Static Test Station

RECE R14, R80 and related FMVSS standards

This station performs static strength tests under these standards on single, 2-, 3- or 5-seat automotive seats with 2-point or 3-point belts (M1, M2, M3, plastic and wheelchair-accessible types), seat belts, anchorages and other automotive components.

Bed size, number of hydraulic cylinders (2 to 10), force direction (tension, compression or both), force range of up to 50 kN per cylinder and cylinder speeds are configured to customer requirements.

Specifications

Precise force control
Our proprietary force control algorithm reaches the target force quickly and precisely within the tolerance band across different material types, delivering outstanding performance.
Accurate data logging
Force and elongation sensor data are recorded every 5 ms (200 Hz) for 200 s. Data are first stored in controller memory and transferred to the PC automatically at the end of the test, eliminating the risk of communication loss between devices. Acquisition and logging at 200 Hz are unaffected by processing load.
Automatic date-stamped test folder
To support ISO 17025, a dedicated date-stamped folder is created for each test at start-up. Test inputs such as the target force curve, operator and participants, test results from sensor data, and sensor calibration values are stored there as MS Excel files.
Automatic reporting
At the end of the test, sensor data are analyzed, a report is generated automatically and emailed to the responsible staff. This reduces the operator's reporting workload and the expertise it requires.
Password-protected pages
Access to the sensor calibration page is password-protected.
Accreditation and safety
Safety fences and safety automation are essential. CE-compliant design and manufacturing can be approved by the relevant accreditation bodies. Fixture dimensions and sensor calibrations are verified by accredited independent laboratories.
High-speed camera video
Optionally, video captured automatically by high-speed industrial cameras can be synchronized with the test graph and sensor data on a dedicated analysis page.
Third column
Some of the hydraulic cylinders can be moved to a third column using hydraulic and electrical quick couplings.
Large-screen TV
For the convenience of test participants, the touchscreen software display can be mirrored wirelessly to a remote large-screen TV.
Hybrid solutions
On request, hybrid solutions can be built in which servo-controlled or pneumatic durability, fatigue or ECE R17 test equipment shares the same bed and the same electronic and hydraulic hardware.

Ingress/Egress Robotic Test Cell

A first in Türkiye

Commissioned by TMEX, this cell uses KUKA's Occubot module, dedicated to ingress/egress testing, to simulate a person sitting down on and getting up from a seat with a robotic manipulator capable of force control along trajectory planes.

In their technical specifications, automotive OEMs use load mat sensors to determine the force fields and vectors that people of average demographic characteristics apply to the seat surface when sitting down and getting up, and share these force curves with their contracted suppliers. Using a 3-axis force sensor at the end of the 6th axis, the Occubot module on the KUKA robot adapts within the trajectory plane whenever the target force is not reached, so that it follows this force tensor-time curve.

Specifications

Special climatic conditions
High-precision temperature and humidity sensors supplied by TMEX measure climate values and seat heater resistance, which are recorded on dataloggers. Dedicated humidifiers, dehumidifiers, heaters and coolers maintain the required climatic conditions.
Advanced software
TMEX's software can apply different force tensor curves on two separate beds and define cycles for manual visual inspection by the operator, photo capture and interim reporting.
Alerts and notifications
This application also includes audible and visual alarms and notifications to mobile devices.
Workplace and operator safety
Workplace and operator safety in the robotic cell is ensured in compliance with standards through simulations and the related safety automation hardware.

Y/Z Road Durability Station

Ford, Renault and Stellantis

Our new-generation Y/Z road durability test station, used for these OEMs, simulates road conditions in three operating modes. It quantifies the deformation of automotive components, such as the foam of a passenger car seat, and identifies fasteners prone to loosening and the extent of loosening.

