Sensors Drive Design Validation and Optimization in the Automotive Industry

Force and torque measurement sensors provide precise measurement capabilities, enabling vehicle manufacturers and component makers to identify and rectify design flaws early in development. This leads to improved product quality, enhanced reliability, and safer vehicles on the road.

Rigorous testing ensures automotive components meet stringent safety standards, reducing the risk of failures and accidents. Efficient test setups and data analysis using sensor technologies streamline testing, accelerating product development and time-to-market.

Automotive Industry Test and Measurement Use Cases

Interface supports the auto industry with sensors and instrumentation for validation and optimization. By providing accurate and reliable data for testing and analysis, the high accuracy and precision measurement ensures that test results are consistent and trustworthy, enabling engineers to make informed decisions about design and performance.

The wide measurement range of these sensors allows them to be used in various applications, from evaluating small components to assessing the structural integrity of entire vehicles. The following highlights three examples, as well as you can find additional information in the case study: Accelerating Automotive Excellence with Interface Testing Lab Solutions

Suspension System Testing

Imagine a scenario where an automotive engineer is testing a new suspension design. They can capture precise force data by strategically placing Interface load cells at critical points within the suspension system and subjecting them to various simulated road conditions using actuators. This data reveals how the suspension components react under different loads, enabling the engineer to:

• Identify Stress Concentrations: Pinpoint areas of high stress or strain, which may indicate potential failure points or design weaknesses.
• Optimize Damping and Spring Rates: Fine-tune the suspension's damping and spring rates to achieve the desired ride comfort and handling characteristics.
• Validate Durability: Assess the suspension system's long-term performance under repeated loading cycles, ensuring it meets or exceeds lifespan expectations.

Steering Mechanism Evaluation

Interface torque transducers integrated into the steering system provide critical insights into the torsional forces experienced during various maneuvers. This data empowers engineers to:

• Minimize Steering Effort: Quantify the steering effort required at different speeds and turning angles, allowing for optimization of steering feel and driver comfort.
• Evaluate Steering Responsiveness: Analyze the relationship between steering input and vehicle response, ensuring precise and predictable handling.
• Identify Friction and Wear: Detect excessive friction or wear within the steering system, enabling proactive maintenance and component replacement to prevent failures.

Engine Mount Analysis

Multi-axis load cells mounted on engine mounts capture the complex forces and moments transmitted from the engine to the vehicle chassis. This data is invaluable for:

• Minimizing Noise and Vibration: Optimize engine mount design to reduce noise, vibration, and harshness (NVH) levels, enhancing passenger comfort.
• Ensuring Engine Stability: Validate engine mount performance under various operating conditions, including acceleration, braking, and cornering, to provide engine stability and prevent damage.
• Predicting Fatigue Life: Assess the long-term durability of engine mounts under cyclic loading, enabling proactive maintenance and replacement schedules.

Interface's Contribution to Automotive Engineering Excellence

Interface sensors are designed for easy integration into existing test systems, simplifying the setup process and streamlining data acquisition. The accompanying software tools facilitate comprehensive data analysis, allowing engineers to visualize and interpret test results effectively. This capability is essential for identifying potential issues, optimizing designs, and ultimately ensuring the safety and reliability of vehicles.

The high accuracy and wide measurement range of Interface load cells and torque transducers give automotive engineers the confidence to make informed design decisions. These sensors' ruggedness and durability ensure reliable performance in demanding test environments, minimizing downtime and maximizing productivity. The seamless integration and comprehensive data analysis capabilities further streamline the testing process, enabling engineers to focus on innovation and optimization.

By harnessing the power of Interface sensor technologies, automotive manufacturers can achieve unprecedented levels of precision in their test and measurement processes. This leads to improved product quality, enhanced safety, accelerated time-to-market, and significant cost savings, ultimately driving success in the competitive automotive industry.

Auto Industry Test Lab Experience

A leading automotive manufacturer must rigorously test various components, including brakes, tires, batteries, ADAS, suspension systems, steering mechanisms, and engine mounts, to ensure their performance, durability, and safety under diverse operating conditions. They required precise measurement of forces and torques applied during testing to validate designs and identify potential weaknesses.

The manufacturer equipped their test and measurement lab with Interface sensor technologies, including load cells, torque transducers, and multi-axis load cells. In addition, the lab used actuators to apply controlled loads and motions. The performance measurement lab includes:

• Load Cells: Standard low-profile and miniature load cells are useful for accurately measuring the forces exerted on components during testing.
• Torque Transducers: Torque transducers measure the rotational forces (torque) applied to components like steering systems and drive shafts.
• Multi-Axis Load Cells: Multi-axis load cells were utilized in complex test setups to simultaneously measure forces and moments in multiple directions. This provides a comprehensive understanding of component behavior under load.
• Actuators: Hydraulic and electric actuators were employed to simulate real-world loads and stresses on automotive components.

Interface sensor technologies enhance the precision and efficiency of test and measurement processes in automotive design and manufacturing. Their high accuracy, wide measurement range, and durability support the necessary testing and validation to deliver superior products, ensure safety, and gain a competitive edge in the market.

Interface shares our expertise and product solutions at the annual Auto Test Expo. Please check in with us if you missed us this year in Novi, Stuttgart, or Shanghai. We'll share some new trends and exciting sensor technologies for auto-testing. Contact our automotive application engineers here.

ADDITIONAL RESOURCES

Sensing the World of Load Cells and Accelerometers

Actuators and Sensors Combine Forces in Test and Measurement

Interface Primer Dives Deep into Torque Measurement

Engineering Peak Performance in Auto Racing Requires Precision Measurement

Automotive Engineering Students Test the Limits with Force Measurement

Force Measurement Solutions Support Innovation in Manufacturing

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