Testing and fatigue strength Automotive

The headquarter in Ottobrunn houses a covered test hall (5,000 m2) with a modern infrastructure, central supply of hydraulic fluid, compressed air and cooling water as well as safety facilities (e.g. works fire brigade).

Our standard and special test benches are used to examine, test and qualify complete vehicles, functional units and individual parts and components. We examine the dimensions and design, the materials used as well as their behaviour when exposed to defined loads.

Furthermore, we develop innovative test equipment. We would be glad to advise you personally - prior to the start of the project, during the complete production cycle and for specific problems.

Our range of services in testing and qualifying covers:

Our seal stands for the quality of our accredited and certified test facilities.

  

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Complete vehicles

Road simulation with climate and solar simulation

Not all functions and aspects of fatigue strength can be covered by component testing. It is often essential to test the complete vehicle. IABG has various test benches and test chambers for this purpose:

  • Roller test benches
    For testing drive shafts, performing engine applications and running function tests.
  • Exhaust gas analysis
    Emission measuring and assessment in compliance with the standard cycles (NEDC, FTP-75, etc.) up to an altitude of 1,600 metres.
  • Vibration testing
    Hydraulic multi-axis vibration table for testing vehicle bodies and vehicle pre-aging.
  • Solar simulation
    Simulation of solar radiation on a complete vehicle.
  • Metrology
    Sensor application, telemetry, photogrammetry, measuring data acquisition and evaluation, analysis of operational vibrations.
  • Road tests
    Application of complete vehicles and performance of road tests.
  • Acoustics laboratory
    Examination of the acoustic properties of vehicles in various acoustics chambers.

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Chassis

Axle drive dynamics test bench

For testing the fatigue strength of chassis components we offer you:

  • Wheel and tyre testing
  • Spring and stabiliser bar testing
  • Air spring and shock absorber testing

New chassis developments, like ARS, ABC, ESP, electronic wedge brakes and runflat tyres, demand new testing methods. Here, you can base the development of future-oriented test procedures for specific innovations on our established test equipment and procedures.

Vehicle bodies

Variable superstructures

Due to the need to build increasingly lighter yet stiff car body structures, it is essential to provide fatigue analyses of car body structures with respect to design, materials and joining technology.

Through our many years of experience in the aerospace sector, our experts are well familiar with qualifying new materials like fibre-reinforced composites, for example, just as with ways of reducing weight and costs by using the latest joining technologies.

We provide diverse test facilities for testing vehicle bodies and vehicle structures:

  • car body test bench (road simulator with climate and solar simulation).
  • Drive-in temperature and climate chambers.
  • Corrosion test chambers.
  • Solar simulators.
  • Variable superstructures, for example on the "HYDRA" hydraulic test facility.
  • Metrology and application.
  • Accredited material and fatigue strength testing laboratory.

Engine & Powertrain

Engine & powertrain testing

To qualify engine and powertrain components it is necessary make diverse tests and examinations in the development process.

Spectrum of our test centre for fatigue strength:

  • Time and cost-optimised thermo-mechanical fatigue testing of cylinder heads on our unique cylinder head test benches
  • Internal pressure testing of diesel and petrol fuel injector rails and their components on our high-pressure (up to 3,000 and 4,000 bar) and low-pressure (up to 350 bar) test benches
  • Crankcase and crankshaft testing on the HYDRA hydraulic test facility
  • Acoustic measurements in anechoic chambers
  • Splash water testing of engine and exhaust gas components
  • Temperature, climate and altitude chambers for testing the starting behaviour of engines and vehicles
  • Testing of electric motors under the influence of dust
  • Corrosion testing
  • Application metrology on crankshafts, for example
  • Testing of valve springs on the IABG valve spring test bench

Interiors

Solar simulation

Interior components are subjected to numerous different types of load. To ensure that interior components do not fail in service, they must be qualified beforehand under conditions that are as realistic as possible. Decisive roles are played by the choice of materials, climatic influences and mechanical loading.

We have the right test equipment for all the relevant influencing factors:

 

  • Temperature and climate cabinets and chambers
  • Various facilities for vibration testing
  • Solar simulators for components and complete vehicles
  • Individual and variable test superstructures
  • Determination of material properties and damage analysis in the fatigue strength and materials laboratory

 

Electronics

lead frame

Increasingly more control devices and electronic components are integrated in the development and production of new vehicles whose reliability is decisively influenced by their fail-safe performance. Today, over half of all vehicle breakdowns are due to failure of the electronics.

We test your control devices for function, susceptibility to failure and suitability for daily use by exposing them to extreme temperatures, high humidity and mechanical loading, for example.

Alongside simulation of environmental conditions we have a universal HIL simulator with which we can test the functions of control devices.