DVP Tests, Performance Test, Durability Test and Endurance Test for child part, assembly and whole vehicle

Please read previous blog for DVP requirement and why it is done, What is front loading concept in DVP and how testing environment is changing in OEMs. 

In this blog we only propose some standard test which are must to go next stage of prototype part development. 

A. Define Performance and Durability Requirement:  

Subsystem	Performance Requirement	Durability Requirement
Engine	High Constant Torque, High Power, Less Fuel Consumption, Less Vibration, High Cooling Efficiency, Low Frictional Loss	High Vibration, High Temperature , Cyclic Loading , High Rotating Parts
Body	High Downforce, Less air resistance , High Crash Strength , Light Weight , Comfortable	Impact Load, Concentric Load, High Vibration, High Temperature
Suspension	Smooth Damping , Low Centre of Gravity, Controlled Drivability , No Slip/Topple/Skit	Impact Load, Jerk Load, Damping Vibration
Brake	Less Driver Effort, High Braking Life, Smooth Braking, Low Braking Distance and time	Cyclic Loading ,High Temperature , High Pressure , Corrosion
Steering	Less Driver Effort,  High Sensitivity & Accuracy, Low Response Time, Quick Angle Ratio	Cyclic Loading, High Wear, Friction

B.1. Child Parts Test Procedure and Criteria: (For these tests both simulation and physical test must be done)

Test	Measure/Check	Criteria
Assembly	Fouling, Touching, Tolerance, Ergonomics, Dimension, Rules/Regulation,	No two part rubbing/fouling, Child part dimensions, design as per rules
Performance Test	A. Leakage Rate, B. Pressure Output , C. Current Consumption, D. Discharge Coefficient E. Sensitivity, F. Pressure Drop, G. Particle Size H. Performance Drop, I. Flow Rate J. Spring Coefficient H. Hysteresis	Part can meet vehicle requirement such as quantity of fuel, air, oil and coolant, Current Consumption, Voltage Gradient, ECU Compatibility
Durability Test	Stress, Strain, Natural Frequency, Bending Moment, Braking Force, Leakage Pressure,   Fatigue, Cyclic Loading, Wear, O-Ring/ Gasket Compression, Creep, Crash/Impact, Sensor Burnt	No deformation, damage, & wear in part. No performance degradation. Meet accuracy and sensitivity.

B.2. Durability Test for Different Subsystem 

Subsystem	Process	Durability Test	Criteria
Engine   Power -Train	1. Check result of Step 1, Step 2 & B.1 2.Measure each part before fitment 2. Do Each Test  3. Record Performance 4.Measure all part Dimension after test	1.Up Down Test- 1000 RPM to 13000 RPM in 5min , for 1000 Hours,  2. High Speed - run engine at 13000 rpm for 2000 Hours  3. Go Stop - On and Off Engine for 1 min,  1000 Times  4. Thermal Test - Run Engine without coolant or with 50% coolant for say 1 hour	No Leakage of Engine oil - Engine coolant- fuel , No damage , No High Noise, No high Vibration  should occur
Body		1. Sweep Vibration Test- 0 hertz to 300 hertz in 10 min in X,Y, Z Direction, 240 Hours   2. Fix Vibration Test -  Fix 300 hertz for 2 min in X+Y+Z Direction, 500 Hours 3. Crash Test – Speed 55Km/h, Front Impact & Side Impact	1/2: No Deformation or Crack in body. 3: No head injury to dummy; No fuel leakage
Suspension		1:Composite Durability- 100°C, Fix 300 hertz for 2 min in X+Y+Z Direction, 500 Hours 2:Weld Strength- Check Braking load  of each welding   3: Dyno Cyclic/Fatigue Damping- Fix suspension on Dyno and damp & Vibrate structure	1/3 No Deformation or Crack in body. 2. Match result with simulation result
Brake		1:Disc & Pad Wear: Rotate disc, apply full brake 1000 Times, measure wear and disc stopping time 2:Pedal Breaking Effort: Driver Apply Breaking Load for Pedal ( Check Annexure for detail) 3: Burst Test for Master Cylinder, Brake Pipe	1: No change in before and after part breaking time. 2: More than 75 Kg load 3:More than 212 Bar
Steering		1:Crash Test- As per Formula Ford Rule 2:Column Breaking Effort- Apply torque at Column  3.Gear Tooth Breaking Load – Measure Rack/Pinion gear tooth breakage load ( Check Annexure for detail)	1:No damage to dummy 2: No deformation, brake , wear in rack and pinion

