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Functional test bench for roll bars

An increasingly large number of car buyers chooses convertibles. This is shown by the latest production figures of roll bar protection systems of a leading automobile manufacturer. The components of roll bar systems require extensive testing in order to guarantee the safety of car passengers. The functional test bench featured here is used for the 100% testing of car roll bars. During the test cycle, the bench records the complete time-angle curve and also traces the trigger points of the limit switches mounted on the roll bar. Strain gauge sensors measure the positioning force of the roll bar and the release force of the two latch mountings. 

Roll-over bar function test bench

Double roll-over bars are inserted by hand in the test bench. First, the hole patterns of the rivet nuts are checked and the barcodes of the two actuators are scanned. Afterwards, the electric characteristic values of the two triggers are determined. When recompressing the roll-over bar, the force to unlock the latch, the height of the bar and the recompressing force are measured and evaluated. In the next step the bars are released one after another. By means of a load test the bar height with and without load is determined. Thus the locking of the latch is also tested. The same step is repeated in both directions after diagonal clamping. After successful testing a label is printed. Thus the bar can be clearly identified and allocated to the pertinent data set.

Assembly line for roll-over bar protection system

Assembly line consisting of several individual manufacturing stations with manual placement and guided assembly
Stations for preassembly of rivets on the frame, preassembly of the activation unit and assembly of single roll-over bar parts
Device for final assembly of all previously installed components

 

Assembly line for roll-over bar protection system

Assembly line consisting of several individual manufacturing stations with manual placement and guided assembly.
Stations for preassembly of rivets on the frame, assembly of the inner profile and preassembly of the activation unit.
Device for final assembly of all previously installed components.

Roll Bar Function Test Bench

The bench has been built for 100% production test of double roll-over bars. For the design a manual loading and fully automatic test performance concept is used.

During the test sequence the installation of attachment parts on the one hand and the following characteristic values of the roll-over bars on the other hand are measured:

  • Electrical values of the pyrotechnical release elements
  • Various heights of roll-over bars
  • Push in force, release force, unlocking force
  • Release times and distinctive release curve.

 

The measurement equipment includes contactless laser displacement measurement systems and various fully integrated force sensors.
After a successful test run the roll-over bars are marked. An integrated label printer creates a unique label for each roll-over bar. The pyrotechnical release elements will be fixed by means of a monitored electrical screw driver system.

Sonplas GmbH- Sachsenring 57 - D-94315 Straubing - Deutschland - Tel: +49 (0) 94 21 / 92 75 - 0 Fax: +49 (0) 94 21 / 92 75 199 - info(at)sonplas.de

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