats used.For this purpose, a testing machineis equipped with compressionplatens that can be heated up to1050 C and apply the vertical testloads. Also, by using an optical displacement transducer, the machinecan highly accurately control thecompression platen distance.The temperature specific coefficientof friction can be determined usingan additional horizontal test axis.Fig. 1: Single-axis fatigue testing on enginemountsFig. 3: Testing of catalytic converter mats13
2.6 Tests on drive trainsWherever power is converted andtransferred, tests ensure the reliability of the installed components.ZwickRoell has over 50 years ofexperience testing engine and drivecomponents. Initially, the load testsperformed were simple, but todayextremely specific properties mustbe measured and documented under realistic operating conditions,at high speeds, torques, and realoperating temperatures.Testing of clutchesThe characteristic curves of thecontact force and travel, as wellas release force and travel, are important in both the developmentand production control of frictionclutches. You can also determinethe release stroke of the clutchpressure plate and the parallelismof the pressure plate to the clutchplate. The characteristic curves arenot only important for comfortableoperation but also for safe clutchtorque transfer. These tests areperformed in new condition and in adefined used conditions.Fig. 1: Determination of contact force and displacement as well as push out force anddisplacement of friction clutchesAxial and torsional measurements on clutch disksDry friction clutches are also usedto apply and to interrupt the torqueflow. In addition to the aforementioned axial characteristic curves,torque characteristic curves aretherefore also extremely important,for example, the drag torque, predamper and main damper characteristic curves or the zero crossing.Fig. 2: Axial and torsional measurements on clutch disks14
ZwickRoell GroupTo meet the increasing demands onpassenger protection, lightweightconstruction, comfort, and functionality, modern self-supporting vehiclebodies are becoming increasinglycomplex structures in hybrid construction. That is why today,high strength to ultra-high strengthsteels, aluminum, and increasingly,fiber-reinforced plastics, are used inaddition to classic grades of steel.High-accuracy testing technologyfrom ZwickRoell supports the design of these sophisticated multimaterial composites.Another important but complex testis the determination of the forminglimit curve, from which engineerscan derive limit strains which shouldnot be exceeded during formingprocesses. ZwickRoell works inclose collaboration with highly specialized partners to offer the opticalmeasurement technology requiredfor recording strains during thedrawing process.3.2 Fracture toughness testingFracture toughness KIc is an important characteristic for metallic materials in safety-related applicationssuch as aircraft construction, powerplant construction, and automotiveengineering. The fracture toughness is determined by an artificiallycracked specimen that is loadeduntil fracture. The fracture toughness KIc can be determined fromthe load-deformation curve and thelength of the crack.Applications
7.1 Testing machines for quasi-static applications 24 7.2 Dynamic testing machines 26 7.3 System for testing at temperature and high temperatures 28 7.4 Testing machines for multi-axial stress states 29 7.5 Special testing systems and instruments 30 7.6. testXpert III testing software 32 7.7 Measurement and control electronics 34
fatigue testing machines, digital torque testing machines, multi-functional testing machines, grinding efficiency testers, run-out testers, digital measuring projectors, environmental testing chamber, grinding and polishing machines, infrared tachometers, vibrations testers and decibel
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