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OVERVIEW Automotive Testing Intelligent testing

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Page 1: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Automotive

Testing

Intelligent testing

Page 2: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Types of tests covered

Zwick testing systems are widely used to determine mechanical

properties and durability of materials, structures and components

Flexure

Tension / Peel / Tear Compression Axial / Torsional Impact / High Speed

Melt flow

Fatigue / Durability Hardness / Nano Indentation

2017Corporate presentation – Automotive 2

Page 4: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Solutions for the automotive industry

Testing solutions for all elements of a vehicle

4 2017Corporate presentation – Automotive

Safety

Engine & drive train

Interior

Body

Source: Porsche

Electrification

Materials

Joining technology

ChassisElectronics / Mechatronics

Page 5: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

Tensile strength

Fatigue strength

Testing specifications:

Determination of elastic limits

Simplified testing of fasteners

oil environment simulation (engine)

Zwick solutions:

Static testing machines

Vibrophores

Servohydraulic testing machines

Customized solutions

Wide range of gripping and extensometry solutions

Fasteners

Specimen grips for

screws and round specimens

Tests on fasteners are efficiently performed

on a number of testing solutions

Fatigue test on

bolts and screws

2017Corporate presentation – Automotive 5

Fasteners

Page 6: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

high-cycle fatigue determination

strength of drive components

Testing specifications:

high specimen throughput

minimal operating costs

temperature capability (90 - 120 °C)

oil environment simulation (engine)

Zwick solution:

Vibrophore

special clevis grips

test frequency up to 250 Hz

oil environment (temp. controlled)

Connecting rods

Testing connecting rods

High cycle fatigue tests on connecting rods

With oil lubrication

2017Corporate presentation – Automotive 6

Con rod

Page 7: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

determination of fatigue life and fatigue limit of chains

testing either an endless chain or chain segments

testing single components (e.g. bridges) also possible

Standards:

customer’s standard - no general standards for fatigue loads

Zwick solution:

Vibrophore

Servo-hydraulic testing system

Chains

Fatigue strength tests on engine chain drive systems and chain

elements, also under environmental conditions

Vibrophore Chain testing

2017Corporate presentation – Automotive 7

Drive chain

Page 8: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirement:

Compression and oscillating

compression load

Static and dynamic load

Zwick solution:

Exchangeable compression dies

for different modules and diameters

Adjustable rack for mounting

of variable wheel sizes

Gear wheels

Fatigue tests on individual gear tooth under static preloading

2017Corporate presentation – Automotive 8

Gear wheel test fixtureFatigue test on gear teeth

Gear wheels

Page 9: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirement:

determination of

spring characteristics

Standards:

EN 15800

Zwick solutions:

PrecisionLine Manual

PrecisionLine Automatic

PrecisionLine Vario

Valve springs

PrecisionLine Automatic

Determination of characteristics of valve springs

PrecisionLine Vario

2017Corporate presentation – Automotive 9

Precision springs

Page 10: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirement:

Determination of torque level

at which joint is formed

Standards:

customer’s standards

Zwick solutions:

Torsion-Line

laserXtens allows the relative

torsion angle of the two

measuring points to each other

to be determined when torsion

is applied

Camshafts

Torsion tests on camshafts with force-fit joints on Torsion-Line

10 2017Corporate presentation – Automotive

Torsion test of force-fit joints

Camshaft assembly

Torsion-Line test system

Page 11: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Rockwell Hardness Testing

Rockwell Hardness Testing on automotive components

Rockwell testing on camshaft Rockwell testing on valve seating

11 2017Corporate presentation – Automotive

Page 12: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Machine: Torsion-Line 1000 for

torque testing up to 1000 Nm

Measurement of maximum torque

and calculation of torque ratio at

different positions

Drive shafts and cardanic joints

Torsion test on automotive drive shafts and cardanic joints

Fatigue and torsional testing

Torsional deformation of specimens

2017Corporate presentation – Automotive 12

Page 13: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Description:

torsional fatigue

and durability of drive shafts

Requirements:

different component

shapes and lengths

determine number of cycles

to failure under torsional load

(monitor rotational angle)

