EOL test, automotive end of line test rig




Today, double-clutch gearboxes, drives for electric battery-powered cars and hybrid technology have led to further development, and the market share of these solutions is anything but small.

For the automotive EOL test, automotive end of line test rig, EOLexpertise has now developed – in addition to its own mechanical and electrical engineering, production, assembly and commissioning facilities – the innovative advanced open test stand automation system, perfect for today’s requirements.

 

EOL test, automotive end of line test rig

 

EOLexpertise draws on substantial experience and shares innovations with customers to help them enhance their production. Feedback is welcomed and integrated into the design work. The growing diversification and quantity of gearboxes means that the demands on test benches are also increasing.

Test benches used to be loaded manually, but starting in 1980, fully automatic loading using conveyors, portals and, later, grip-arm robots was established. To realize these kinds of systems, EOLexpertise has developed customer-specific knowledge reflecting the complexity of vehicle transmissions.

EOLexpertise’s track record and team demonstrate that changes in special-purpose engineering are leading away from classic mechanical engineering toward software-based systems integration. Customers require complete EOL test, automotive end of line test rig solutions from a single supplier, so systems integrators are closely associated with the purchaser’s workflow to bring the necessary knowledge.

Due to the high level of vertical integration, EOLexpertise sources very few complete subassemblies, but taps into extensive in-house expertise.

 

EOL test, automotive end of line test rig



TDI engine cylinder head assembly line fuel pipeline test



Function and feature of EOL test, automotive end of line test rig

 

  • At the end of the TDI engine cylinder head assembly line, the quality of the injector press-fit is determined by blockage and leakage tests.
  • Check the injector action by supplying the appropriate current to the injector
  • Through blocking the fuel rail inlet, leakage meter is applied to check the leakage of fuel rail
  • Injector leak test equipment is a fully automated intelligent test system. The equipment will automatically complete all the test items and then automatically send out the expected material
  • It can automatically determine a variety of models. By using servo control system, the size of the blockage test mechanism can be automatically adjusted and compatible with a variety of model operations
  • The drive mechanism can precisely perform four degrees of freedom (X-axis, Y-axis, Z-axis and θ-angle) through the servo mechanism control. Different models can be automatically docked according to setting procedures, including:

 

TDI engine cylinder head assembly line for fuel line test

 

  1. Through the fuel rail leakage test to test 3 axes (longitudinal X, forward Y and tilt θ) continuous variable mechanism
  2. Injector Press-fit part leakage to test 3-Axis (pitch X, forward Y and tilt θ) continuous variable mechanism
  3. Injector on and off to test 3-axis (pitch X, forward Y and tilt θ) continuous variable mechanism

 

Test item of EOL test, automotive end of line test rig

 

  • Fuel rail leakage test
  • Injector press-fit part leak test
  • Injector on and off test

 

TDI engine cylinder head assembly line for fuel line test

 

Testing accuracy of EOL test, automotive end of line test rig

 

1. The fuel rail leakage condition is 350 Kpa

  • Measurement accuracy under constant flow generator value (3cc) is within ±5% (Workpiece amount: 3)
  • With standard workpiece, measurement repeatable accuracy is within ±10% (Workpiece amount: 10)

 

2. Injector Press fit part leakage conditions should be 350 Kpa

  • Measurement accuracy under constant flow generator value (1cc) is within ±5% (Workpiece amount: 3)
  • With standard workpiece, measurement repeatable accuracy is within ±10% (Workpiece amount: 10)

 

3. Injector open and close test conditions for the injector press-fit part of leakage test is OK

  • Measurement accuracy under constant flow generator value (1cc) is within ±5% (Workpiece amount: 3)
  • With standard workpiece, measurement repeatable accuracy is within ±10% (Workpiece amount: 10)





Static low-pressure and high-pressure ignition spark plug test

 

Static low-pressure and high-pressure ignition spark plug test

 

Function and feature of EOL test, automotive end of line test rig

 

