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    EDAG’s unique accredited test centre

Testing / CAE

A solution is only as good as the results it provides when put into practice. If you are involved in developing new, ground-breaking product concepts today, then you need to be sure that your solutions will do exactly what they are meant to when you come to apply them. With our all-round spectrum of testing services and in-depth knowledge, we know what really counts. Using virtual or real-life methods, components or complete vehicles, test systems or material testing in our own accredited test laboratory - we can come up with the right solution, and give you early, conclusive and validated feedback from real-life scenarios.

CAE

By validating products and product properties at an early stage, development periods are shortened, development costs reduced, and last but not least products improved. The key factors here are virtual simulation and testing within the framework of computer-aided engineering (CAE), because whatever can be simulated while the concept is still in its initial stages will not need to be constructed at a later date - a process which is both complex and expensive.

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Our CAE experts support production development with the functional design of components, systems and complete vehicles. By applying virtual simulation and calculation, we are able to optimise the stresses of components, in this way reducing weight, to test various material concepts (e.g. steel, plastic, aluminium, GRP, CFRP) in intelligent networks with our test laboratories, and to carry out different load situations, including vehicle crashes. And if the existing software tools are unable to cover the desired application, we have a solution for that, too – our software team programmes tools for customers' specific applications, to optimise in-house process times and generate new solutions.

We offer the following solutions and services to meet your needs:

  • Rigidity, strength and misuse loads
  • Vibration and acoustics
  • Operational strength and fatigue resistance
  • Vehicle dynamics
  • Vehicle safety
  • Structure design (crashworthiness)
  • Passenger safety (design of restraint systems)
  • Pedestrian protection
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Dimensional Management

In modern cars, it is essential to maintain constant clearance between adjacent parts. As small a clearance as possible and low tolerance are indicative of high quality and improved vehicles. An easily recognisable quality feature that is subject to increasingly stringent requirements. We see dimensional management (tolerance management) as a way of permitting the greatest possible component tolerances during the development phase while at the same time complying with geometrical target specifications.

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The advantage to you is obvious - the high, reproducible geometrical quality of your products. And therefore better vehicles for your customers.

We offer the following solutions and services to meet your needs:

  • Definition, documentation and visualisation of geometrical target specifications:
  • Gap, offset, parallelism
  • Interfaces
  • Functions
  • Definition of reference point systems (RPS) and documentation
  • Creation of clamping and fixing concepts
  • Conducting three-dimensional tolerance calculations/simulations
  • Rigid body simulation (rigid body analysis)
  • Tolerance simulation taking component deformation into account
  • Tolerance analysis to detect drivers for tolerance and for targeted product and process optimisation during development and in the series
  • Visualisation of the tolerance variations
  • Definition of measurement points
  • Toleration of components (GD&T) in accordance with DIN ISO 1101 and ASME
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Test Laboratories

Components today must be more effective than ever before. Every single material must do its best. Not just once, but for the vehicle's entire life cycle. We have the experience and a wide range of test equipment and facilities to guarantee functionality and durability. Our laboratories will analyse and test components, modules, engines and transmissions and even complete vehicles for you. Our key focus here is on components made of polymeric materials, ageing, weathering and dust simulations, acoustics, thermal properties, material cards, electrical and electronic components.
Concept study or standard component – we can show you the most promising ways to success.

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The key here is our ATC Fulda (Accredited Test Centre Fulda), a test laboratory accredited by DAkkS (the German accreditation body) to DIN EN ISO 17025 standards. We have been granted flexible accreditation, attesting to our competence not only to test in accordance with stipulated specifications and standards, but also to modify these if necessary. A flexibility that fits in perfectly with the modern, rapidly changing requirements of the automotive industry.

In addition, we ofer numerous besting possibilities for the northern region in Wolfsburg and for the southern region in Munich.

We offer the following solutions and services to meet your needs:

  • Calculation of material properties and advice on materials
  • Environment simulation and operational stability
  • Vehicle safety, bumper and sensor crashes
  • Vehicle and motor acoustic testing, NVH (vibration analysis, noise analysis)
  • Aggregate cooling and inspection of A/C components
  • Function test
  • Initial sample testing
  • Development and validation of new testing methods
  • Damage analysis
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Test Systems

Having your own test facilities gives added flexibility in vehicle development. We can help to solve any problems you might have with trial and test activities in development and production. Our Test Engineering department in Recklinghausen offers a full range of services and experience in the design, development, construction, assembly and maintenance of test stands - including engineering responsibility for the entire process, from analysis of the test procedure to the turn-key installation.

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We offer the following solutions and services to meet your needs:

  • Test stands for determining strength and service life (e.g. wheel bearing and belt test stands)
  • Flow benches for vehicle components (cylinder heads, valves, turbochargers, exhaust systems, heating, air-conditioning and air mass flow meters)
  • Test and trial fields for turbo machines (vacuum pumps, compressors, fans)
  • Test stands for engine assembly (frictional torque, piston protrusion, valve clearance)
  • Test stands for sensors (e.g. pressure sensors and NOx sensors for vehicles)
  • Test stands for carrying out trials and fatigue tests on doors, flaps and seats
  • Modernisation of wind tunnels
  • Control and process monitoring systems (for wind tunnels, testing and trial processes) switch system construction for testing and trial facilities
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Validation and Certification

The validation and certification process is one of the most important milestones in the process to create a new generation of vehicles. This is where the decision is made as to whether a vehicle, concept or prototype meets the criteria for SOP and complies with legal requirements. As experts in the field of complete vehicle development, we know that taking a holistic attitude to the development process can make all the difference.

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We supervise customers' vehicle development projects, from the preparation of product specifications through to SOP. Starting with detailed competition analysis, the drafting of vehicle technical specifications and generation of complete validation plans, then continuing though to complete vehicle testing and approval recommendation - we do everything to ensure that project milestones are met within the prescribed time limits.

Besides providing support for complete vehicle projects, we also take care of special fields such as corrosion prevention or homologation. The former means that your products are protected from corrosion and stone impact. With homologation, the important thing is to work in close cooperation with the authorities and testing and certification bodies. Differences in local regulations - national or international - can considerably influence vehicle requirements, testing and validation schedules. You can count on our services through to the coordination and implementation of the certification process.

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Pedestrian Protection

When it comes to vehicle safety, it is no longer enough to concentrate on the passengers alone. In order to guarantee the safety of both the driver and other road users, it is necessary to keep an eye on everything that is going on around the vehicle. This means that, for us, pedestrian protection is a key element of vehicle development.

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Our expert knowledge, which begins with project management and simulation, covers all areas through to testing on our fully equipped test stands. At many sites, and also close to you.

We offer the following solutions and services to meet your needs:

  • Project and supplier management
  • Support with type approval and during the certification process
  • Development of active systems (bonnet, airbag)
  • Sensor layout
  • Component localisation
  • Test management and test coordination in our fully equipped test laboratories
  • Parts logistics
  • Test field definition in software (Ansa, Generator, Cava) and hardware
  • Simulation and validation (Radioss, PAM-Crash, LS-Dyna, Abaqus)
  • Deformation analysis and worst case point definition
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