 

For road simulation

  • Sinusoidal motion in the Y and Z axes
  • Sinusoidal motion in the Z axis only
  • Road data playback in the Z axis

Specifications

Simulation of real road conditions
For road data playback, the system is synchronized with data acquisition hardware such as VBOX, so that real road conditions are reproduced in the laboratory as accurately as possible.
Precise servo control
Dedicated servo axis algorithms, combined with sub-micron-resolution motors and linear components, achieve precise motion profiles at a 1 kHz data acquisition and processor/servo cycle time. Linear scales with 2.5 µm resolution record the maximum deformation of the seat foam in every sinusoidal stroke with high accuracy, for every cycle.
DC actuators
Weights are positioned by DC actuators, with no need for a pneumatic system.
Optional acoustic sensors and accelerometers
Acoustic sensors and accelerometers can optionally be added to detect loosening parts.
Periodic photo capture
Photos taken at set cycle intervals make it possible to analyze a loosening part against cycle count.
Lifetime simulation
Dedicated lifetime analysis software checks the compatibility and cycle life of the selected servo and linear hardware, and hardware selection is optimized accordingly.
AI software add-on
The machine learning and trend analysis algorithms in the AI software add-on identify the system dynamics parameters. This makes it possible, for example, to predict a failing seat foam deformation result after only about 10% of the test duration, significantly shortening test and validation times.

Specifations

Flexible programming editor
In the flexible programming editor on the data entry page, programs can be written line by line and saved after simulation. Target cycle count, visual inspection interval and photo interval (via a webcam connected to the test PC) can be entered.
Various signal types
In addition to triangular, trapezoidal and multi-segment linear signals, multi-step programs with sinusoidal and absolute sinusoidal force and position control can be created.
Precise data logging
In this integrated setup, which performs both static and durability tests, all sensor data are logged continuously at 200 Hz in static force tests and at a set point of every cycle in durability tests, unaffected by power or communication interruptions. An external extensometer measures the actual deformation of the specimen, independent of the servo position.
Digital-ready
Notifications are sent to the operator's mobile phone at each visual inspection interval and in case of breakage, excessive elongation, power failure or manual stop. A date- and time-stamped traceability log is kept and a report is generated automatically at the end of the test. The main test page, with all relevant data, can be monitored remotely in real time from mobile devices and computers.
Visual inspection interval
A single cycle is run at the start of the test and the system automatically calculates the cycle time. Based on the entered inspection interval, the system shows the date of the next manual visual inspection stop.
Traceability
The software logs the date, time and reason for every test start, end and stop (breakage, manual stop, scheduled inspection). This shortens response time when an anomaly occurs.
Monitoring from computers and mobile devices
Test start and stop events are sent as notifications to a mobile phone number. The test page and a live video of the test, from a camera connected to the station, can be viewed on mobile phones or any computer.

Durability & Fatigue Test Station

Servo-cylinder technology

Built on the precision of servo cylinders, this station was developed for durability, fatigue and endurance testing of general-purpose automotive components (seats, armrests, backrests, seat cushions, footrests, map pockets, etc.) and industrial products.

The axes can run independently, sequentially or in synchronized mode. In sequential mode, for example, the armrest, then the footrest and backrest can be tested in turn at the appropriate force and position values. Applying simultaneous sinusoidal and absolute sinusoidal forces on 4 axes under specific train seat standards is truly challenging, and TMEX has accomplished it.

On request, single- or dual-axis designs are available with different stroke lengths, speeds and force ranges.

Energy Dissipation & Impact Test Station

ECE R21 and R25 standards

For energy dissipation testing under these standards, there are 3 topologies: free fall, sled-guided free fall and fluid-driven pendulum.

In free-fall topologies, brief friction right after impact, followed by rebound and a second hit, is likely, and the velocity cannot be measured exactly.

In the pendulum-type impact test station developed by TMEX, a servo drive with EtherCAT communication and a central encoder delivers a single, clean impulse. Impact velocity is measured accurately and precisely at millisecond resolution.

Specifications

CFC 1000 filter
The standards require data from 2 accelerometers to be acquired at a minimum of 10 kHz and filtered with a CFC 1000 filter. This variable-parameter, recursive filter is applied in the software during analysis.
Velocity measurement
Velocity is measured at millisecond resolution with a high-resolution encoder at the pivot of the arm and high-speed counter input modules.
Automatic reporting
Our software passes raw sensor data through this filter, generates a report automatically without operator intervention, and evaluates whether and for how long impact decelerations exceed the 80 g specified in the standard.
Drive force
A servo drive is used to reach the required 24.1 ± 0.8 km/h at the point of impact. Our software and easy-to-use electronic hardware achieve this velocity with high accuracy.

