Intelligent concepts, intelligently tested
With regard to technologies such as automated and, in the future, autonomous driving, vehicle manufacturers are faced more than ever with the task of developing intelligent safety and comfort systems – to protect both vehicle occupants and other road users such as pedestrians and cyclists.
This is why automotive suppliers are equipping their products such as bumpers, spoilers and other components in the "automotive exterior" sector with more and more functions. Complex and safe test systems are needed to meet the increasing demands on the safety of all road users. Berghof Automation has also developed automotive exterior testing into a core competence – alongside test systems for interior equipment.
Sensors in the bumper are an important contribution to greater safety on the road. Today, they often contain highly complex safety-relevant functions such as distance and lane departure warning systems, sensors for pedestrian and cyclist detection, and blind spot assist. To ensure that this sophisticated technology in the bumper functions smoothly at the end customer, Berghof Automation has developed the bumper tester for automotive suppliers. In this way, we are doing our part to make road traffic safer and more comfortable.
You have the choice between three expansion stages: The simple test table, the highly standardized, extremely variable test system for electrical bumper testing and the fully automated robotic test system with a cycle time of less than 45 seconds.
All variants of the bumper test at a glance
In our new brochure "Bumper Testing Product Information" (PDF) in the Download area Test and Inspection Technology you will find all the details on our three different bumper test systems.
Bumper tester ALL-IN-ONE: Bumper test system with integrated mounting device
With our new bumper test system, we combine the elementary assembly steps (trims, covers, OEM symbol, etc.) with the possibility of testing all electrical components in parallel.
The major advantage: Instead of two stations, you only need one with our new solution. This not only saves time and space, but, of course, also costs.
The mounting fixture can also be flexibly adjusted and tilted during the work. This makes it child's play to attach components to the outside and inside.
In compliance with current test specifications, the ALL-IN-ONE bumper tester features automatically adjustable impact obstacles for functional testing of the ultrasonic sensors. Nevertheless, the cycle time for a complete test remains under 30 seconds, even with lowering and retracting the impact obstacles.
Your advantages at a glance:
- Time savings of up to 30 seconds per test item due to fusion of test and assembly equipment
- Significantly lower space and investment requirements
- Flexible adjustable assembly table
- Integrated function test with variably adjustable impact obstacles
- Self-contained test system (measurement technology, mechanics)
- Simple operation of the test surface
- Graphical representation of the IO/NIO results
- Results storage in a database system
- Variant-related test parameter sets
- Predictive maintenance
Building on proven technology
Based on LIN and CAN communication, the ALL-IN-ONE bumper tester precisely performs all required resistance, current and voltage measurements on the bumper.
The system electrically controls the proper functioning of both the lighting and safety components as well as all radar and ultrasonic sensors of the bumper.
The heart of the test system is our in-house Berghof test and inspection software. It tests bumpers reliably, documents the results of the test runs, prepares them graphically in a simple and clear manner, and stores them in a database system.
Thanks to the graphical user interface, the system is also intuitive and easy to use.
Application report "Bumper Tester ROBOTIC": Electrical and optical bumper testing – fully automated, fast, highly flexible
In recent years, Berghof Automation has made a name for itself with its testing expertise in the quality management of bumper manufacturers. Now the bumper test system achieves new best values in terms of cycle time, flexibility and degree of automation. The best highlights: With the aid of a driverless transport system, the test bench can be operated completely without a factory. And: Thanks to a camera movement completely without intermediate stops, the inspection robot manages a full 55 inspection features in a cycle time of less than 45 seconds.
Want to learn more about our latest test system for fully automated bumper testing? Then read more about it here!
Application report "Bumper Tester ELECTRIC": Electrical bumper testing – highly standardized, minimal operator effort
Berghof Automation adds another test system for intelligent bumper testing to its test system portfolio. Highlights: The system is maximally flexible, tests independently of variants – and does so in a cycle time of less than 30 seconds. The test system for purely electrical bumper testing has a standardized coupling that makes it possible to hook every conceivable test specimen variant into the test system – current and future, front and rear bumpers, and all at the same time on a single system.