Zwick solution:

servo-hydraulic rotary

actuator, torque cells,

digital controller,

T-slot table, specimen grips,

software for fatigue testing

Drive Shafts

Fatigue and torsional testing

Fatigue and torsion testing

Torsional fatigue test rig

2017Corporate presentation – Automotive 13

Page 14: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirement:

determination of S-N curve

(fatigue life and strength to

DIN 50100)

specimens: 15 - 30

Standards:

customer’s standards

Zwick solution:

Servo-hydraulic

testing machine HB 50

Digital controller (10 kHz)

complete solution including special

test fixtures

Crankshafts

HB 50

Fatigue tests on crankshafts

Fatigue testing of crank shafts

2017Corporate presentation – Automotive 14

Page 15: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Clutch

Testing requirements:

zero (null) point

pre and main dampening reference curve

friction point

clutch face-plate reference curve

parallelism

clutch disk thickness

drag torque

compression and release force

Standards:

customer’s standard. No general standards

Zwick solution:

custom-made torsional clutch disk tester

Allround-Line testing machine

Clutch disks

Axial and torsional testing of clutches and clutch disks

Horizontal testing machine

Test fixture

2017Corporate presentation – Automotive 15

Page 16: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Exhaust system

Testing requirements:

Simulation of real life conditions

Bi-axial loading of structure

Standards:

customer’s standard - no general standards

Zwick Solution:

Portal load frame with 2 servo-hydraulic actuators

for axial and lateral loading

T-slot table

Digital controller and software

Test on complete exhaust system

Structural testing of an entire exhaust system

2017Corporate presentation – Automotive 16

Page 17: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Reproduced service data

Includes entire exhaust system with engine

Exhaust systems

4 Actuator rig

Modernized exhaust test rigs

2 Actuator rig

17 2017Corporate presentation – Automotive

Page 18: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

testing support mats during

loading/temperature influences

RCTF: Real Condition Test Fixture

TMA: Thermo-Mechanical Analysis

determination of friction coefficient under

temperature and compression influence

Standards:

customer’s standard - no general standards

Zwick Solution:

heated 10 kN compression platens

temperatures up to 1050°C

Catalytic converter material

Testing support mats

Testing support mats for catalytic converters during loading and

under high temperature influences

18 2017Corporate presentation – Automotive

Page 19: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

testing decoupling element

Axial and torsional loading

Simulation of large displacement

Standards:

customer’s standard - no general standards

Zwick Solution:

Servo- hydraulic testing machine with axial

and torsional actuator

Exhaust system

Axial/Torsional test on exhaust decoupling element

Axial and torsional loading of a exhaust gas decoupling element

19 2017Corporate presentation – Automotive

Exhaust decoupling element

Page 20: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Chassis

20 2017Corporate presentation – Automotive

Suspension springs

Tie rods

Steering system

Steering linkage Shock absorbers

Brake discs

Brake pads/linings

Wheels

Tires Steering column

Examples of tested parts on a chassis

Page 21: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Test requirements:

tension / compress. 20 kN maximum

torsion 100 Nm max.

tension / compression 1 kN max.

Universal baseplate for fixtures and supports

Zwick solution:

multi-axis solution with simultaneous load types

20 kN horizontal testing table with adjustable

torsion and side loading axes

complete safety shield – CE-compliant

Steering linkage

3 test axes for steering linkage

Multi-axial testing of steering linkages to determine internal friction

moments and „stick – slip“ effects

3

5

1

2

3

Steering linkage

2017Corporate presentation – Automotive 21

Page 22: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

operating test

measurement of displacement

forces for extension and

compression

check retaining ring

measurement of rolling friction

Zwick Solution:

extended 5 kN table-top

machine with

pneumatic torsion drive,

clamping device,

transport units,

angle transducer

Steering columns

100% production-line testing of steering columns for commercial

vehicles

22 2017Corporate presentation – Automotive

Testing steering column Testing steering column

Page 23: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Constant velocity joints

