Vehicle and component parts testing

1. Vehicle and component parts testing SUT 25 NOV 2012

2. WittawatWisetwisai (Aood) • Product development Engineer • Auto Alliance Thailand • (A Ford and Mazda joint venture)

3. Course outline • Overview (1hr) • Why need testing for vehicle level and component part level? • Introduction vehicle product development cycle. • Introduction vehicle components. • Introduction vehicle assembly process.

4. Course outline • Vehicle level testing (1.5hr) • Introduction vehicle testing required. • Safety and Regulation testing. • Durability testing. • Vehicle function testing. • Test method and facility • Crash test (Euro NCAP) • Wind tunnel test • Noise vibration harness test(NVH) • Squeak and rattle test • Hot cold and humility test • Water leak test • Air leak test • Engine test • Chassis and suspension test • Electrical module test • Brake test • Steering test • Body in white test • Interior testing • Fuel system test • Lighting system test

5. Course outline • Vehicle component level testing (1.5hr) • Introduction vehicle component testing standard. • มอก • UNECE • SAE • JASO • ISO • Test method and facility • Wheel and tire • Drive shaft and spinning shaft • Shock absorber • Dynamic sealing • Movable and fixed Glass • Seat and Seat belt • Hard trim and soft trim • Body attachment • Engine component • Chassis and suspension component • Electrical module component • Brake component • Steering component • Body in white and sheet metal component • Interior component • Fuel system component • Lighting system component

6. Why need testing for vehicle level and component part level? • Accident!!! • Durability • Perform vehicle function intent Car crash - Ferrari 599 GTO Vs Taxi in Singapore http://www.youtube.com/watch?v=HWECP9rF4HE Ferrari Graveyard: Video of 14 supercar pile-up in Japan http://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

7. Why need testing for vehicle level and component part level? • Accident!!! • Durability • Perform vehicle function intent Ford Ranger 2012 http://www.youtube.com/watch?v=57eYBS-o8Y0&feature=related 2012 Ford Ranger Winter Weather Test Drive http://www.youtube.com/watch?v=wc6541sC0wo 2012 Ford Ranger High Altitude Test Drive http://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 Kerl http://www.youtube.com/watch?v=tg3v5j3Dx-A&feature=related

8. Introduction vehicle product development cycle.

9. Introduction vehicle components.

10. Introduction vehicle assembly process.

11. Introduction 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 Welding http://www.youtube.com/watch?v=1-J_EzKm_70 BMW Plant Spartanburg Body Shop http://www.youtube.com/watch?NR=1&feature=endscreen&v=EE61uUqgQmQ BMW Plant Spartanburg Vehicle Assembly http://www.youtube.com/watch?v=il0N4dSAr-A http://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 –Paintshop http://www.youtube.com/watch?v=_o5dTOHWwqk&feature=related Audi A4 on the Production Line http://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

12. Vehicle level testing • End of line testing • Off line testing • Evaluation lab testing • Product development testing

13. Vehicle level testing • Appearance inspection • Water leak test • Brake test 2012 Chevrolet Cruze Water Leak Test http://www.youtube.com/watch?v=kF73SPz4IcI http://www.youtube.com/watch?v=snUACEZuIN8 New Mini Production Video(painting , road testing) http://www.youtube.com/watch?v=WA5krnTKTHY&feature=related

14. Vehicle level testing • Noise vibration harness test(NVH) • Air leak test Noise and Vibration Test | Malibu | Chevrolet http://www.youtube.com/watch?v=4EIkIgr_AqM

15. Vehicle level testing • Crash test (Euro NCAP) • Squeak 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 Stand http://www.youtube.com/watch?v=VXP8PCCErR4 All new Ranger - Squeak & Rattle track test http://www.youtube.com/watch?v=rpYS7oA-Yg0

16. Vehicle level testing • Wind tunnel test • Hot 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

17. Vehicle level testing • Engine test • Chassis and suspension test • Steering test • Lighting system test • Electrical module test 2012 Mercedes Benz M-Class Chassis Testing http://www.youtube.com/watch?v=EQiAVOGONtg&feature=related Golf 6 Testing (Suspension) http://www.youtube.com/watch?v=MFf6OLzXw-s

18. Vehicle component level testing • มอก • มาตรฐานผลิตภัณฑ์อุตสาหกรรม คือข้อกำหนดทางวิชาการที่ สำนักงานมาตรฐานผลิตภัณฑ์อุตสาหกรรม(สมอ.)ได้กำหนดขึ้นเพื่อเป็นแนวทางแก่ผู้ผลิตในการผลิตสินค้าให้มีคุณภาพ เป็นเครื่องหมายที่แสดงกับผลิตภัณฑ์ที่เป็นมาตรฐานไม่บังคับ ผู้ผลิตสามารถยื่นขอใบอนุญาตแสดงเครื่องหมายมาตรฐานได้ด้วยความสมัครใจ เป็นเครื่องหมายที่แสดงบนผลิตภัณฑ์ที่มีกฎหมายกำหนดให้ต้อง เป็นไปตามมาตรฐาน เพื่อคุ้มครองความปลอดภัยให้แก่ผู้บริโภค และป้องกันความเสียหาย ที่จะเกิดขึ้นแก่เศรษฐกิจของประเทศ ผู้ผลิต ผู้นำเข้า และผู้จำหน่าย จะต้องผลิต นำเข้าและจำหน่ายเฉพาะผลิตภัณฑ์ ที่ต้องเป็นไปตามมาตรฐานเท่านั้น

19. Vehicle component level testing • UNECE • European New Car Assessment Programme with a realistic and independent assessment of the safety performance • SAE international • Society 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. • JASO • Japanese Automotive Standards Organization , is an organization that sets automotive standards in Japan. • ISO • International 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.

20. Vehicle component level testing • Wheel and tire • Shock absorber • Brake 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 Stand http://www.youtube.com/watch?v=G3FgpjlHd6I

21. Vehicle component level testing • Seat and Seat belt • Fuel system component

22. Vehicle component level testing • Drive shaft and spinning shaft • Steering component

23. Vehicle component level testing • Chassis and suspension component • Steering component

24. Vehicle component level testing • Dynamic sealing • Movable and fixed Glass • Hard trim and soft trim • Body attachment • Electrical module component • Body in white and sheet metal component • Interior component • Lighting system component

27. ขอบคุณครับ