Would you like more information about this bumper test system that will allow you to fully exploit your possibilities? You can learn more about it here!
High variability: complete inspection system (measurement technology, mechanics and inspection robot with image processing) or integration into an existing assembly line
Speed: optimized test sequence for short cycle time
Easy operation of the test interface, graphical display of the IO/NIO results
Results storage in a database system
Variant-related test parameter sets
Service functions for fast elimination of production faults
To the brochure "Bumper Testing Product Information" (PDF) in the download area Test and Inspection Technology
To the case study "EOL Bumper Tester" (PDF) in the download area Test and Inspection Technology
To the Case Study "Electrical Bumper Testing" (PDF) in the download area Test and Inspection Technology
"Bumper Tester BASIC": The basic system for bumper testing
Identification, completeness and surface of the bumper
Electrical test (function check) of all radar and ultrasonic sensors
Visual inspection of the correct mounting position of the pedestrian protection hose
Optical presence and variant control of mechanical components (add-on parts, clips, chrome parts)
Optical documentation after the test
Testing of lighting and safety component
Resistance, current and voltage measurement, LIN and CAN communication, optical inspection
Automatic or manual operation
Force application machine (FAM)
The interiors of modern vehicles are increasingly dominated by electrics and electronics, as current models offer numerous, sometimes highly complex safety and comfort functions that make driving a comfortable experience. To make this customer experience safe and reliable, Berghof Automation offers high-performance test systems for various safety and comfort functions in the "Automotive Interior" area. With the help of our testing technology expertise, our customers always ensure the highest product quality.
Calibration of the seat occupancy mat with fast, controlled and highly precise force regulation
Seat occupancy mats are installed in more and more car seats. Their task is to activate the seatbelt tensioning system in the event of an accident or to individually control the deployment of airbags, depending on the weight of the front passenger. Thus, they are a significant factor in passenger safety.
Berghof Automation's FAM tests and calibrates this mat with fast, controlled and highly precise force control. The system can also be optionally equipped with the possibility of image documentation.
Advantages of the FAM
Automatic: integrated self-calibration
High flexibility: Attachment, testing and calibration of a wide range of seat types and models from different OEMs possible – automatic positioning of the force unit depending on the seat type
Precise: Calibration with high-precision automatic force application – controlled force application 0 to 1000 N, ± 5 N
Fast and economical: Calibration and test sequences of less than 60 seconds guarantee short cycle times
Optional with SFT: Combination of seat function test and calibration possible
Certified by the manufacturer of the seat covering mats: meets all manufacturer specifications and standards
Driving forces – in carefully tested quality
Even if they are often hidden from view, electric drives play a significant and growing role in today's mobility. Without it, neither the vehicle moves, nor does much move in the vehicle. So-called small electric motors are at the heart of numerous comfort functions and assistance systems: Sunroof, power windows, seat adjuster, tailgate, wipers, ABS drive and pump, parking lock and many more.
The shift towards electromobility has produced electric motors with new voltage ranges. Furthermore, e-mobility is creating additional demand for electric motors for components that previously obtained their drive energy from the internal combustion engine. For example, the air conditioning system in a hybrid or all-electric vehicle now requires an electric drive.
That is why Berghof Automation has made testing these diverse drives one of its core competencies.
In this context, we offer, for example, a climatic endurance test bench for BLDC and DC motors (brushless and brushed three-phase motors), a torque test system for DC motors and a characteristic test bench for spindle drives. They are all adapted to the respective customer-specific needs.
In addition, we are supplementing this knowledge in electromobility with the testing of energy storage devices.
