Description:F O R M 2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patent Rule, 2003

COMPLETE SPECIFICATION
(See section 10 and rule 13)

“A FACILITY FOR TESTING AUTOMOTIVE VEHICLES”
by
Mahindra & Mahindra Limited, a company registered under the Indian Companies Act, 1913, having address at Mahindra & Mahindra Ltd., Mahindra Research Valley. Mahindra World City, Plot No.41/1, Anjur P.O., Chengalpattu, Kanchipuram District, Tamilnadu – 603004, India

The following specification particularly describes the invention and the manner in which it is to be performed

FIELD OF THE INVENTION
The invention relates to a facility for Automotive vehicles, and more particularly to test chamber for a body in white (BIW) of the vehicle to be tested in extreme weather conditions with combination of hot, rain, dust, and corrosion facilities in a single chamber.
BACKGROUND OF THE INVENTION
Automotive vehicles are subjected to different environmental conditions like hot in summer, cold in winter, dust in desert, corrosion in seashore (salt air) and rain in rainy season. During vehicle life, many of the above conditions are applicable for all automotive vehicles. When vehicles are operating in these conditions, there can be performance, functional and perception issues, which is not liked by the customers. And these extreme environmental vehicle operating conditions with all probable combinations can create vehicle non operative, safety and aesthetic related concerns. For making most robust test process, all above extreme weather conditions must be simulated in one chamber to validate the BIW or the complete vehicle for corrosion performance, static test performance and durability life for closures and its mechanism.
Therefore, there is need for a facility which can provide different test conditions for testing vehicle for analysing and improving the durability of automotive vehicles.

OBJECTIVE OF THE INVENTION
These objectives are provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This objective is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
An important object of the invention aims at providing a facility for testing automotive vehicles in extreme weather conditions with combination of hot, rain, dust, and corrosion facilities in a single chamber.
Another object of the invention is to simulate combination of all environmental (80%) conditions in testing chamber to find the premature failures in vehicles doors and its mechanism.
Yet another object of the invention is to conduct a test cycle comprising a corrosion test, a hot simulation test, a shower test, and a dust spray test in the same test chamber.
Object of the present invention is not limited to the above mentioned problem. Other technical problems that are not mentioned will become apparent to those skilled in the art from the following description.