Rockwell testing inside a constant velocity joint

Rockwell hardness test in difficult to reach parts

23 2017Corporate presentation – Automotive

Page 24: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Drive Coupling

Rockwell hardness on drive coupling

Rockwell hardness test on drive coupling shaft surface

24 2017Corporate presentation – Automotive

Page 25: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

determination of axial friction forces on

struts under lateral load influences

determination of torque on struts under

lateral load influences

determination of spring piercing points and the resulting

force, force progression and the side load on the

compression coil springs

Zwick solution:

20 kN testing system

torsion drive unit (located below the crosshead)

3-channel measurement platform above and a

6- channel set-up below

optional side load up to 3 kN force

MacPherson Strut

Test on entire MacPherson Strut

Determination of a axial friction forces on MacPherson strut

25 2017Corporate presentation – Automotive

Page 26: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

friction moment in a tie-rod

under axial load

measure drag torque in the

tie-rod while under axial load:

initial test - in new condition

subsequent test - in used condition

(equates to 50,000 km wear)

Zwick solution

testing system with 20 kN axial

force, 200 Nm torsion, testControl

controller, testXpert® software for

2 test axes

axial joint with integrated

measurement transducer

(rotation angle)

other applications: shock absorbers,

MacPherson struts, steering linkage,

damping elements

Tie-rod

Torsion testing machine

Axial and torsional testing on tie rods

Fatigue torsion test on tie rod

26 2017Corporate presentation – Automotive

Page 27: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

Brake pad deformation/stiffness

under compression load

Zwick solution:

3 measuring transducers connected

in parallel, deformation 1 – 3 µm,

accuracy 0.1 µm

interchangeable compression die

(brake piston)

solutions for various brake pads

(position stop system)

Disk brake pads

Compression test on disk brake pads

27 2017Corporate presentation – Automotive

Brake pad testing Allround-Line

Page 28: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Description:

dynamic characterization and

durability test on air suspension

springs at various temperatures

Zwick solution:

250 kN servo-hydraulic testing

system (model HB 100) with

crosshead-mounted actuator and

hydrostatic bearings for improved

performance

special compression fixture with

diametral measurement transducers

temperature chamber,

temperature range

- 80° to + 250°C,

removable via trolley

Air suspension springs

Dynamic characterization and durability test on air suspension

springs at various temperatures

28 2017Corporate presentation – Automotive

Temperature chamber 250 kN servo-hydraulic testing system

Page 29: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Air suspension springs

Testing on air suspension spring

Testing requirements:

leakage test (compression against time)

compression in relation to axial force

axial and radial stiffness, axial isobar characteristics

Control parameters:

axial force and travel, horizontal force and travel

air pressure or fluid charge

Zwick solution:

250 kN test machine (wide) with specimen-positioning

table and horizontal testing axis

load measurement platform with 5 load cells

load measurement platform above the crosshead with

three vertical and two horizontal load cells

horizontal drive unit (lower left)250 kN testing system

Static test according to EN 13597

29 2017Corporate presentation – Automotive

Page 30: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Suspension springs

3D real-time display of the resulting force on multi-channel measuring

platform guarantees fast and safe component evaluation

Static testing machine Test results

Results calculated and displayed online:

point of application and point of effect of the

resultant force

spring diameter with additional enveloping

circumference measuring device

spring height

up to 9 force channels

all torques

2017Corporate presentation – Automotive 30

Page 31: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Description:

high-frequency test on a rubber-metal

damper element

quality control verification

Zwick solution:

servo-hydraulic testing system

table-top load unit with a T-slot table

load cell (adjustable mounting position)

digital controller

elastomer application software

Indication light for “pass“ or “ fail“ condition

Light curtain and hand placement station

for safety and automatic test initiation

Rubber damper element

Servo-hydraulic testing system HC5

High cycle fatigue test on a rubber-metal damper element

31 2017Corporate presentation – Automotive

Page 32: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Damper elements

Robotic testing system

Description:

static compression hysteresis tests on production

damper elements for passenger cars

Zwick solution:

automatic testing system with built-in circumferential

orientation to support production throughput

Zwick load unit

Polar robotic system

testControl controller with testXpert®

barcode marker /reader and weighing station

Specimen feeding system

Robotic testing systems for high specimen throughput and high

reproducibility of test results

32 2017Corporate presentation – Automotive

Page 33: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Description:

Cyclical loading test

on trunk dampers.