Dynamic Test Station

ECE R16

Under ECE R16, this station determines the seat belt's dynamic locking position during a crash with sub-micron precision, and performs retractor durability, locking force and strength tests.

With its hybrid design, it performs all 3 test types with the same mechanical structure, software interface and electrical system.

Specifications

Acceleration control (Jerk)
Beyond the usual position and velocity control of servo systems, the controller ramps up to the acceleration values specified in the standard within a defined time (constant jerk).
10 kHz precise data logging
Position (1 µm precision) and acceleration values are recorded every 0.1 ms (10 kHz). Data are first stored in controller memory and transferred to the PC automatically at the end of the test, unaffected by processing load. The risk of communication loss between devices is eliminated.
ISO 17025 support and digital features
To support ISO 17025, a dedicated date-stamped folder is created for each test at start-up. Test inputs such as target values, operator and participants, results from servo position, acceleration and sensor data, and axis and sensor calibration values are stored there as MS Excel files. At the end of the test, sensor data are analyzed, a report is generated automatically and emailed to the responsible staff. This reduces the operator's reporting workload and the expertise it requires.

Strength Test Station

ECE R17 + fatigue

For these tests, the station can be designed for single, 2- or 3-seat automotive seats. With servo axes, precision load cells and 0.2%-accuracy torque sensors at the H-point, our new topology enables more precise and more varied tests.

During the test, the backrest fixture first pushes back around the R-point until a torque of 373 / 530 Nm is reached; the upper servo cylinder then bears on the head restraint and applies a force of 890 N.

Specifications

Precise and versatile testing
With servo axes, precision load cells and 0.2%-accuracy torque sensors at the H-point, our new topology enables more precise and more varied tests.
Servo actuators
They precisely achieve the force-dependent speeds specified, and with a 2000 N capacity they provide a standard, spare-parts-friendly solution with the headroom and flexibility for future revisions of the standard.
Flexible programming software
With the flexible programming software, the additional servo cylinder used for the head restraint deformation test can also be used for durability and fatigue tests of seat parts such as armrests, backrests, cushions, head restraints and recliner mechanisms.
Hybrid solutions
On request, it can be built as a hybrid station combining ECE R17 with other fatigue and durability tests such as R21/R25, sharing a common bed, controller and test PC.

Break-in & Measurement Test Station

Modular in-line unit

Designed as a modular in-line unit, this station performs the break-in required by the material properties of automotive door hinges, followed by 100% measurement.

Özellikler

Break-in and measurement in one station
After break-in, torque is analyzed against angle, and conformity is verified both on the station display and through a graphical view of the measurement sample file on an external computer.
Traceability
For traceability, the time-stamped moment-of-inertia graph is saved via Ethernet to the central manufacturing execution system (MES).
Flexible topology and software
The topology and software blocks are designed flexibly to accommodate laser marking if needed.

Tractor & Cab Test Station

ECE R58, R73 and R93 standards

In test equipment for these standards and 89/173/EEC, 4 types of force and energy tests of up to 200 kN are performed with 500 mm stroke cylinders.

Moving a cylinder by 1 mm against a specimen of variable material and elasticity, at forces of up to 200 kN, demonstrates our superior control performance.

Remote monitoring via a connected webcam, automatic reports in a format agreed with the customer, date-stamped test folders and automatic cloud backup of all folder contents are standard features, as on our other test equipment.

Specifications

Test types
Four test types are supported: manual force control with stepwise force increase, manual position control with stepwise displacement, target force in target time, and target energy.
Precise data logging
Force (1 N resolution), cylinder position and external extensometers (25 µm / 0.025 mm resolution) are recorded at 200 Hz.
Zero position
Once the test type and cylinder are selected, the data entry fields become active. Cylinder speeds can be selected and, as on CNC machines, zeroing is done by touching the cylinder tip to the specimen.Position datum is accomplished by driving and providing contact between the piston tip and the test specimen as in CNC machines.
Automatic analysis and reporting
Applied energy is calculated by integrating force over displacement, and elastic and plastic deformation and the r ratio are computed.

