Validation Testing

Are you doing something new with a product and aren’t sure how to prove that it will work as expected? Are you experiencing structural issues; or chasing failure from one place to another?

Any of these indicate a need to improve your Product Validation Process.

Many small to medium-size manufacturers operate on the build-it/break-it principle but are finding their markets are demanding lighter, more functional, more durable, less expensive products. A faster and more cost-effective approach is to leverage computer simulation tools to do much of the validation digitally and use testing to support the simulation model for up-front loads and downstream validation. In other words, build the physical product confident it will meet performance targets.

Drawing from decades of experience over a range of industries, 6D can help improve your validation process. We will meet with your staff to understand your validation process and requirements.  We will offer constructive suggestions about how to cost-effectively validate your products with available tools.  We’ll train your staff on the use those tools as they work to validate one of your actual products. We’ll support your engineering team to ensure the quality of their work and answer any questions about the validation process on future products.

We provide a cost-effective engineering solution to validate next generation products or design enhancements.  We offer a unique combination of field testing, analytical simulation, and decades of experience to determine if your designs will meet design, performance, and durability targets.

Product Validation Services

• Benchmark your current process against industry practices.
• Recommend updated process steps and, if needed, software and hardware.
• Help your validation process become an integral part of your standard operating procedure.
• Supplement Finite Element Analysis and/or testing
• Leverage & train your internal resources.
• Assist as needed with the complete validation process from developing an overall process to final field testing.

Proving Grounds

Proving grounds are an optimum way to validate vehicle designs. But vehicle transport, track time, driver compensation, and more and just a few examples of costs associated with this validation process.  By collecting and projecting a small sample of test track data, 6D can provide the answers you’re looking for at a fraction of the time and cost.

Here’s How:

• The vehicle finite element model used in the design process is used to determine potential high stress areas based on basic static load cases such as body twist, bending, and inertial “g” loads.
• Although these basic loads do not directly replicate the much more complex loads experienced in road environments, they are effective in identifying stress “hot spot” locations.
• Strain gages are applied to these “hot spot” regions in order to determine the actual stresses in operation. Also, some strain gages are located in key nominal stress areas to assist in correlating the FEA model. Selected locations are instrumented with accelerometers to assist in scaling and confirming the FEA “g” loadings.
• Data is recorded for staged events to assist in correlating the FEA model. Data is also recorded on roads representative of customer usage and proving ground durability events.
• The data is processed using cumulative damage methods based on material and weld properties to estimate fatigue life.
• If life issues are encountered, we loop back to the FEA simulation to evaluate design improvements.  We will then potentially rerun the staged events with updated vehicle to validate final design.

FTA/Altoona Testing

Vehicles purchased with federal funds must achieve rigid FTA/Altoona structural integrity and durability certification. Together with our strategic partners, InDepth Engineering Solutions and Navistar Proving Grounds; 6D works with specialty vehicle manufacturers prior to official FTA/Altoona testing to ensure that their vehicles are structurally ready to meet the requirements of those tests.

We combine field testing with analytical simulation to provide a low-cost solution to predict if your product will successfully complete the required number of durability miles.

RLDA – Public Roads

Used for test-based design validation using random vibration or simulation rig testing, Vehicle Road Load Data Acquisition (RLDA) measures vehicle response to road loads.

RLDA testing can be conducted at proving grounds, special events, public roads, international venues. Vehicles are instrumented and data collected remotely via unattended testing techniques. Data can be stored on a recorder or uploaded to the cloud for storage and analysis. This includes all critical vehicle components such as steering, suspension, power train & driveline, seats, exhaust systems, electronics, and more.

Test Lab

In many cases materials and components require lab testing to either determine its material properties or response to loads.  We partner with other local test labs as well as has its own in-house lab testing capabilities. Typically, a part is instrumented with strain gauges at critical locations before applying and measuring loads.

Test Lab Examples:

• Load Cell Fabrication & Calibration
• Material Testing
• Strain/Stress Load Response
• Modal Analysis
• FEA Validation

Rotating Machinery

6D specializes in testing and analyzing rotating machinery. Our capabilities include comprehensive evaluation and assessment of various types of rotating machinery, such as motors, turbines, pumps, compressors, and generators. We employ advanced techniques and cutting-edge technology to provide precise and detailed insights into the performance and behavior of these machines.

• Vibration Analysis: We conduct in-depth frequency and phase vibration analysis to identify and quantify the vibrations produced by rotating machinery. This analysis helps detect any unbalanced forces, misalignments, resonance issues, or other sources of vibration that can affect performance, reliability, and safety.
• Modal Analysis: By performing modal analysis, we determine the natural frequencies, mode shapes, and damping characteristics of rotating machinery. This information is crucial for understanding the dynamic behavior of the equipment and optimizing its design to avoid resonance and excessive vibrations.
• Structural Analysis: We assess the structural integrity of rotating machinery and its components to ensure they can withstand the operational loads and forces. This analysis involves finite element modeling, stress analysis, and fatigue assessment to identify potential weaknesses and recommend structural improvements.

Our team of experienced engineers and analysts works closely with clients to tailor our testing and analysis services to their specific needs. Whether it’s performance optimization, troubleshooting, failure investigation, or design validation, we provide comprehensive solutions to ensure the reliable and efficient operation of rotating machinery.

Industrial & Power Generation Equipment

6DOF Testing & Analysis has a wide range of capabilities when it comes to testing industrial equipment. We understand the criticality of ensuring the reliability, safety, and performance of industrial machinery, and our services are designed to meet these requirements. Here are some of our key industrial equipment testing capabilities:

• Performance Testing: We conduct comprehensive performance testing to evaluate the efficiency, output, and overall performance of industrial equipment. This includes testing parameters such as power consumption, torque, speed, pressure, flow rate, and other relevant performance metrics.
• Durability and Reliability Testing: We assess the durability and reliability of industrial equipment by subjecting it to rigorous testing conditions. This involves performing endurance tests, accelerated life testing, and reliability prediction analysis to identify potential failure modes and improve the equipment’s design and robustness.
• Failure Analysis: In the event of equipment failure or malfunction, we offer fault diagnosis and failure analysis services. Our experts use advanced diagnostic tools and techniques to identify the root cause of failures, recommend corrective actions, and prevent future occurrences.
• Customized Testing Solutions: We understand that each industrial equipment may have unique testing requirements. Our team works closely with clients to develop customized testing protocols and procedures to address specific needs, ensuring comprehensive evaluation and validation of the equipment.

Our experienced team of engineers and technicians, coupled with state-of-the-art testing equipment and facilities, enables us to deliver accurate and reliable testing results. We are committed to providing our clients with actionable insights to enhance the performance, reliability, and safety of their industrial equipment.