SUMMARY OF THE INVENTION
According to an aspect of the invention, a facility for testing an automotive vehicle, comprises a test chamber configured to accommodate the vehicle for testing, the test chamber formed by the area enclosed by a frame, a door, a top side, a bottom side, a first side wall, a second side wall and a third side wall, wherein the top side, the bottom side, the first side wall, the second side wall and the third side wall are all arranged on the frame, the top side is arranged opposite to the bottom side, the first side wall and the second side wall are arranged opposite to each other, and the door is arranged on the frame and opposite to the third side wall.
A corrosion system configured for the test chamber comprises a saline solution container mounted on the top side, the lower surface of the top side is provided with a salt fog discharge line connected to the saline solution container and the salt fog discharge line connects a salt fog applicator.
A hot simulation system configured for the test chamber comprises at least a fan and a room heater setup, the room heater setup having a heating coil and an air blower, the room heater setup is positioned behind the side wall such that the air blower passes through the side wall therein.
A shower system configured for the test chamber comprises a water container mounted on the top side, the lower surface of the top side is provided with a water flow in pipes connected to the water container and the water flow in pipes connects a shower nozzle.
A dust spray system configured for the test chamber comprises a dust container mounted on the top side, the lower surface of the top side is provided with a dust flow in pipes connected to the dust container and the dust flow in pipes connects a dust spray nozzle.
A control unit in communication with the corrosion system, the hot simulation system, the shower system, and the dust spray system, configured for running and replicating a test cycle comprising a corrosion test, a hot simulation test, a shower test, and a dust spray test in the same test chamber.
According to another aspect of the invention, a method of testing an automotive vehicle in a test facility comprises the steps of conducting in a test cycle a corrosion test in a corrosion test system, a hot simulation test in a hot simulation system, a shower test in a shower system, and a dust spray test in a dust spray system; and controlling the test cycle by a control unit communicating with the corrosion test system, the hot simulation system, the shower system, and the dust spray system, wherein the corrosion test, the hot simulation test, the shower test, and the dust spray test are conducted in the same test chamber.
Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawing, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail with reference to an embodiment which is illustrated in the following figure:
Figure 1 shows a facility for testing an automotive vehicle, according to an embodiment of the present invention;
Figure 2 shows a corrosion system configured for the test chamber, according to an embodiment of the present invention.
Figure 3 shows top view of test chamber for corrosion system, according to an embodiment of the present invention;
Figure 4 shows a hot simulation system configured for the test chamber, according to an embodiment of the present invention;
Figure 5 shows a shower system configured for the test chamber, according to an embodiment of the present invention;
Figure 6 shows top view of test chamber for shower system, according to an embodiment of the present invention; and
Figure 7 shows a system configured for door slam test, according to an embodiment of the present invention.
Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF THE INVENTION
The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
Figure 1 shows a facility (100) for testing an automotive vehicle (102), according to an embodiment of the present invention. The test facility (100) for an automotive vehicle (102), comprises a test chamber (104) configured to accommodate the vehicle (102) for testing. The test chamber (104) formed by the area enclosed by a frame, a door, a top side, a bottom side, a first side wall, a second side wall and a third side wall, wherein the top side, the bottom side, the first side wall, the second side wall and the third side wall are all arranged on the frame, the top side is arranged opposite to the bottom side, the first side wall and the second side wall are arranged opposite to each other, and the door is arranged on the frame and opposite to the third side wall.
The exterior and interior of test chamber (104) is insulated with expanded polystyrene (EPS) panel board of at least 50mm thick and laminated with a pre-coated galvanised iron (PCGI). The interior walls of the test chamber (104) are coated with epoxy of grade EPILUX 44, and the bottom side is coated with epoxy of grade RAL 7035. The test chamber (104) during the test cycle is completely sealed.
According to an embodiment of the invention, the test chamber (104) is built uniquely to simulate slam durability under different environmental conditions. The test chamber (104) size is configured to accommodate various vehicle segments like sedans, hatch back, sport utility vehicle (SUV), multi-purpose vehicle (MPV) and light commercial vehicles. The test chamber walls are insulated with EPS panel board of 50mm thick. The complete test chamber (104) is coated with corrosion resistance coatings having resistance to chemicals and withstand the temperature and humidity conditions. In the test chamber (104) provisions are made for pneumatic air supply (130), pneumatic hose, pneumatic air line, pneumatic flow regulator (128), electric line and drain line. Test chamber (104) is also provided with safety control procedures to take care of vehicle from hazards during testing. The lighting system provided in the chamber are IP rated and able to function under different temperature and humidity conditions.
Further, it is preferable that the constitution of the test chamber is such that the inner bottom of the test chamber (104) has an inclination. In the constitution of the present invention, it is preferable that the wall of the test chamber (104) described above uses a heat insulating material. It is preferable that the constitution of the test chamber (104) is that the inside of the test chamber is painted with a high temperature paint.