Rubbing Test Station

Ford ST0809

In this station, designed for seat fatigue and aging tests to automotive manufacturers' own standards, automotive seats are humidified and heated under load in a controlled way. Single or double seats can be tested.

Specifications

Inverter-driven motors
Under different loads, inverter-driven motors generate the rubbing motion at variable speeds, programmed in the flexible editor of the interface software.
Low-flow humidification
Water is applied by seepage at variable, very low flow rates through special pumps and small-diameter hoses.
Dedicated heaters and controllers
Dedicated heaters and controllers keep the seat surface at a set temperature.
Automatic reporting
Throughout the test, seat surface temperature and humidity can be monitored and shared as a live graph; the sensor output file is then saved as an automatic report.

Rollover Test Station

ECE R66, R107 and R111 standards

Under these standards, this station is used to test tanks and tankers of category N and O vehicles with a test pressure below 4 bar, as well as buses and coaches.

Considering the risks of telescopic cylinders under heavy, unbalanced loads and the excavation work required for recessed cylinders, the design includes a ramp for the vehicle to drive onto the platform.

A shared-responsibility business model can be considered within the project.

Specifications

Segmented platform
The platform, 6 to 15 m long, is built in one piece or in segments and driven by hydraulic cylinders. For segmented designs, the hydraulics support both independent and synchronized movement of the segments.
Inclination sensors
Wireless sensors monitor the tilt angle in real time, and the angle values and timestamps can be overlaid on high-speed camera video.

Specifications

Optional acoustic sensors
Acoustic sensors can optionally be added to determine noise level over aging time, loosening of platform connections or resonance frequency.
Mobile access
Start and stop notifications are sent to a mobile phone. Test status can be watched live on mobile phones via a camera connected to the station.

Vibration Test Station

DIN 45678

Wherever vibration durability measurement is required under DIN 45678 or similar standards, this station is used on vehicle seats, bolted automotive parts and parts whose resonance frequency must be determined.

There are 2 test types: resonance frequency determination and vibration durability.

Target fixed frequency, run time, visual inspection interval and, for resonance tests, the frequency sweep are entered on the touchscreen. The software records accelerometer data from the table and the specimen.

Digital Eco-Series Pneumatic

Durability Test Station

Special-purpose durability and fatigue testers typically use smart relays, which limit the target cycle count to around 30,000 and require tedious entry with small buttons. In this model, TMEX instead uses a cost-effective touchscreen and controller solution.

Besides the target cycle count, this allows manual visual inspection intervals (for example, every 50,000 cycles) to be entered, even for counts in the millions.

Specifications

Standard aluminium profiles
Durability and fatigue tests typically apply forces of up to 1000 N. The frame is built from standard aluminum profiles rated for these loads, which can easily be added or rearranged for different tests.
Simple, flexible operation
The software interface accepts position-based signals in both pull and push directions. Target force is set with pressure switches, position with cylinder sensors and speed with throttle valves. The touchscreen is designed like a smartphone, with easy swipe navigation.
Visual inspection interval
A single cycle is run at the start of the test and the system automatically calculates the cycle time. Based on the entered inspection interval, the system shows the date of the next manual visual inspection stop.
Breakage detection
If a cycle exceeds its preset duration, breakage or excessive elongation of the specimen is detected automatically and the test is stopped.
Traceability
The software logs the date, time and reason for every test start, end and stop (breakage, manual stop, scheduled inspection). This shortens response time when an anomaly occurs.
Remote camera monitoring
The specimen can be watched live on mobile phones via a camera connected to the tester.
Communication with mobile devices and computers
Test start and stop events trigger an audible alarm and a notification to a mobile phone number. Test, process and counter values of multiple testers can be monitored from office computers over Ethernet.