Testing provides the baseline data to drive simulations along with the insight to predict and measure performance, validate design integrity, and pinpoint areas of concern. Because of this, the ultimate success of any new product or design change is directly tied to the accuracy and quality of data that is collected.
This data must reflect the environment, conditions, and extreme range of forces to which the product will be subjected. When baseline data is not consistent with these conditions, the results are excessive warranty claims, failed products, lost market share, and even litigation.
The best way to ensure reliable data accuracy, type, and quality is through comprehensive test planning. 6D works with manufacturers, end users, and product development organizations to create and often execute test plans. The company’s services range from test planning and assistance, data collection and analysis, design validation, and problem-solving performance issues related to in-service products.
Example: Vehicle Design
Today’s vehicles are a sophisticated collection of components, sub-assemblies, and assemblies. The interaction of these systems, generally from diverse suppliers, is critical to overall performance. Even simple design modifications can introduce levels of vibration or interference creating an adverse effect on seemingly unrelated components or assemblies.
With an understanding that engineering analysis and product success go hand-in-hand, a prominent manufacturer of small to medium size coaches mandated that full analytical models be created to validate all new or changed designs. 6D was asked to instrument the vehicles, collect test data, and provide that data to a third-party for finite element modeling and analysis.
Each vehicle has unique properties, and all design changes must be correlated with data pertaining to that specific vehicle. Because engineers at the manufacturer never had to create such detailed programs, it quickly became apparent that the manufacturer’s current level of activity was insufficient to support the validation program.
As a result, the manufacturer called upon our experience and expertise. Today, 6D is integrated into manufacturing and FEA for a team-oriented validation approach. The company’s involvement includes defining test objectives, developing specific test plans for each vehicle, instrumenting vehicles, collecting data, working with the FEA team, and analyzing the models for fatigue and other issues.
Case Study