Intelligent concepts, intelligently tested
With regard to technologies such as automated driving, and also future autonomous driving, car manufacturers are facing the task of developing intelligent safety and comfort systems more than ever – not only to protect car passengers but also to protect other traffic participants, such as pedestrians and cyclists.
That is why automotive suppliers are equipping their products, such as bumpers, spoilers and other exterior components, with more and more functions. Meeting the increasing demands on safety for all traffic participants requires complex and safe test systems. In addition to test systems for interior fittings, Berghof Testing has also developed automotive exterior testing as its core competence. The company’s portfolio includes, among other things, test systems for testing bumpers and spoilers.
Sensors in the bumper are an important contribution to additional safety in road traffic. These days they often contain highly complex safety-related features, such as distance and lane departure assist, sensors for detecting pedestrians and cyclists or blind spot assist. So that this sophisticated technology works smoothly in the end customers’ bumper, Berghof Testing has developed the bumper tester for automotive suppliers. Thus, we are making our contribution to making road traffic safer and more comfortable.
Application report: Electrical and optical bumper testing – fully automated, fast, highly flexible
In recent years Berghof Testing has made a name for itself with its testing competence in quality management of bumper manufacturers. Now the bumper test system achieves new benchmarks in terms of cycle time, flexibility and degree of automation. The biggest highlights: With the help of a driverless transport system, the test stand can be operated completely workerless. And: Thanks to a tracking shot completely without intermediate stops, the testing robot can handle a full 55 inspection features in a cycle time of less than 45 seconds.
Would you like to learn more about our latest test system for fully automated bumper testing? Then read more about the concept here!
Identification, completeness and surface of the bumper
Electrical testing (functional check) of all radar and ultrasonic sensors
Visual inspection of the correct mounting position of the pedestrian protection hose
Visual presence and version check of the mechanical components (attachments, clips, chrome parts)
Visual documentation after the testing
Testing the lighting and safety components
Resistance, current and voltage measurement, LIN and CAN communication, visual inspection
Automatic or manual operation
High variability: complete test system (measurement technology, mechanical components and testing robots with image processing) or integration into an existing assembly line
Speed: optimized test sequence for a short cycle time
Simple operation of the testing interface, graphic representation of the OK/NOK results
Storage of results in a database system
Version-based testing parameter sets
Service features for quickly rectifying production faults
Spoilers on vehicles by no means exist only for visual reasons: They ensure that the air flows over the vehicle in a way that improves its aerodynamics. They do this by reducing the vehicle’s lifting force, thereby improving the driving properties – such as the driving stability, the cornering speed and the braking distance. This makes the spoiler as well as the bumper a safety-related component of a vehicle. This makes it all the more important that all spoiler components are correctly positioned to ensure the optimal function. That is why Berghof Testing offers a test system for testing spoilers in all relevant parameters after production. Thereby, we can make full use of our power of innovation and our testing expertise: In cooperation with a renowned automotive supplier for spoilers, we have developed a completely new type of testing concept that saves the customer about half of the space required and therefore also costs.
As an individual test bench or end-of-line-tester in the production line
Testing the correct installation and position of components
Short linear conveyor belt without workpiece carriers
- Exact determination of the component position and the respective model
- Quick and safe take-up of the test specimen
Quick detection of components via 3D scanner
Scan comparison with a master stored in the system
Independence of contrast and light conditions
Results can be flawlessly reproduced
New concept: version-independent and flexible EOL testing
Flexible: handling of differently painted surfaces and different components
Simple and compact: no workpiece carriers – mechanical setup saves production space, retrofitting effort, testing time and costs
Mixed operation of all versions implemented in the test system
High level of flexibility for future testing tasks: quick and easy adding of new models using the user interface
No set-up times: linear conveyor belt instead of individual workpiece carriers – test specimens lie freely on top