Friction determination

Zwick solution:

Zwick Z020 with

additional lateral test axis

Trunk dampers

Zwick Z020 for testing

trunk dampers

Cyclical loading test on trunk dampers with additional side loading

Horizontal and vertical

testing axes

33 2017Corporate presentation – Automotive

Page 34: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

testing lateral stability of vehicle wheels

measurement of deformation on tire and rim

Control parameters:

axial force and crosshead travel

horizontal force and travel

tire air-pressure

Zwick solution:

Zwick 50 kN test machine (wide frame) with

20 kN horizontal drive system (± 50 mm)

five-component load measurement platform

(axial and horizontal directions)

testXpert® software to control both the drive

systems and the air pressure

Tires

Tire bulge test

Tire bulge test to test lateral stability of wheels

2017Corporate presentation – Automotive 34

Page 35: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

Mechanical deformation of

wheel-rim flange

Easy setup and flexibility of

different wheel dimensions

Zwick solution:

100 kN materials testing

machine

T-slotted crosshead

compression mandrel

Hardness testing machine

for Brinell hardness

Wheels

Wheel testing system

Mechanical deformation and hardness measurement of

wheel-rim flange

Brinell hardness test

35 2017Corporate presentation – Automotive

Page 36: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

8 Actuators

8 x Single channel

Cubes with 1SV8TX

64 transducers

QanTiM

Dura

Complete chassis

8 x 1SV8TX

FlexMAST system modernized with Control Cube

36 2017Corporate presentation – Automotive

Test on Pick-up truck chassis

Full body test

Page 37: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Sheet metal

Rivets

Adhesives

Paint

Insulation

Joints

Structures

Crash structures

Side impact bars

Spot welds

Body

37 2017Corporate presentation – Automotive

Examples of tested parts on body elements

Page 38: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Sheet metal

High-speed tensile/ compression and penetration tests

on sheet metal

38 2017Corporate presentation – Automotive

Testing requirements:

High speed impact tests on sheet metal

for material characterization

Zwick solution:

Servo-hydraulic High Speed Testing

Machine

Fmax = 500 kN

vmax = 10 m/s

Piston stroke = 250 mm + 50 mm

end cushioning

3 large proportional valves (1500

l/min) for high speeds and additional

servo valves for low speeds

Rigid 4-column test frame,

dynamic test force 2 MN

Piezoelectric force measurement

testControl II with testXpert®

Research

High speed testing system

Sheet metal samples

Page 39: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

Determination of crash structure

deformation at low speeds

Zwick solution:

Machine: Z1200E materials testing

machine

Fmax = 1200 kN

vmax = 400 mm/min

high lateral rigidity

Load cell with multiple strain-gage

applications and transverse force

monitoring

T-slot platform: width 2350 mm,

depth 4000 mm

Interface for 3-D optical

deformation analysis

Crash structures

1200 kN testing machine for deformation tests on bodywork

components at low speeds.

39 2017Corporate presentation – Automotive

Deformed crash structure Low speed crash testing system

Truck crash structure

Page 40: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

Determination of deformation of high

strength steel side impact structures

Zwick solution:

Machine: Z250 Allround, 3-pt.

flexure test on door structures

Side impact bars

3-point flexure device

Flexure test machine for tests on reinforcement steel structures

Side impact bars

40 2017Corporate presentation – Automotive

Page 41: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Description:

flexible testing system – standard tensile

testing and static component testing

door stiffness during side impact

Zwick solution:

