Highly standardized bumper test system by Berghof Testing
News | Berghof Testing

One investment, numerous possibilities

August 18, 2020

Berghof Testing, the testing expert of the Berghof Group, has once again succeeded in developing an intelligent concept for testing bumpers. To be precise, it's about electrical testing of bumpers with minimized cycle time. The highlights: The system is highly flexible, tests independently of variants – and does so in a cycle time of less than 30 seconds.

Just recently, the experts from Berghof Testing set new standards in terms of cycle time, flexibility and degree of automation with their new robot bumper test system. Now they are causing a sensation again with a new concept for testing bumpers.

This new concept, developed and implemented for one of the biggest tier-1 suppliers for the automotive industry, involves the purely electrical testing of all elements of the automotive component – highly standardized and with maximum flexibility. With this concept, the testing team is adding the next level of testing to its existing portfolio of bumper testers – in expanse to the simple test bench and the highly complex robotic test system for optical and electrical bumper inspection.

This new test system shows the next higher level of standardization: Berghof Testing can build all such systems identically up to a standardized coupling, depending on the stage of expansion. This brings maximum flexibility for the customer and short development and setup times for Berghof Testing as well as optimized pricing. Furthermore, Berghof Testing is now quickly adapting the mechanical holder for the different test objects to new types (variants) of test objects on a project-specific basis. Here too, depending on the variant, Berghof works with a modular, standardized test object holder (removable frame).

The standardized coupling enables the customer to attach any variant of the test object to the test system. Thus, one single system can test all current and all future variants. If necessary, the front and rear bumpers or different variants are tested simultaneously on a single system.

Accordingly, the system is not only suitable for integration into an existing production line, but also, for example, as an emergency test station if one of several test systems fails. In addition, the test system is rollable and is therefore mobile within the customers plant. So to speak, the Berghof Testing team also provides an emergency concept for the worst-case scenario as an option for free.

The respective expansion stage is freely selectable by each customer depending on his requirements. The activation of new test object variants is carried out via the Berghof test application – the creation and setup of variant and test sequence are quick and easy. For a new variant, the customer only needs a new suitable holder. In the case of a model change, the changeover times are less than two minutes. Only the frames are to change. The system itself is a one-off investment for different series, subsequent variants and mixed operation – the customer does not have to retrofit or even buy a new one.

In addition, the test sequence itself is child's play, so to speak: the optimized test time of less than 30 seconds achieves by the parallel feeding and removal of the bumpers, as the test system contains two rotating frames. Thus, while the system tests one bumper, the worker or a driverless transport system can simultaneously remove an already tested bumper and mount the next test object into the system. This not only ensures short cycle times, but also minimized personnel costs. In addition, it is also possible to work with a driverless transport system during loading and unloading and, if required, to have the contacting between bumper holder and test system coupling carried out automatically.

Despite the high level of standardization, this new concept for bumper testing still has “adjusting screws” for customer-specific solutions: The system is optionally available, for example, with RFID technology for automatic variant recognition or with hardware coding (e.g. traceability via coding of test specimens). Furthermore, it is possible to integrate the customer’s existing transport systems into the bumper test concept and to adapt it to customer-specific test trolleys.

Summary: With this bumper test system for the variant-independent testing of bumpers, Berghof Testing has a highly standardized new test system in its portfolio. The software developed in-house which is an important advantage for the customer. At the same time, the system offers customers much flexibility, minimal cycle time as well as short changeover times and a high potential of cost-savings.