V&S 511 – Automotive Vibration And Shock Testing

Overview for management and participants

  • Purpose of environmental testing, particularly vibration and shock
  • Purpose of environmental stress screening (ESS)
  • Types of vibration tests: resonance search/dwell, fatigue, specification

Quiz for evaluation of attendee prior knowledge

Classical sinusoidal vibration never observed in service; useful concept

  • Introduction: terminology, structural resonant behavior
  • Sinusoidal vibration measurements: units, sensors, readouts, errors
  • Calibration of sensors and systems; traceability to NIST

Most machinery vibration is complex; introduction to spectrum analysis

Introduction to sinusoidal vibration testing

  • Electrohydraulic and electrodynamic shakers; theory, tradeoffs, limits
  • Power amplifier theory, operation, limitations, distortion effects
  • Analog and digital controls for sinusoidal vibration testing
  • Sinusoidal vibration test practice
    • Interpreting and implementing SAE and other standards
    • Controversial test methodology: tracking filters, switching and averaging among sensors
  • “Buzz, squeak and rattle” investigations and testing

Introduction to random vibration

  • Sources of automotive random vibration; transportation
  • No possible equivalence to sinusoidal vibration
  • Terminology and definitions
  • Spectral density measurement and analysis – the frequency domain
  • Probability density – the time domain

Random vibration test practice

  • Interpreting and implementing SAE and other standards
  • Equalization before testing; methods and limits
  • Quick review of analog with most emphasis on digital controls
  • Multi-axis testing

Combined environment (CERT) testing; reliability tests, e.g. MIL-STD-781

Environmental stress screening (ESS); accelerated testing

Shock and vibration test fixtures; fixtures for stress screening

  • Recommended designs, materials, fabrication methods
  • Experimental evaluation before use

Instrumentation for measuring shock in service and during tests

  • Sensors, readouts, errors; calibration
  • Shock spectrum analysis; shock response spectrum

Shock testing standards and methods

Witnessing of tests

Summary of course for management and participants

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