Vehicle and component parts testing

SUT25 NOV 2012

Wittawat Wisetwisai (Aood)Product development Engineer

Auto Alliance Thailand(A Ford and Mazda joint venture)

Course outline

Overview (1hr)oWhy need testing for vehicle level and component part level? oIntroduction vehicle product development cycle. oIntroduction vehicle components.oIntroduction vehicle assembly process.

Course outlineVehicle level testing (1.5hr)Introduction vehicle testing required.

Safety and Regulation testing.Durability testing.Vehicle function testing.

Test method and facilityoCrash test (Euro NCAP)oWind tunnel testoNoise vibration harness test(NVH)oSqueak and rattle test oHot cold and humility testoWater leak testoAir leak testoEngine testoChassis and suspension testoElectrical module testoBrake testoSteering testoBody in white testoInterior testingoFuel system testoLighting system test

Course outlineVehicle component level testing (1.5hr)Introduction vehicle component testing standard.

oมอกoUNECEoSAEoJASOoISO

Test method and facilityoWheel and tire oDrive shaft and spinning shaftoShock absorberoDynamic sealingoMovable and fixed GlassoSeat and Seat beltoHard trim and soft trimoBody attachmentoEngine componentoChassis and suspension componentoElectrical module componentoBrake componentoSteering componentoBody in white and sheet metal componentoInterior componentoFuel system componentoLighting system component

oWhy need testing for vehicle level and component part level? oAccident!!!oDurabilityoPerform vehicle function intent

Car crash - Ferrari 599 GTO Vs Taxi in Singaporehttp://www.youtube.com/watch?v=HWECP9rF4HE

Ferrari Graveyard: Video of 14 supercar pile-up in Japanhttp://www.youtube.com/watch?v=BAtelRZCFWc

Ferrari 458 on fire. watch a Ferrari burn down to the ground. A burning ferrari http://www.youtube.com/watch?v=TWy8q-N8MQM&feature=related

oWhy need testing for vehicle level and component part level? oAccident!!!oDurabilityoPerform vehicle function intent

Ford Ranger 2012 http://www.youtube.com/watch?v=57eYBS-o8Y0&feature=related

2012 Ford Ranger Winter Weather Test Drivehttp://www.youtube.com/watch?v=wc6541sC0wo

2012 Ford Ranger High Altitude Test Drivehttp://www.youtube.com/watch?v=R0LCvUcKCnY&feature=relmfu

Ford Ranger Tropical Climate Test Drive 2012 http://www.youtube.com/watch?v=5PqFepzBZXs&feature=relmfu

Ford Ranger im Test: Offroad ein echter Kerlhttp://www.youtube.com/watch?v=tg3v5j3Dx-A&feature=related

oIntroduction vehicle product development cycle.

oIntroduction vehicle components.

oIntroduction vehicle assembly process.

oIntroduction vehicle assembly process.

2000 Ton Automotive Tandem Line With YaskawaRobotics(Stamping)http://www.youtube.com/watch?v=6DIz8FpkAis&NR=1&feature=endscreen

KUKA Robot- Automotive Line Spot Weldinghttp://www.youtube.com/watch?v=1-J_EzKm_70

BMW Plant Spartanburg Body Shophttp://www.youtube.com/watch?NR=1&feature=endscreen&v=EE61uUqgQmQ

BMW Plant Spartanburg Vehicle Assemblyhttp://www.youtube.com/watch?v=il0N4dSAr-Ahttp://www.youtube.com/watch?v=X-6wp3_xYJs

New Mini Production Video(painting , road testing)http://www.youtube.com/watch?v=WA5krnTKTHY&feature=related

Volkswagen AG Golf production factory Wolfsburg –Paintshophttp://www.youtube.com/watch?v=_o5dTOHWwqk&feature=related

Audi A4 on the Production Linehttp://www.youtube.com/watch?v=YeQ_M2NLI4I&feature=relmfu

Golf production factory Wolfsburg - driving the car off the assembly line(door assembly)http://www.youtube.com/watch?v=koLWv0LPVbU&feature=related

2010 BMW X1 SAV Production Line Footage(full assembly)http://www.youtube.com/watch?v=wclWBkgHWm4&feature=relmfu

Vehicle level testing

o End of line testingo Off line testingo Evaluation lab testingo Product development testing

Vehicle level testing

o Appearance inspectionoWater leak testoBrake test

2012 Chevrolet Cruze Water Leak Testhttp://www.youtube.com/watch?v=kF73SPz4IcIhttp://www.youtube.com/watch?v=snUACEZuIN8

New Mini Production Video(painting , road testing)http://www.youtube.com/watch?v=WA5krnTKTHY&feature=related

Vehicle level testing

oNoise vibration harness test(NVH)oAir leak test

Noise and Vibration Test | Malibu | Chevrolethttp://www.youtube.com/watch?v=4EIkIgr_AqM

Vehicle level testing

oCrash test (Euro NCAP)oSqueak and rattle test

New Crash Test Video Amazing 5-Star Rating Ford Ranger European Auto Safety Testing 2011 http://www.youtube.com/watch?v=R3d3uDsCPYs

MB Portable DBE Squeak and Rattle Test Standhttp://www.youtube.com/watch?v=VXP8PCCErR4

All new Ranger - Squeak & Rattle track testhttp://www.youtube.com/watch?v=rpYS7oA-Yg0

Vehicle level testing

oWind tunnel testoHot cold and humility test

Mercedes-Benz SLS AMG Developement and Testing Wind tunnel http://www.youtube.com/watch?v=sV_6E1Lh7yo

Pagani Zonda F wind-tunnel testing http://www.youtube.com/watch?v=2CYUuBiW_lY

M7 Wind Tunnel Testing http://www.youtube.com/watch?v=QrQuB_tTZmc

Novitec Rosso Ferrari 458 Italia in Wind Tunnel http://www.youtube.com/watch?v=CdE7IT-EsZ0&feature=related

Vehicle level testing

oEngine testoChassis and suspension testoSteering testoLighting system testoElectrical module test

2012 Mercedes Benz M-Class Chassis Testinghttp://www.youtube.com/watch?v=EQiAVOGONtg&feature=related Golf 6 Testing (Suspension)http://www.youtube.com/watch?v=MFf6OLzXw-s

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Vehicle component level testing

o UNECEo European New Car Assessment Programme with a realistic and independent assessment of the safety performance

o SAE internationaloSociety 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.

o JASOoJapanese Automotive Standards Organization , is an organization that sets automotive standards in Japan.

o ISO oInternational 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.

Vehicle component level testing

oWheel and tire oShock absorberoBrake component

Tire Force Test http://www.youtube.com/watch?v=nmo_dkNZIHM

Bridgestone tires tests (2009)http://www.youtube.com/watch?v=HHFqNew645o&feature=fvwrel

HORIBA ATS GIANT 6200 Brake Test Standhttp://www.youtube.com/watch?v=G3FgpjlHd6I

Vehicle component level testing

oSeat and Seat beltoFuel system component

Vehicle component level testing

oDrive shaft and spinning shaftoSteering component

Vehicle component level testing

oChassis and suspension componentoSteering component

Vehicle component level testing

oDynamic sealingoMovable and fixed GlassoHard trim and soft trimoBody attachmentoElectrical module componentoBody in white and sheet metal componentoInterior componentoLighting system component

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