Component testing

Exova has been providing structural and mechanical cyclic testing for over 20 years. The structural and mechanical testing facilities support the automotive, commercial truck & bus, off-highway and military industries.

Exova’s structural testing provides the facilities and equipment to test individual components, sub-systems and fully operational systems. Operational service environments subject components and systems to complex loading conditions in a laboratory environment.

Full vehicle simulations and Proving Ground Testing require longer duration test times. Current design times and limited funding minimizes the number of full systems available for testing.

Laboratory testing allows for multiple components or sub-systems to be evaluated at compressed time to meet the development schedule. Load and displacement parameters from Road Load Data Acquisition (RLDA) or computer model predictions can be used to develop single or multi-axial inputs block cycle or constant amplitude structural durability tests.

Exova can also integrate environmental conditioning & other auxiliary thermal, pressure and electrical inputs if required during the structural durability testing. Exova’s structural and mechanical test facilities utilise hydraulic, pneumatic, robotics and electrical equipment to support these test activities.

Over the last few years suppliers have been asked consistently to shorten part design and launch times but increase quality. In order to meet this challenge there has been a growing interest in ‘continuous conformance’ or ‘start of production’ lot testing.

Continuous conformance or start of production testing processes take a specific percentage of parts from a production batch and test them for design and mechanical performance. Typical examples are safety systems, engines and drive train components.

In today’s automotive economy it is often found that manufacturing facilitates do not have either the capital, manpower or support structure to accommodate short term testing programs. Exova has been working with a number of OEMs and Tier one suppliers to design flexible test systems.

These test systems allow Exova to identify the client’s needs and design test cells that meet the necessary quality, reporting, administration and testing functions of a specific program. Once the parameters have been identified Exova will assemble and install the test cell either in, or near your production facility. Exova employees will then staff the cells and will typically service clients for the initial three to twelve months of production or until the lot testing requirements are met.

Vehicle Structures and Dynamics

Test Applications include:

• Connecting Rod Cycling
• Piston Sidewall Fatigue
• Air Induction Systems
• Cooling Modules
• Frame & Suspension
• Springs & Suspension Modules
• Axle Beaming Durability (Heavy Duty)
• Axle Torque
• Control Arm, Ball Joint & Spring Durability
• Shock, Strut & Stabilizer Bar Durability
• Engine & Body Mounts & Bracket Durability
• Exhaust Components & Systems
• Hot & Cold Vibration
• Brick Crush
• Engine Roll w/ Thermal Inputs
• Joint Fatigue
• Single and Multi Axial Loads Seat Systems
• Seat Anchorage Testing
• Occupant Restraint
• Lumbar Durability
• Jounce & Squirm
• Rearward Load Strength & Fatigue
• Power/Manual Track Durability
• Power/Manual Seat System Durability
• Ultimate Load Strength
• Latch Strength
• Ingress/Egress
• Parallelogramming

Supporting Capabilities

• Engineering Services
• Simulation Facilities
• MAST Facilities
• Vibration Facilities
• Environmental Conditioners
• Root Cause Analysis
• Fixture Design & Fabrication
• High Security Testing & Work Areas
• Experienced Engineering & Technical Support
• Access to Other Bodycote Expertise & Facilities

Equipment

Hydraulics

Controllers

• MTS - 407, Flex Test, Flex Test GT
• Instron

Actuators

• 100+ Cylinders
• 1Hz to 400 Hz
• Three (3) Rotary Actuators - 20,000 in-lbs 50,000 in-lbs

Pneumatics

Controllers

• Various PLCs

Actuators

• 200 + Cylinders
• 1” to 24” Stroke
• 30 Rotary Actuators - 5 ft-lb to 100 ft-lb

Over the last few years suppliers have been asked consistently to shorten part design and launch times but increase quality. In order to meet this challenge there has been a growing interest in ‘continuous conformance’ or ‘start of production’ lot testing.

What is continuous conformance or start of production lot testing?

These processes take a specific percentage of parts from a production batch and test them for design and mechanical performance. Typical examples are safety systems, engines and drive train components.

How can Exova support these requirements?

In today’s automotive economy it is often found that manufacturing facilitates do not have either the capital, manpower or support structure to accommodate short term testing programs. Exova has been working with a number of OEMs and Tier one suppliers to design flexible test systems. These systems allow Exova to identify the client’s needs and design test cells that meet the necessary quality, reporting, administration and testing functions of a specific program. Once the parameters have been identified Exova will assemble and install the test cell either in, or near your production facility. Exova employees will then staff the cells and will typically service clients for the initial three to twelve months of production or until the lot testing requirements are met.

Typical support services offered include

• Engine Testing, both hot and cold
• Airbag deployment and safety systems
• Drive train components including metallurgical support

Support is offered in the following geographical regions:

• United States
• Canada
• Mexico
• Mainland Europe
• United Kingdom