The key to success for automotive suppliers is to design components that meet reliability targets, keep warranty costs low, while at the same time achieve low production costs. Traditionally, automotive components are tested using generic specifications based on historical damage profiles with little connection to the vehicle that the component will be used on. The result is that the component may be overdesigned for some types of vibrations while remaining vulnerable to others.
Valeo has pioneered a new approach that transforms road load data acquired from the vehicle on which the components will be used into a test signal that realistically represents the fatigue loads seen by the component during its life on the actual vehicle. Valeo worked with HBM Prenscia to implement this approach in nCode GlyphWorks test data analysis software and uses this software to quickly generate synthesized test signals to drive fatigue test systems. The result is that the component is designed to meet the specific requirements of the vehicle, resulting in a reduction both in manufacturing and warranty costs.