Structural integrity is highly significant for a vehicle’s life expectancy – how is the vehicle’s integrity in terms of body construction, chassis or other components such as damping, axles, powertrain mounts or entire assemblies? How do environmental conditions such as temperature, humidity and sunlight impact the vehicle’s structural integrity? The following parameters should be balanced:
- Optimal weight and dimensioning of the overall construction
- Safe operation
During testing, a vehicle has to withstand typical mechanical loads encountered in operation over a specified simulated lifetime. Failure in the form of fatigue, incipient cracks or degradation is not acceptable.
Before running real-world field tests in dedicated proving grounds, the validation of a vehicle’s structural integrity is conducted as a full simulation on a PC and as tests in automated test facilities in durability labs. Here, road load data is reproduced by actuators. Read more about lab testing
HBM Darmstadt is the worldwide centre of excellence for measurement and data analysis of structural integrity.
Get the complete toolbox – from lifetime fatigue analysis based on FEM models to mobile in-field and lab-based data acquisition solutions including powerful EDGE software, and powerful server-based data analytics. This, of course, with the goal of the whole team providing rapid test and analysis and providing an efficient outcome towards management sign off.
Benefits Using HBM for Structural Integrity
Accelerate testing in all areas – simulation, field and lab. Focus on your data, simplify your development and de-risk your testing.
The HBM structural integrity toolbox allows you to orchestrate and act on your simulation and testing data from your individual virtual and physical test specimen.
- Dramatically reduce time and resources, working with HBM experts, the seamless tool chain and all necessary services
- PC simulation: CAE-based fatigue analysis with nCode DesignLife
- Complete measurement chain of strain gauges, data acquisition systems and software, with all components working together perfectly
- Broad portfolio of electrical strain gauges with short delivery times, including pre-wired gauges for immediate use
- Data acquisition system input schematics with highest immunity against electromagnetic interference and thermal drift due to carrier frequency technology, distributable amplifier modules and auto-calibration on all channels
- DAQ system input schematics compensation of cable effects with 4-, 5-, and 6-wire circuit-based patented amplifier technology
- Same data acquisition system for Road Load Data Acquisition (RLDA) and lab testing
- DAQ system perfectly integrated into MTS-329 road simulator rigs with FlexTest/RPC Pro and into MAST and all component test stands with INSTRON LabSite
- Complete software solution for the application, ready-to-start without programming
- Powerful server-based data processing and analysis based on nCodeDS
- Overall data management and collaboration based on Aqira
- Material testing and evaluation as a service with HBK testing equipment
Integrate the best fit hardware combinations from different vendors in your overall testing solution with technologies such as EtherCAT, PROFINET, ASAM xCP-on-Ethernet or a simple API.
- Integration into INSTRON (click to enlarge)
- Integration into MTS (click to enlarge)
- Integration into Zwick/material testing (click to enlarge)
QuantumX / SomatXR DAQ: Parallel Data Acquisition and Control
Supports standard TCP/IP Ethernet and Industrial Ethernet standards such as EtherCAT® to:
- Reduce cable wiring, number of inputs on the controller side and overall cost
- Reduce setup time and cost
- Reduce complexity and possible errors
- Increase availability and time for testing, and shorten development times
- Improve data quality and overall reliability
- Allow single time stamp and different clock cycles (distributed clock, 3 sync managers)
catman Software and Analytics
catman is comprehensive and adaptable non-programmable software, conceived for data acquisition, online calculations and analysis by monitoring the entire testing process. It features extensive reporting functions with a graphical presentation of the results.
All acquired measurement data sets run into data analytics, by rainflow cycle counting and the Monte-Carlo methods. The software offers either the creation of a fatigue curve (Woehler) or a variable amplitude fatigue curve (Gaßner).
The efficient and process-oriented workﬂow reduces cost and shortens testing times.
A Structural Durability Lab Testing Assessment is one of the last stages before a vehicle prototype can be released onto the market. To create structural test programs covering true market requirements, hydraulic, pneumatic and electric actuators, vibration tables and climatic chambers are used.
An operation profile defines the conditions to be monitored but also the target damages of the accelerated testing. In the lab, mainly strain and force-based measurements are used to characterize loads under replayed real-world operating conditions and calculate resulting accumulated fatigue damage.
To authentically imitate the road in numerous types of dynamic and static tests, different loads applied to the system under test are reproduced:
- Multi-axis, full-scale 4-poster road simulation, covering six degrees of freedom
- Vehicle stress and strain analysis
- Bi-axial, axial-torsional, multi-axis load machines
- High-cycle and low-cycle fatigue
- Thermo-mechanical fatigue
- Fracture mechanics
- Crack propagation and growth studies
- Fracture toughness, high strain rate, quasi-static, stress-relaxation
- Steering system validation and static strength, torsion, bending
- Ultimate strength testing
Finally, the machine prototype is also tested on a suitable proving ground to replicate real-world service loads. Testing on proving grounds – Road Load Data Acquisition (RLDA) – is performed by using wheel force transducers, accelerometers, strain gauges, acceleration transducers, string potentiometers, GNSS/GPS/IMU and additional video.