Static Test Station

Regarding ECE R14, R80 and correspondent FMVSS regulations,

The static force resistance of seats of single, double, triple or 5-seat automotive seats of M1, M2, M3, plastic or disabled types connected to 2P or 3P point seat belts as well as anchorage parts and other automotive components.

The table size, the number of hydraulic pistons between 2 and 10, the force direction as tensile, compressive or both, the force scale up to 50 kN per actuator, the piston speeds are determined as per request.

Specifications

Precise force control
The unique force control algorithm provides fast and precise following to the target force curves in different material types and shows outstanding performance.
Accurate data logging
Force and extensometer sensor data are recorded every 5ms (200Hz) all along the test duration up to 200 seconds. The records are first logged in the controller's memory, and is automatically transferred to the PC files at the end of the test. Communication interruption risks during the tests are eliminated. Sensing and recording at 200 Hz is not affected by processing cycle time.
Time stamped test folder
Before each test, a special time stamped folder is created to support ISO 17025. In this test folder, test inputs such as target force curves, test operator, participants, test output that contains load cell and extensometer sensor data, sensor calibration values are saved as MS Excel files.
Automatic report generation
At the end of the test, the sensor data is analyzed and an automatic report is generated and sent to the authorities via e-mail. These functions ease the operator report workload and competences.
Password protected pages
Access to the sensor calibration page is password protected.
Accreditation and occupational safety
Safety fences and automation for occupational safety are vital. Design and production in compliance with CE norms can be approved by the relevant accreditation bodies. Tool end measurements and sensor calibrations are verified by accredited independent laboratories.
Fast cam video
Optionally, video automatically recorded on the high-speed industrial cameras can be matched and analyzed with the test graph and sensor data on a special page.
3rd colomn
Some of the hydraulic pistons can be transferred to the 3rd column via hydraulic and electrical quick coupling equipment.
Large-screen TV
To serve easy watching to the test participants, the HMI software on the touch test PC can be transferred to a remote large-screen TV via a wireless module.
Hybrid solutions
Hybrid solutions are designed in such a way that the same table, the same electronic and hydraulic equipment can be used as a common infrastructure for test devices such as servo controlled or pneumatic a life, fatigue or ECE R17 test benches.

Durability Test Station

ECE R17 + fatigue

test stations can be designed for single, dual or triple automotive seats. With servo-equipped axes, precise load cells, and torque sensors with an accuracy of 0.2% at the center of H, it is possible to perform more precise and various test using our new topology.

In the test, the backrest apparatus is first rested around point R until it reaches a torsional torque of 373 / 530 Nm, then the upper servo piston rests against the head. From this point on, the upper piston applies a force of 890 N.

Specifications

Precise and various tests
With servo-equipped axes, precise load cells, and torque sensors with an accuracy of 0.2% at the center of H, it is possible to perform more precise and various tests using our new topology.
Servo cylinders
Servo cylinders can precisely achieve the specified speeds and, with their 2000 N force capacity, provide a standard solution, sufficiency, and flexibility in terms of spare parts stock for future norm revisions.
Flexible programming software
An additional servo cylinder used for headrest deformation testing can be used for lifespan and fatigue testing of seat components such as armrests, backrests, seats, headrests, and side opening mechanisms via flexible programming software.
Hybrid solutions
Produced according to request as a hybrid station that combines other fatigue and lifespan testing that uses a shared workstation, controller, and testing compuer.

Measurement and Breaking-in Station

a dedicated in-line station

that is responsible for a 100% of the measurement functions and the breaking-in of car door hinges needed because of their material structure.

Specifications

Simulation software
After analyzing the cycle time, we have used simulation software to optimize parameters such as post-reducer torque and velocity, opening force, minimum air pressure, and extrusion force to achieve time savings and long lifespan performance.
Traceability
For traceability we have recorded the moment of inertia’s graph with time-stamps and connected it to the manufacturing execution system (MES) via Ethernet infrastructure.
Flexible topology and software
Designed the topology and software blocks flexibly for possible laser marking.

Friction Test Station

Fatigue and aging

tests of seats in accordance with the automotive manufacturers’ own standards (Ford ST0809), the dampness and heating of the manufacturer’s automotive seats are checked under the load.