B.3. Performance Test for Different Subsystem 

Subsystem	Test Name	Criteria
Engine	Dyno  Test with/ Without Transmission	1:High Constant Torque; 2:Volumetoic Efficiency above 90% at all RPM; 3: Low Pumping Loss; 4.Emission Norms as per EURO6
Body	Wind tunnel Test	1:Low Air Resistance ; 2: High Downforce
Suspension	Chassis Dyno Test	1:Comfort; 2:Damping /Vibration Transfer to Driver Seat/Steering Wheel
Brake	Bench Test	1:Low braking Distance; 2:Braking  Response Time;
Steering	Bench Test	1:Wheel to Steering Wheel Ratio;2:Low Steering Effort

B.4. Vehicle Performance & Durability Test

Related to	Calibration/Physical Tuning	Performance Test	Durability Test
Engine   Power -Train	ECU+ All Sensors+ Actuators+ Motors; Valve Timing, Fuel Injection Timing, Emission, Intake/Exhaust Tuning	Acceleration,  Cruise, Cold Start Test, Fuel Consumption, Emission	1. Vehicle will run 2000 Km on different type of road condition then all parts dimension will be checked. 2. Dynamic Test : run vehicle in different driving patter such as corner, high/low ambient temperature, sudden braking, sudden steering 3. Static Vehicle Test: After above Test 1 & 2 check for fuel leakage, oil leakage, compare performance before and after test.
Body	All  Sensors, Driver Position,  Yaw, Roll, Pitch	Vehicle Downforce, Air Drag, Stability,
Suspension	All Sensors, Damping, Camber, Caster, Cabin Vibration	Suspension Vibration & Damping, Tyre Wear
Brake	Brake Sensors, Pedal Position, Ergonomics; Fuel Cut Off Brake Fail ( Check Annexure for detail)	Dry/Wet Braking Distance & Time, Uphill/Down Hill Braking, Braking Force
Steering	Steering Sensor, Steering Position, Ergonomics, Fuel Cut Off Steering Fail ( Check Annexure for detail)	Steering Force Test; Corner Steering; Up/Down Hill Steering; Maximum Steering Angle; Steering with high Slip; Flat/Wear Tyre Steering

Performance Test is done for function check for All Sensors/Motors/Pumps/ Actuators/ Embedded parts/moving parts such as Fuel Injector, Throttle body, Spark Plug, Fuel/Oil/Water Pump, springs.

Durability Test is done for life check for all functional, non functional and structural parts such as brake pad/disc/pipe, steering column/rack/pinion, engine piston/cylinder/crank, chassis frame/wings, suspension spring/frame.

Common Performance Test Name

A. Leakage Rate, B. Pressure Output , C. Current Consumption, D. Discharge Coefficient E. Sensitivity, F. Pressure Drop, G. Particle Size H. Performance Drop, I. Flow Rate J. Spring Coefficient H. Hysteresis

Common Durability Test Name

1. Leak Test 2. Burst Pressure Measurement 3. Joint Leakage Test 200 Bar for 30 Sec 4. Salt Spray (NaCl), 5. Material Test 6. Impact Drop Test 7. Thermal Test, 8. Heat Shock 9. Boiling Point, 10. Composite Durability, 11. 30g Vibration Test, 12. Chemical Resistance, 13. Dimension Test, 14. Tolerance, GDNT, Assembly Check, 15. Hardness Test, 16. Temperature Density Graph 17. Temperature Viscosity Graph18. 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