how vehicles are engineered for safety andperformance

Introduction

An Automotive Product Testing Lab is crucial for the Automotive Industry to ensure safety, reliability, and compliance with regulations. This testing encompasses various aspects, from material analysis to software validation and real-world performance evaluations. Modern vehicles, with their complex components and systems like advanced driver-assistance systems (ADAS), require rigorous testing methodologies to identify and address potential issues early in the development cycle.  

The Important tests done on Automotive parts are

Mechanical / Dynamic Tests Environmental & Climatic Tests Corrosion Tests Degree of Protection Tests Electrical & Electronic Tests Material Tests Functional & Performance Tests Fit & Finish Tests Dimensional Inspection (CMM, 3D Scanning) Color Matching & Gloss Testing Packaging and Transport Simulation.  

Spotlight on Vibration Tests (Dynamic Test)

Automotive components and structures are consistently exposed to random vibrations from road inputs and periodic vibrations from engine firing. These vibrations can significantly affect a vehicle’s performance, durability, comfort, and safety

Common Sources of Vibration in Automobiles

Road Inputs: Bumps, potholes, and other road irregularities transmit vibrations through the wheels, suspension, and chassis. Engine and Powertrain: Engine combustion, rotating components (e.g., crankshaft, driveshaft), and gear meshing generate vibrations that propagate throughout the vehicle structure. Other Components: Cooling fans, power steering pumps, exhaust systems, and other auxiliary components can also contribute to vibration levels. Types of automotive failures induced by vibration

Failure Type

Affected Components

Consequences

Fatigue Failure

Chassis, mounts, suspension

Cracks, structural failure

Electronic Damage

PCBs, sensors, ECUs

Faults, shutdowns, erratic behavior

Wear and Tear

Bearings, gears, rotating parts

Noise, inefficiency, failure

System Malfunction

Sensors, actuators, control modules

Reduced performance, error codes

Loose Connections

Fasteners, electrical plugs, mounts

Rattles, part detachment

Ride & Health Impact

Seats, cabin, steering wheel

Discomfort, health risk

In conclusion, understanding and addressing vibration-induced failures is critical in the design, development, and maintenance of safe and reliable automobiles. By incorporating appropriate design principles, utilizing damping and isolation techniques, and adhering to rigorous testing protocols, manufacturers can significantly reduce the risk of vibration-related problems and enhance the overall quality and lifespan of their vehicles

Vibration Testing at ATS Test Lab

Sine, Random and Mechanical Shock and with Combined Thermal Test

Sinusoidal Vibration Test is a type of mechanical test used to evaluate how a product or component responds to sinusoidal (smooth, periodic) vibrations. It’s primarily used to identify resonant frequencies, assess structural integrity, and simulate real-world vibrational conditions. A Random Vibration Test subjects a product or component to a broad spectrum of vibrations that occur simultaneously at different frequencies and amplitudes. Unlike the smooth and predictable pattern of a sine vibration test, random vibration simulates the unpredictable and real-world conditions. Mechanical Shock refers to a sudden, high-magnitude force or impact applied to a product or material to evaluate its ability to withstand abrupt acceleration changes.

The Test Equipment 

Typical Parameters: Sine and Random

Frequency Range: e.g., 5 Hz – 3,000 Hz Amplitude: Depends on the Standards Direction: Vertical, Longitudinal, Transversal Mechanical Shock: 1g to 100g depends on standards, maximum 11m,  90mm max stroke.

Standards Followed:

MIL-STD-810G(Part-II 516.6):: 2008, IS 9000 (Part-8)::2021, JSS-55555 (2012 REV-3)- Test Number, 28:: 2012, IEC 60068-2-27 & more