Specifications

Inverter driver motors
Via a flexible programing editor in the interface software, and with the movement of the inverter driver motors, a rubbing motion is created at varying motor speeds under different loads.
Humidified by infiltration
Humidified by infiltration using water at variable and very low flow rates through special pumps and small diameter special hoses.
Special heaters and controllers
With special heaters and controllers, the temperature on the seat surface is kept at a certain level.
Automatic reporting
Throughout the test, the humidity and temperature on the seat’s surface can be monitored, a live graph is shared, and the sensor data output file is later automatically saved as a report.

Energy Dissipation & Crash Test Station

Regarding ECE R21 and R25 regulations,

There are 3 types of topology in energy dissipation and crash test benches: free fall, sled assisted free fall and fluid driven pendulum.

In the free fall topology, short-term friction occurs immediately after impact, followed by the retraction and later a second impact. The impact speed cannot be exactly measuered.

In the pandelum-type impact test devices developed by TMEX, only one point impact is applied. Impact velocity can be measured in milliseconds actually, accurately and precisely.

Specifications

CFC 1000 filter
On the ECE R21 and R25 norms, it is stated that 1kHz data of 2 accelerometers should be logged and filtered with CFC1000 signal filter. This filter has been coded for the analysis phase.
Speed estimation
It is possible to obtain the defined impact speed via the high resolution encoder on the center of rotation and the developed software. The speed is measured in milliseconds via fast counter input modules .
Automatic report generation
In the developed software, raw sensor data is filtered through this special signal filter, an automatic report is generated without operator intervention, and impact accelerations exceeding 80 g’s specified in the norm and their durations are evaluated.
Impact force
Pneumatic drive is preferred to reach the speed of 24.1 ± 0.8 km/h’s at the impact point. The initial motion of the frame carrying the impact head is carried out by a fast piston. Pre-filling tank is used to be avoid air flow changes on the centralized pneumatic system and fast response valves are used to eliminate the valve response times. The correlation amongst the total energy transferred, the impact speed, the initial angle of the carrying frame, the position during impact, the frame length, the prefilling tank volume, post-filling pressure, initial impact cylinder dimensions and hose thicknesses is formulated with the complex differential and fluid equations.

Dynamic Test Station

Regarding ECE R16 regulations,

the test bench performs dynamic locking position, retractor life, locking force determination and endurance tests of the seat belt.

The hybrid framework allows to perform 3 types of tests within the same mechanical structure, software interface and electrical system.

Specifications

Acceleration control (Jerk)
The servo systems can control position and speed. In this application above that, the ramped acceleration with fixed jerk has been achieved specified in the norm.
10 kHz accurate data logging
Position and acceleration and values with 1 micron precision are logged for every 0.1 ms (10 kHz). The logged data is initially stored in the controller memory, then automatically transferred to the PC at the end of the test and not affected by the processing scan time. Data interruption risks between hardware are avoided.
ISO 17025 and digital technology support
Before each test, a special time stamped folder is created to support ISO 17025. In this test folder, the test inputs such as target acceleration curves, test operator, participants, test output that contains position, acceleration and force data as well as calibration values are saved as MS Excel files. At the end of the test, the output data is analyzed and an automatic report is generated and sent to the predefined e-mail addresses. These functions ease the operator workload and competences.

Y/Z Road Strength

Used for Ford, Renault and Stellantis

road conditions are simulated in three working mode, the deformation of automotive components, such as the seat cushion in passenger cars, are digitized, and the fittings and ratios where potential loosening may occur are identified.

 

For road simulation purposes:

  • Sinusoidal motion in the Y and Z axes
  • Sinusoidal motion only in the Z axis
  • Replication of road data in the Z axis can be obtained.

Specifications

Road conditions simulation
In the road data application, it is synchronized with data collection hardware such as VBOX. By doing this, the road conditions are simulated in the best way in the lab environment.
DC cylinders
Weights are placed using DC cylinders, removing the need for a pneumatic system. The special algorithms for servo axes, with the motor and linear equipment of sub-micron resolution, enable 1kHz data acquisition and getting precise motion profiles during the processor/servo cycle. Electronic scales with 2.5 micron resolution record the maximum deformation in each sinusoidal movement on the seat cushion with high accuracy and frequency for each cycle
Acoustic and acceleration sensors
Acoustic and acceleration sensors can be optionally added to detect part loosening.
Modern notification system
During the test, when the number of cycles gets to the number at which the manual observation is needed, the system automatically stops, and in addition to the visual and audible warnings, notifications to mobile devices are sent.
Periodic photo capturing
The periodic photo capture function allows for the analysis of a loosened part according to its cycle count.
Specialized lifecycle analysis software
Using specialized lifecycle analysis software, the compatibility and cycle lives of selected servo and linear components are examined, and component selections are optimized based on these criteria.
AI ​​software plugin
The AI ​​software plugin includes machine learning and trend analytics algorithms to determine system dynamics parameters. This allows it to predict, for example, that deformation in a seat cushion will cause a negative test result, within 10% of the testing period. This significantly reduces testing and validation times.

