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IABG tests lightweight car body structures for electric vehicles

The multi-component car body test stand (MEKKA III), developed by IABG, is now also being used for fatigue strength verifications of lightweight car body structures made from carbon fibre composite materials, developed specifically for modern electric vehicles.

In addition to the mechanical stress to the car body (distributed via 19 channels), changing climate conditions are being applied in the course of the test. The combination of mechanical loads with environmental conditions is a unique feature in total vehicle testing and represents a valuable security tool in testing new vehicle concepts.

The influence of high and low temperatures as well as dampness plays a crucial role for the structure as a whole and for the interfaces of the different material combinations (metal/plastics) in the form of sticking and screw connections in particular. This requires a test concept able to simulate the mechanical and environmental influences on fatigue strength of a lightweight car body structure in the laboratory.

MEKKA III simulates the road-typical wear and tear determined in the course of test drives. The mechanical load is transferred via the chassis of the completely installed vehicle into its body in real time.

The innovative construction of today's lightweight car bodies for electric vehicles using new materials such as CFRP requires that, in addition to mechanical loads, environmental influences are considered more and more. With MEKKA III, IABG offers reproducible superimposed testing in the form of a total package, from preparation of the item under test to the creation of mechanical control signals as well as the climatic superimposition up to permanent operation and the subsequent evaluation of the entire test result.

With IABG’s multi-component body test stand, entire vehicles can be tested at simulated near-reality conditions with regard to the mechanical operating stress of the body, also in combination with temperature, humidity and sun exposure.

IABG is a leading European technology enterprise. Our main focus lies on trend-setting high technology and science applications. We plan, implement and operate. With more than 1,000 experienced and committed employees we offer our customers solutions in the sectors Automotive, InfoCom, Transport, Environment & Power Engineering, Aeronautics, Space as well as Defence & Security.