100 kN wide load frame with test areas above

and below the crosshead

Upper test area:

tensile testing experiments with separate

load cell, wedge grips, adjustable

extensometer, testControl electronics,

testXpert® software

Vehicle doors

Testing passenger car doors

Testing passenger car doors

41 2017Corporate presentation – Automotive

Page 42: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Description:

determine the supplier quality and

formability characteristics of

galvanized steel for car bodies

Zwick solution:

50 kN testing system

hydraulic gripping system with

interchangeable inserts to

satisfy different test

specifications:

draw-bead test

friction coefficient for Renault

friction coefficient for

VW Salzgitter (abrasion)

Sheet metal

Pneumatic grips

Draw-bead test for determination of sheet metal formability

characteristics

Draw-bead test

42 2017Corporate presentation – Automotive

Page 43: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Description:

Ejection of welded parts on steel

components of chassis units

Zwick solution:

50 kN load frame (C-shaped)

Riveted joints

Riveted sample

Testing of riveted joints in R&D

C-frame testing machine

43 2017Corporate presentation – Automotive

Page 44: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Description:

Determination of fender deformation

Zwick solution:

Electromechanical actuator

Test portal

Can be combined with full field 3D imaging

Formed sheet metal

Deformation of car fender

Deformation tests on various points on passenger car fender

44 2017Corporate presentation – Automotive

Page 45: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Testing requirements:

Determination of short span flexure

capability of body sheet metal

Zwick solution:

Reinforced support rollers and

cage for short support spans

Specimen size 60 x 60 x t mm

Flexure fin with r=0,2 mm and 0,4 mm

Design improved together with

Daimler for standardization

Standard fixtures do not work!

Sheet metal

Special test fixture for short span flexure tests on metal and

aluminum sheets according to PAPP PWT 4101 and VDA 238-100

45 2017Corporate presentation – Automotive

Short span flex fixture

Test setup

Page 46: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Solutions for the automotive industry

Electronics / Mechatronics

46 2017Corporate presentation – Automotive

Safety

Engine & drive train

Interior

Body

Source: Porsche

Electrification

Materials

Joining technology

ChassisElectronics / Mechatronics

Page 47: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Description:

perform a low-torque test on a three-position rotary switch as part of a routine

quality control check on automotive and industrial switches

Test results include:

torque

angle of rotation

switch contact point

Zwick solution:

zwicki-Line testing machine with torsion drive adapter,

control electronics and integrated electronics and software

Rotary switch

Test on rotary switch

Testing rotary electrical switches

47 2017Corporate presentation – Automotive

Page 48: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Description:

tensile test on a complete cable,

consisting of wire cores, insulation, and sheathing,

to verify compliance with specification D41 1674

tensile test on wire insulation/sheathing

(consisting mainly of elastomers, PE, PP or PVC)

Specifications: LV 112, EN 60811, VW 603 06

Zwick solution:

pneumatic grips (and controller),

automatic extensometer, testXpert® software

Cables

Tensile test

2017Corporate presentation – Automotive 48

Tensile tests on electrical cables

Page 49: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Description:

determination of the quality of electrical wire

(specifications LV112, VW 60306) and the indentation

resistance of the insulation

Zwick solution:

testing machine with testControl and testXpert®

the cable is loaded in compression resting on an anvil fixture

and the contact force is measured at the exact moment there

is contact between the metal anvil and the cable wire

(electrical signal is conducted) - accomplished with switch contact

Wire

Insulation test

2017Corporate presentation – Automotive 49

Indentation / insulation test

Page 50: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Electrical connectors

Pull out test

Description:

determine the connection quality of electrical connectors

Zwick solution:

testing system with adjustable screw grips

(minimal influence on test results)

maximum force and extension at disconnection point are measured

test performed to various specifications

(ISO, automobile manufacturers)

Tensile testing of connectors

Tensile tests on connectors

2017Corporate presentation – Automotive 50

Page 51: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Electronic circuit board