Vibration Test Station

Regarding DIN 45678 norm,

It is used on vehicle seats, automotive parts with bolted connections, and parts where the resonance frequency shall be determined.

There are 2 test types, namely resonance frequency determination and vibration life test.

For the two test types, resonance frequency determination and vibration life test, constant set frequency, set life time, manual inspection frequency, frequency curve for the resonance tests are entered on the touch screen. The software records the accelerometer data on the table and on the test specimen.

Specifications

Acoustic sensors
Optional acoustic sensors can be added. Sound level, loosening of bolt connections or resonance frequency are determined in accordance with the aging.
Interaction with mobile devices
Test start and stop states are shared as the mobile phone notification in addition to buzzer. The test status can be monitored online on the mobile phones via a camera connected to the test device.

Robotic Quality Cell

For the first time in Turkey,

the ingress-egress test implemented by TMEX, the Occubot module of the Kuka robot brand simulates the sitting and standing movements of a human in a chair model, using a robotic manipulator capable of controlling force in orbital planes.

Automotive manufacturers (OEMs) define the force fields and vectors applied to the seat surface by human standing and sitting behaviors, based on average demographic characteristics, using load mat sensor equipment in their technical specifications, and share these force curves with their contracted suppliers. The Occubot module in the Kuka robot uses a 3-axis vector force sensor at the 6th axis end to perform a planar translation when force is not reached in the trajectory plane, in order to conform to this force tensor-time curve.

Specifications

Creating specific climatic conditions
TMEX supplies highly sensitive temperature and humidity sensors that measure climate control values ​​and seat heater resistance, record this data in datalogger units, and create specific climatic conditions using special humidifiers, dehumidifiers, heaters, and coolers.
Sophisticated software
The software developed by TMEX allows for the application of different force tensor curves on two separate tables, and enables the definition of manual operator visual inspection, photo capture, and interim report generation cycles.
Modern notification system
Audible and visual warning systems and mobile device notification features are also included in this application.
Occupational safety
The safety of the robotic cell and its operators is ensured in accordance with standards through simulations and related occupational safety automation equipment.

Digital Basic

Life & Fatigue Test Station

Smart relays are generally used in special purpose life and fatigue test benches. Smart relays allow entries up to 30 thousands for the counter set value. Number entry is thru tiny buttons. TMEX has implemented 4.3’’ touch screen HMI and controller solution which supports cost advantage also in this model.

In this solution, besides the counter set value, manual inspection frequency, such as in every 50 thousand cycles, are also allowed to be entered even in million digits.

Specifications

Construction of standard aluminium profiles
Forces up to 1000 N are generally applied in life and fatigue tests. The mechanical structure is constructed from standard aluminum profiles that can withstand these forces and allows profiles to be easily added and reconfigured for different test scenarios.
Simple and flexible use
On the HMI interface, both tensile and compressive forces and position test types can be selected. The target force is adjusted by pressure switches, the position by cylinder sensors, and the speed by throttle valves. The touch screen interface is designed in mobile phone style and screen scrolling ease of use.
Estimation of manual inspection date
At the beginning of the test, a single cycle is applied and the system automatically calculates the elapsed time in a single cycle. Based on the entered manual inspection frequency, the system estimates the date of the next manual visual inspection pause.
Determination of deformation
TIf the predetermined time of a single cycle exceeds, breakage or excessive deformation is automatically detected and the test is paused.
Operational log traceability
The software traces the test start, end, stop date, time and reasons (breakdown, manual pause, inspection at the control frequency), which improves the intervention response time in case of abnormality.
Remote camera access
The test specimen can be monitored instantaneously on mobile phones via a camera connected to the test bench.
Interaction with mobile devices and computers
Test start and stop states are shared as the mobile phone notification in addition to buzzer. Using the Ethernet connection on the touch screen, the test data can be followed up online on the office PC’s even for multiple test benches.