  • Performing low-pressure ignition and high-pressure ignition condition test and focusing on fault status under testing of too small and too large spark plug gap accordingly
  • Single cylinder multiple parameters analysis to analyze single-cylinder spark plug gap and breakage
  • High-efficiency testing process. The single tester test time is less than 42s
  • Self-developed ignition control module for multiple spark ignition test. The real-time engine simulation ignition mode is not necessary and accurately analyze the spark plug gap whether it is reasonable
  • Sophisticated off-line analysis system. High-performance servers and databases are applied to store all the test data for each engine and provide detailed quality report and statistical analysis tools
  • Maintenance expert system provides detailed engine failure information for engine repair worker to quickly locate the failure point
  • The ignition harness can be manually inserted or removed according to the site requirement. Automatic docking can be designed

 

Static low-pressure and high-pressure ignition spark plug test

 

Testing items of EOL test, automotive end of line test rig

 

  • Static low-pressure ignition test
  • Static high-pressure ignition test

 

Testing accuracy of EOL test, automotive end of line test rig

 

Testing spark plug to determine whether the gap is normal ±0.3mm

 

Testing principle of EOL test, automotive end of line test rig

 

  • Testing engine spark plugs, coils etc. ignition system components whether there are any faults, such as abnormal clearance, high-pressure wire breakage, ceramic body rupture, coil abnormalities etc.
  • Obtaining system discharge voltage change directly from the ignition coil, or use the position sensor to obtain the system discharge voltage changes





Clutch function test for lift displacement and compression force

 

Clutch function test for lift distance (displacement) and compression force

 

Key features of EOL test, automotive end of line test rig

 

  • The relationship curve testing between lift distance (displacement) and compression force
  • The relationship curve testing between separation of travel and separation of force
  • The relationship curve testing between separation of travel and lift distance
  • The curve test between mounting height and angle
  • Different colors can be applied to indicate whether the values are acceptable
  • System pressure can be set
  • Testing of average compression force at the failure point
  • The average clamping force at the installation point (new)
  • Pre-adjustable separation force and so on

 

Clutch function test for lift distance (displacement) and compression force



Automobile EOL test, automotive end of line test rig


Products must be well thought-out and every aspect tried with automotive end-of-line test before delivering to customer. No car manufacturer can afford a recall, especially double-clutch gearboxes or electric motors.

Parameters such as surface finish, dimensions, and various forms of non-destructive testing such as ultrasonic inspection are usually adequate for quality control of components. However, controlling the quality of dynamic systems, complex electrical components and highly resonant components and systems often requires more evolved methods of testing.

This is particularly true when the satisfactory response of a system to an external stimulus may be critical in order for it to be accepted. Noise and vibration measurements are often effective tools.

Components such as automotive mirrors are particularly sensitive to external input. The fit of the system, or how loose the mirror is on the assembly, is one of the most important criteria. Over a certain tolerance, the looseness of the mirror assembly will produce excessive image distortion in driving conditions.

Electric motors lend themselves to vibration testing for quality during the production phase. A simple spin up of the motor can quickly determine many defects including noisy bearings, wire rub, rotor strike, mylar strike, pad drag, and rotor cap. Similar success has been found with other rotating equipment such as gears, bearings, and fans. These applications benefit greatly from the ability to use many different criteria and complex conditional tests.

 

EOL test, automotive end of line test rig

 

The resonance of automotive anti-vibration components such as engine mounts is of particular interest to the overall NVH of the vehicle. Many manufacturers perform 100% production testing on these components to verify the resonance frequency prior to supplying them for installation.

Basic resonance testing of mounts is typically performed by attaching a fixture to an electrodynamic shaker with one or more mounts on the fixture, and evaluating the resonance of each of the mounts using a short sine sweep. Software automatically detects if the mounts pass or fail, and indicates this to the user either through a simple software interface or by triggering an external alarm or PLC.

As NVH models become more sophisticated, high-frequency mount testing has gained importance, and special electrodynamic shaker configurations to preload the fixture are often used.

Important characteristics of a dynamic quality control test system include the ability to set complex conditional limits and failure detection criteria; accurate measurements and proper frequency domain processing; easy-to-use interfaces for operators that clearly indicate pass and fail conditions; the ability to automate by communicating with external platforms; generation of logs or reports; and storage of the raw data for later analysis and processing.

 

EOL test, automotive end of line test rig
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