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:
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
HBK 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.
Accelerate testing in all areas – simulation, field and lab. Focus on your data, simplify your development and de-risk your testing.
The HBK structural integrity toolbox allows you to orchestrate and act on your simulation and testing data from your individual virtual and physical test specimen.
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.
Supports standard TCP/IP Ethernet and Industrial Ethernet standards such as EtherCAT® to:
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:
In Road Load Data Acquisition (RLDA), the vehicle is equipped with additional sensors: Strain gauges (SG), acceleration sensors, string potentiometers, special measuring wheels on one or two axes for force and torque measurement, GNSS/GPS/IMU sensors for position and kinematics, as well as video cameras for recording the driving situation.