Life and Fatigue Test Station

Using servo pistons'

precision and technology, the test bench has been developed for general-purpose life, fatigue and durability tests of all automotive components (seats, armrests, backrests, footrests, magazine holders etc.) and industrial products.

Axes can be operated independently, sequentially or synchronously. For example, the sequential forces to first armrests, then footrests and backrests can be applied in accordance with the predefined force and position values. Although really difficult, the simultaneous sinusoidal and absolute sinusoidal force control in 4 axes has been completed within the scope of special train seat test norms.

Single or 2-axis designs of different axis stroke, speed and force scale are available upon request.

Specifations

Flexible programming editor
On the data input page, a program can be formed line by line in the flexible programming editor, then can be saved after simulation. Counter set value, manual inpection frequency and the frequency of the cam shot over the web camera connected to the test PC can be programmed as well.
Various signal types
Not only the triangular, trapezoidal or multi-segment linear signals but also multiple steps such as sinusoidal and absolute sinusoidal force and position control can be programmed flexibly.
Accurate data logging
All sensor data are recorded continuously at 200 Hz in static force tests, and at a certain moment of the cycle in life tests, and are not affected by power or communication interruptions. The external extensometer measures the actual deformation on the test specimen beside the servo position.
Compliance to digital techs
A notification is sent to the operator's mobile phone in case of frequential manual inspection pause, manual pause, breakage or over deformation and power black out anomalies. Traceability is logged with time stamps and an automatic report is generated at the end of the test. The main test page, which contains all necessary data and online camera video, can be watched remotely from mobile devices and computers.
Estimation of manual inspection date
At the beginning of the test, a single cycle is applied and the system automatically calculates the elapsed time in a single cycle. Based on the entered manual inspection frequency, the system estimates the date of the next manual visual inspection pause.
Operational log traceability
The software traces the test start, end, stop date, time and reasons (breakdown, manual pause, inspection at the control frequency), which improves the intervention response time in case of abnormality.
Monitoring on mobile devices and remote PCs
Test start and stop states are shared as the mobile phone notification. The test page and the instant video of the test can be monitored on mobile phones or any computer via a camera connected to the test bench.

Tractor & Cabinet Test Station

Regarding ECE R58, R73 and R93 regulations

as well as 89/173/EEC, 4 types of tests on force up to 200 kN and energy application are performed with pistons of a stroke of 500 mm.

Under a force level of up to 200 kN, moving the piston 1mm on a specimen with varying material structure and elasticity is achieved by the outstanding control performance we engineered.

Monitoring the test remote on a connected webcam, automatic report generation in the format determined by the customer, time stamped test folders and automatic storage of all folder contents on cloud are standard features that are shared by other models of our test benches.

Specifications

Test types
4 test types are supported: manual force control with step increments, manual position control with step increments, set force control and set energy tests.
Accurate data logging
Force is recorded in 1 N’s, piston position and extensometers are recorded 25 micrometers (0.025 mm’s) resolution at 200 Hz.
Automatic datuming
After the test type and the piston to be applied are selected, the data entry fields are enabled. Position datum is accomplished by driving and providing contact between the piston tip and the test specimen as in CNC machines.
Automatic report generation and analysis
The applied energy is estimated from the integral of the force and position values, the elastic and plastic deformation and the r ratio are calculated.

Rollover Test Station

Regarding ECE R66, R107 and R111 regulations,

It is used for the tests of tanks and tankers with the test pressure of less than 4 bar of N and O category vehicles as well as bus type commercial vehicles.

Considering the risks for the telescopic pistons under heavy and unbalanced loads and the construction excavation work that will be required in case the pistons are buried underground a ramp is designed where the vehicle can drive onto the platform.

The task-sharing business model can be negotiated.

Specifications

Partial platform
The platform with the length of between 6 m and 15 m’s is produced as one piece or in parts and is driven by hydraulic pistons. In case of the partial design of the platform, the relevant hydraulic design have been considered for both independent and synchronous motion of the platform parts.
Inclination sensors
With wireless sensors, the inclination angle can be monitored instantly, the angle values of inclination sensors and time stamp can be included on the fast camera video frames.