Exterior test

Testing of body and attachments

Testing    Exterior - Functional tests

Functional tests

  • Torque measurements
  • Pull-off and ejection forces
  • Assembly & disassembly
  • Car wash inspection
  • Driving tests

Plastic components

  • Sill covers & extensions
  • Bumper covers & roof edge spoilers
  • Emblems, lettering, etc.

Roof load systems

  • Railing
  • Supporting bars
  • Emblems, lettering, etc.

Testing    Exterior - Pendulum test

Material pendulum

  • Impact speed 4 km/h
  • Impact plate over the entire height
  • Recording with high-speed cameras
  • Trolley & pendulum each with up to 2.5T weight

Security tests

  • Impact speed up to 15 km/h
  • Impact height 16-20" or 445mm
  • Impact angle 0° to 30°

Environmental simulation

  • Temperature range from -30°C to +80°C
  • Sunlight simulation

Testing    Exterior - Catch hook forces KU mounting bracket

Catch hook forces KU mounting bracket

  • Determination of component stiffness of plastic mounting bracket
  • Dynamic tensile and compressive stress
  • Static tensile and compressive stress
  • Force introduction at the bolt bearing of the catch hook
  • Temperature range from -40°C to +90°C
  • Load cell 10 kN and climate-compatible displacement transducers
  • Measuring amplifier system “MGCplus” or multi-point measuring device “UGR 60”
  • Measurement software “Catman”
  • Linear motor: Continuous force 2 kN / Max. force 7 kN / Application Fmax < 0.2s

Testing    Exterior - Climate resistance

Climate chambers

  • Size up to 130 m³
  • Temperature range from -75°C to +180°C
  • Humidity range 10% to 98% relative humidity
  • Infrared irradiation
  • Motor operation possible

Sunlight simulation

  • Size up to 130 m³
  • Testing under temperature and humidity possible
  • Radiation up to 1100 watts
  • Outdoor weathering simulation
  • Testing according to DIN 75220

Testing    Exterior - Mechanical stress

Compressive stiffness test bench

  • Point load in x, y and z directions
  • Force up to 1000 N / travel up to 80 mm / angle 0° to 90°
  • including force and displacement sensors / variable test specimen

XYZ Shaker LDS V875-440 with sliding table

  • Tempering box for sliding table operation / temperature range -40°C to 100°C
  • Force (sine, noise) 35.6 kN peak / Frequency range 5 – 3000 Hz / Vibration displacement: 76.2 mm peak-peak / Load compensation 600 kg / Clamping area 750 x 750 mm

Z-Shaker LDS V8-440 in climate chamber

  • Temperature range -50°C to 120°C including humidity / Design for PV2005 and PV1200
  • Sine force 57.8 kN peak; noise 66 kN rms / Frequency range: 5 – 2500 Hz / Vibration displacement: 63.5 mm peak-peak / Load compensation 700 kg / Clamping area 1220 x 1220 mm

Testing    Exterior - Optical measuring methods

TRITOP

  • Static photogrammetry system for deformation analysis
  • Object size: 0.1 m to 6 m
  • Temperature: -40°C to +100°C

ATOS

  • 3D surface scan for comparison with CAD data or reference measurements
  • Object size: 0.05 m to 3 m (larger geometries supported by TRITOP)
  • Temperatures: 0°C to +40°C

PONTOS

  • Quasi-static to highly dynamic photogrammetry system for motion analysis
  • Object size: 0.1 m to 3 m / Recording frequency: 60 Hz to 2000 Hz / 0°C to +40°C

Testing    Exterior - Wiper Lab

(Climate) wet endurance run 3+10 pst.

  • Measuring tracking force
  • Measuring the set angle
  • Any sequence of wet, dry and down times
  • Wiping angle narrowing / measurement

Characteristic curve measurement

  • Engine braking (up to 50 Nm braking torque)
  • Determination of torque at 5 rpm

(Climate) braking endurance run 2+7 pst.

  • Constant braking torque (up to 13 Nm).
  • High/low temperature test in climate chamber
  • Humidity in warm conditions, cyclical

Testing    Exterior - Tightness

Splash water test

  • Checking protection classes IPX3, IPX4, IPX4K
  • Adjustable water quantity
  • Defined pivoting movement of the bow
  • Parameter recording

Diving test (protection class IPX7)

  • Adjustable immersion water temperature
  • Test medium can be colored for visualization
  • Parameter recording

Dust test (test dust Arizona/Portland cement)

  • Test room dimensions (WxDxH) 900 x 900 x 800 mm
  • Variable height adjustment of the test specimen

Testing    Exterior - Determination of friction coefficient

Use

  • Determination of friction values of e.g. wiper rubbers
  • Transfer behavior and wear of wiper lips
  • Recording with high-speed cameras

Details

  • Load from 0 N to 50 N
  • Rotating, oscillating and linear drive
  • Measurement under various ambient conditions (-30°C to +70°C; 0% r.h. to 100% r.h.)
  • Parameter recording

Testing    Exterior - Self-certification

Self-certification

  • Preparation of self-certification reports
  • Glazing
  • Vehicle Identification Number (VIN)
  • Monitoring the revision at the model year change
  • If necessary, update of the SZ reports