DVP, Performance, Strength, Durability and Endurance Test for different automotive systems

Different Types of DVP Tests 

Child Part Simulation Test	Check/Test	Feedback
Child Part Assembly to make whole vehicle in Digital Mock Up	Fouling, Touching, Tolerance, Ergonomics, Dimension	Change Layout, Dimension, Location
Child Part Durability Simulation	Stress, Strain, Natural Frequency, Bending Moment, Braking Force, Leakage Pressure	Change Stiffness, Thickness, Weight, Material , Manufacturing Process, Increase Factor of Safety
Child Part Dynamic Simulation	Fatigue, Cyclic Loading, Wear, Pressure & Temperature Variation, Creep
Child Part Performance Simulation	Coefficient Of Discharge & Pressure Drop for all fluid flow parts= Throttle, Intake/Exhaust Manifold etc. Electricity Consumption for all sensor and actuators.	Change in child part performance, specification, selection criteria

Engine DVP Test 

Child Part	Requirement	Test Number **/ Duration Weeks	**Test Number : Part Level	Dyno Test	Vehicle Level Test
Piston Block Crank Head	High Strength, High Fatigue/ Cyclic Loading, No Deformation,	1,2,3,4,5,6,7,8,10, 11,12,13,14, 15	1. Leak Test at 200Bar for 30 Second at -40 °C,140 °C 2. Burst Pressure Measurement 3. Joint Leakage Test 200 Bar for 30 Sec 4. Salt Spray (NaCl) 200 Hour No Red/White Rust 5. Material Test 6. Impact Test hit part by 10N Force / Drop Test: Drop part from 1m height: No mark or damage 7. Thermal Test: 2000 hour for 140 ° C 8. Heat Shock: 1 hour 0 °C to 1 hour 140 °C for 500 Cycle 9. Boiling Point Measurement from 1Bar to 200 Bar 10. Composite Durability: Pressure 0 to 200 Bar with Frequency 30 to 300 Htz at 20°C 11. 30g Vibration Test X, Y, Z Direction 100 Hours each at 300 Htz Frequency 12. Chemical Resistance: 100 Hour in Water, Oil 13. Dimension Test as per drawing 14. Tolerance, GDNT, Assembly Check 15. Hardness Test 16. Temperature Density Graph 17. Temperature Viscosity Graph 18. Fluid Compressibility 19. Water Content % Check 20. Voltage Graph 21. Current Graph 22. Resistance Graph 23. Pressure Graph 24. Pressure Sensitivity 25. Spring Constant 26. Grip, Sharp Edge, Ergonomics 27. Hand Brake Cable Braking Force Measurement 28. Cable Elongation	Durability 1. High Speed Test: Run Engine for 1000 Hours at 13000 RPM 2. Up Down Test: 1000RPM to 13000RPM in 1 Min, 1000Cycle 3. Thermal Test: Run Engine with 50% Coolant and 50% Oil for 1 Hour 4. Go Stop: On & Off Engine 1000 Times Dyno Calibration 1)ECU matching 2)Emission 3)Power 4)Torque 5)Knocking 6)Injection Timing	1. Vehicle will run 2000 Km on different type of road condition then all parts dimension will be checked. 2. Dynamic and Static Vehicle Test will be done when all parts are fitted on vehicle. Dynamic Test  1. Dry Brake Distance Test 2. Wet Brake Distance Test 3. Brake Pad Wear Test 4. Brake Pedal Force Test 5. Ramp Brake 6. Up/Down Hill Braking Test 7. Corner Braking 8. High Slip Braking 9.Flat/Wear Tyre Braking 10. Under Water Braking Test 11. Ice Braking Test 12. Brake Fail Test 13. Brake Sensor Test 14. Pedal Pressing Force 15. Pedal Displacement Fuel Cut Off Check   16. Brake and ECU Calibration 17. Pedal Displacement Speed Graph 18. Vehicle Deceleration  Static Test: 1. Leg Space Check 2. Ergonomics Check
		8
All Engine Sensor	0 to 5 Volt, Low Current Consumption, High Sensitivity, High Insulation, 1% Accuracy	9, 16,1718,19
		6
All Gasket O-Ring Nut Bolt	Leak Pressure, Leak Rate, Compression, Tightening Torque	4, 5,6,7,8,10,11, 12,13,14,15,
		8
All actuator Injector Throttle Pump	Dia =45mm, Burst Pressure = 250 Bar	1,2,3,4,5,6,7,8,10, 11,12,13,14, 15
		8
	Bore =10mm, Capacity = 15cc Burst Pressure = 250 Bar	1,2,3,4,5,6,7,8,10, 11,12,13,14,15
		8
	Area =50Cm2 Depth =40mm Thickness =15mm	4, 5,6,7,8,10,11, 12,13,14,15,
		8
Exhaust Manifold	Level Length =300mm Pedal Area = 50X50mm2	4,5,6,78,10,11,12,13,14 15,23,24,25,26,27,28
		8
Fuel Pump	Pressure = 0 to 12 Bar Accuracy = 1% Voltage = 0 to 5Volt	20,21,22, 23,24,
		2
	Length =300mm Handle Dia = 20mm Weight = 1Kg Max No Sharp Edge	4, 5,6,7,8,10,11,12,13 14,15,23,24,25,26
		8
	Braiding, Ductility, Dia, Length	4, 5,6,7 8,10,11,12,13 14,15,23,24, 25,26,27,28