Testing electronic circuit boards

Testing machine with two test areas Compression test on circuit boards

51 2017Corporate presentation – Automotive

Page 52: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Description:

determination of the push-out

resistance of circuit-board pins

Zwick solution:

zwicki 1.0 kN test machine

with motorized X-Y table and

joystick for positioning

(and to assist in learn mode)

Electronic circuit board

Testing electronic circuit boards

Zwicki-Line testing machine Push-out test

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Page 53: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Testing requirements:

Determination of force-stroke

performance of valve solenoids

Zwick solution:

Electromechanical actuator,

integrated into production

Solenoids

Testing actuator 3 actuators in-line

In-line performance test on valve solenoids

53 2017Corporate presentation – Automotive

Solenoid

Page 54: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Solutions for the automotive industry

Interior

54 2017Corporate presentation – Automotive

Safety

Engine & drive train

Interior

Body

Source: Porsche

Electrification

Materials

Joining technology

ChassisElectronics / Mechatronics

Page 55: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Interior

55 2017Corporate presentation – Automotive

Head rests

Trim

Seats

Supports

Seals

Adhesives

Leather

Textiles

Seat belts

Structures

Foams

Sensors

Examples of tested parts in the interior

Advanced vehicle interior

Page 56: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Description:

electro-mechanical testing

actuator for static or dynamic tests

Testing requirements:

determine the quality, strength and

durability of passenger headrest supports

Zwick solution:

Electromechanical actuator: 1 kN

Headrest

Testing headrests

56 2017Corporate presentation – Automotive

Testing of headrests

Testing of headrests

Page 57: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Description:

supplier quality assurance testing;

support for new product development

(integrated seat sensors for safety

and airbag control)

Zwick solution:

modified load frame (wide) with horizontal

loading crosshead and special platen for

mounting seat component

crosshead-mounted load cell with

horizontal adjustment

testControl controller

testXpert® software

Seats

Allround-Line

Static seat-testing

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Page 58: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Description:

durability test on soft foam

determination of compression stress

value before / after durability test

cyclical loading

Zwick solution:

Electromechanical actuator with load frame

testControl electronics and testXpert software

Foam

Testing foam

Cyclical testing of foams with an electromechanical actuator

58 2017Corporate presentation – Automotive

Page 59: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Description:

Dynamic compression test

Zwick solution:

Servo-hydraulic testing system

with side load actuator

Seats

Test arrangement with

two axes for seat testing

Dynamic compression test on seats with a bi-axial servo-hydraulic

testing system

Dynamic compression

test on seats

59 2017Corporate presentation – Automotive

Page 60: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Description:

dynamic seat testing to determine the

characteristics and durability of seats as supplied

Zwick solution:

flexible bi-axial component testing system

(servo-hydraulic)

special wide load frame with hydraulic jacks

and locking system and adjustable horizontal

actuator rated at 10 kN

special T-slot mounting base, bi-directional slip

table (Teflon bearings) and three-dimensional

seat platen with gimbaled mount

Seats

Dynamic compression test on seats

Dynamic compression test on complete seats

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Page 61: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Description:

determine supplier quality and characteristics

of window seals with integrated tactile sensors

(safety feature for accidental closure on fingers,

heads etc.)

Zwick solution:

zwicki table-top testing system, 1.0 kN force

specially-designed seal-holder

barcode reader (window seal identification)

integral electrical resistance measurement

system

(e.g. 30 N force = 600 ohm signal in the

window-seal sensor)

Window seals

Window seal testing

Window-seal testing

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Page 62: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Technical seals

Deformation characteristics of technical seals

with synchronized video capturing

62 2017Corporate presentation – Automotive

Testing machine is connected to a camera Sychronized video sequence of the test

Page 63: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Elastomer joints

Elastomer joint mounting fixture

Description:

determine the required assembly forces for mounting

and dismounting elastomer joints

Zwick solution:

Base unit with spring supported base plate

Load cell mounted on fixture crosshead

Specimen support and compression platens

For various sheet metal thicknesses (0,8 - 4,5mm)

Elastomer joint mounting fixture

Test fixture for the determination of mounting and dismounting

forces of elastomer joints according VW PV 3365

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Page 64: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Solutions for the automotive industry