Test benches for research and development / audit
Climatic endurance test bench for BLDC motors
BLDC motors must function faultlessly under a wide variety of environmental conditions. Because cars are on the road in midsummer as well as in the depths of winter, in wet and sometimes extreme dry conditions. So in order to be able to test them under specific, previously defined thermal conditions, our endurance test bench for BLDC motors has a climatic chamber. This enables our customers to simulate real, dynamic load profiles – but also extreme situations to put the drive through its paces.
Our test bench is used in particular as an audit test station in quality management. Test specimens can typically be ABS pump drives. Berghof Automation's test system for brushless DC motors is capable of precisely recreating the operating environment of the test specimens. At the same time, it is so flexible that we can also adapt it quickly and easily to future requirements.
Highly dynamic generation of the load for the motors
Simulation of the loads of a real application or a limit load
Six to eight test item recordings per endurance test bench
Thermal conditioning with the help of a climatic chamber
Basis for measurement application and user interface: Berghof Automation Framework, created in LabVIEW
Acquisition of currents, voltages, angles, speeds, torques, temperatures
Enables endurance testing with mixed equipment (free variant mix of DUTs)
Operation of up to eight asynchronously controlled BLDC motors
Highly dynamic servo drives as load motors → realistic testing
Fast control of the presets due to precision torque sensors
Fast real-time data acquisition with the NI PXI real-time measurement system
A climatic chamber enables the investigation under extreme environmental conditions
Flexibility: individual creation of emerging load cases
Application Report: Combination of electrical and mechanical BLDC testing
Berghof Automation has added a unique new feature to its proven test system for BLDC motors. As of now, the climatic endurance test bench is also able to test the engines in their real hydraulic environment. Your benefit: This allows them to test them in the respective oil, just as they would later in real use – and under absolutely realistic conditions. Thus, the system tests the components, according to the life cycle of the engines, with different types of oil, different degrees of contamination of the oil and, thanks to the climatic chamber, in the complete temperature range.
Would you like to learn more about BLDC testing in an oil bath? Then you are welcome to read our report on the subject!
You think (moving) pictures say more than a thousand words? Then take a look at our product video !
Technical articles on the subject
Learn more about testing BLDC motors in our technical article "Flexible auditing of electric drives".
Characteristic test bench for spindle drives
Spindle drives move convenience functions such as the sunroof, window lifters, seat and steering wheel adjusters, and the tailgate. To ensure that they perform their task properly, a Berghof test bench checks their function beforehand. Berghof Automation has added this powerful system to its portfolio – both as a characteristic curve test bench for a single spindle drive and as an endurance test bench for several spindle drives. They are used in development, audit and also in production.
The load is simulated by dynamic servo drives with spindles. Specially developed H-bridges (bridge circuits) with short switching times and currents of up to 100 A are used to control the DC motors. Our test benches for spindle drives work with technologies that are also used in the climatic endurance test bench for BLDC motors.
- Simulation of the loads of a real application or a limit load up to blocking
- Highly dynamic servo drives as load motors→ realistic testing
- Fast regulation of the presets due to precision force sensors
- Fast real-time data acquisition with the NI PXI real-time measurement system
- Flexibility: individual creation of emerging load cases
- Endurance tests at room temperature are possible
- Basis for measurement application and user interface: Berghof Automation Software, created in LabVIEW
- Acquisition of currents, voltages, position, velocity, forces, temperatures
Test benches for production – end of line (EOL)
Torque testing for DC motors
Berghof Automation is the specialist for testing small electric motors: In addition to BLDC drives, we also offer our customers our expertise in testing DC drives – i.e. brushed DC motors. Our standardized torque test system for all types of automotive electric motors is the best choice for our customers' assemblies with actuators such as tailgate actuators, door locks, window regulators or seat racks. The system performs the electrical and mechanical end-of-line function test semi-automatically.
Programmed test sequence
Preset current voltage curves
Mechanical testing: Load simulation (e.g. force curve of a tailgate)
Measurement of current, voltage, force, displacement and torque angle curves
Visual display or individual output of test results