Safety

64 2017Corporate presentation – Automotive

Safety

Engine & drive train

Interior

Body

Source: Porsche

Electrification

Materials

Joining technology

ChassisElectronics / Mechatronics

Page 65: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Safety

65 2017Corporate presentation – Automotive

Deploying airbag in a crash test

Safety Restraint

Systems

Airbag textiles

Connectors

Textiles

Seat belts

Buckles

Torsion bars

Examples of tested safety elements

Page 66: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Description:

tensile test on seat belts

Safety

Tensile test on seat belts with videoXtens

Tensile test on seat belts and seat belt buckle

66 2017Corporate presentation – Automotive

Zwick Z050

Seat belt buckle test

Page 67: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Torsion bar

Determination of torsion bar performance under real conditions

Torsion testing arrangement for dynamic tests on torsion bar Seat-belt components

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Page 68: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Description:

determination of material

properties (airbag texture)

for quality assurance

Zwick solution:

Zwick 100 kN Allround-Line

Airbag textiles

Tensile test on airbag textiles and airbag seams

testXpert® screenshot

68 2017Corporate presentation – Automotive

Tensile test on airbag textile

Page 69: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Testing requirements:

Determination of connector contacting

points with video monitoring

Zwick solution:

Zwicki-Line and 4 integrated

video camera systems

Airbag connectors

Determination of contacting forces of an airbag connector with 4

synchronized video streams

69 2017Corporate presentation – Automotive

Testing of an airbag connector

Synchronized display of sample and test diagram

Page 70: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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(Hybrid) Electrical vehicles

In addition to the classical areas of testing hybrid and electrical

vehicles require new elements to be tested

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Page 71: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Description:

determine the surface adhesion forces

of electrode coating

Zwick solution:

Machine: Z010 Allround-Line

with testControl II electronics

Fast (2000 Hz) synchronous

measured-value acquisition

Special Z-direction tensile fixture

to measure adhesion forces

High repeatability due to up to 5 tests in one

setup

Li-Ion battery cells

Testing surface coating adhesion on anodes and cathodes of

lithium-ion batteries

71 2017Corporate presentation – Automotive

Z-direction tensile test on cathode coating

Li-Ion battery cell layers

Page 72: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Description:

determine the magnet adhesion

force in stator

Zwick solution:

Machine: Z010 Allround-Line

Special rotation fixture for

precise positioning

Manual magnet positioning

Electric motor

Details of electric motor

Shear test to determine magnet adhesion forces in

electric motor stator

72 2017Corporate presentation – Automotive

Testing magnet adhesion

Page 73: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Composites in hydrogen environment

Dewar vessel

Tensile, flexure and fracture toughness tests on composite specimen

submerged into liquid nitrogen (at 77 Kelvin)

73 2017Corporate presentation – Automotive

Interlaminar fracture

3-point flexure test

hydraulic actuators

Dewar

vessel

lead-through for

load transmission

Page 74: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

OVERVIEWMENU

Fuel cell elements

Fuel cell components such as gas diffusion layers are being tested in

compression with high accuracy determination of deformation

74 2017Corporate presentation – Automotive

Test set up including 2-point flexure fixture Compression test on gas diffusion layer

Gas diffusion layers

Page 75: Automotive Testing · 2020. 9. 14. · Zwick solutions: PrecisionLine Manual PrecisionLineAutomatic PrecisionLine Vario Valve springs PrecisionLine Automatic Determination of characteristics

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Zwick Roell AG

Through constant innovation, we offer all components

necessary for professional material testing.

testXpo in Ulm What is testing? SAFETYDIRECT LINKS:

Extenso-

meters

Grips &

Toolings

Load Cells Modernization Customer

Support

Impact

Testers

Plastometers HDT-Vicat Sheet metal

testing

Robotic

testing

Static testing

machines

Hardness

testers

Innovations

Fatigue testing

machines

Reliable Test Results

Software Electronics

2017Corporate presentation – Automotive 75