Figure 2 - 3 shows a corrosion system configured for the test chamber (104), according to an embodiment of the present invention. Corrosion system configured for the test chamber (104) comprises a saline solution container (106) mounted on the top side, the lower surface of the top side is provided with a salt fog discharge line (108) connected to the saline solution container (106). The salt fog discharge line (108) connects a salt fog applicator (110). The corrosion system according to the invention is operated to conduct the corrosion test by dissolving 5 ± 1 parts by mass of sodium chloride in 95 parts of water, with humidity in the range of 10 to 95 % ± 4.1% RH. Corrosion test in the test chamber (104) is conducted for 24 hours and component level for 0, 25%, 50% 75% & 100% of slam cycles.
Figure 4 shows a hot simulation system configured for the test chamber (104), according to an embodiment of the present invention. The hot simulation system configured for the test chamber (104) comprises at least a fan (112) and a room heater setup (114). The room heater setup (114) having a heating coil (116) and an air blower (118). The room heater setup (114) is positioned behind the side wall such that the air blower (118) passes through the side wall therein. The hot simulation system is operated to circulate air to conduct hot simulation test in the temperature range of ambient to 80°C ± 3°C discontinuously, with heating-up rate of 1.5°C/min without vehicle, and 1°C/min with vehicle.
Figure 5 shows a shower system configured for the test chamber (104), according to an embodiment of the present invention. The shower system configured for the test chamber (104) comprises a water container mounted on the top side, the lower surface of the top side is provided with a water flow in pipes (120) connected to the water container and the water flow in pipes (120) connects a shower nozzle (122). The shower system is operated to conduct the shower test with water discharge rate of 1.1 Liter per min per nozzle at 2 bar pressure for 20min.
A dust spray system configured for the test chamber comprises a dust container mounted on the top side, the lower surface of the top side is provided with a dust flow in pipes connected to the dust container. The dust flow in pipes connects a dust spray nozzle. The dust spray system is operated to conduct the dust spray test at 1 bar pressure for 2-3 minutes.
A control unit in communication with the corrosion system, the hot simulation system, the shower system, and the dust spray system, configured for running and replicating a test cycle comprising a corrosion test, a hot simulation test, a shower test, and a dust spray test in the same test chamber. The facility according to the present invention further comprises a control room (126) adjacent to one of the side wall, said side wall is provided with monitoring window to monitor test conditions from the control room. The chamber entry and exit doors, monitoring window and entry provisions are completely sealed during the operation cycle for effective test chamber operation.
Figure 7 shows a system configured for door slam test, according to an embodiment of the present invention. According to this the test facility is provided with at least a pneumatic actuator (124) inside the test chamber (104) for conducting a door slam test. In addition, the test chamber (104) has provisions for pneumatic hose, air line, saline solution line, water line, electric line and drain line. Facility is also given in the chamber for bringing pneumatic lines inside so that actuators, shall be used for door slam operation with control unit.
In a preferred embodiment, the test chamber can be built by combining two containers with an available testing space of dimensions: length 5800 mm, width 4800mm, and height 2330 mm. The exterior and interior of the test chamber is made of EPS insulated ISO build sandwich panel board of 50mm thick and PCGI laminated on both sides. Interior wall is coated with EPILUX 44, which is abrasion resistant, resistant to chemicals and oil, heat resistant, with superior durability and film strength. The bottom side that is floor of the test chamber can be coated with epoxy of grade RAL 7035 light grey material, which is solvent-free, UV-resistant, and crystallization-stable, high transparency (crystal clear) and high mechanical and chemical resistant. The door side can have two entrance, each of 2m width x 2m height x 50mm thick metal and EPS panel board doors.
In the test facility, the corrosion system, hot simulation system, shower system, and dust system are so arranged such that when the vehicle is parked in test facility during the test cycle, uniform flow is achieved along the vehicle surface. Also, there is no contact between vehicle and the side walls. In case two vehicles are tested in the test chamber simultaneously, vehicles are parked such that no physical contact between them.
According to an embodiment of the invention, in a test cycle, to conduct the corrosion test salt solution is prepared by dissolving 5 ± 1 parts by mass of sodium chloride in 95 parts of water. The salt solution is stored in a saline solution container. Humidity can be regulated between 10 to 95 % ± 4.1% RH, as per requirement at ambient temperature humidity is 55 % RH. The salt fog applicators are placed on top side of the chamber at chamber centre and at corners in such a way that uniform fog condition prevails. The fog applicators are cut off when 95% RH condition reached by its controller and resume its operation once the limit reduced. The vehicle is exposed in the test environment for test duration in multiples of 24 hours. Normally, the test period is 96 hrs and can be done as per combined new test cycle based on real world usage pattern (RWUP).
In door slam hot simulation test, door systems like door outer and inner panels, seals, handles, actuators, switches, latches, hinges, check arm, power window mechanisms, trim pads, ORVM and exterior claddings are evaluated during slam durability test with hot simulation application for automotive vehicles. Shower test and dust test can be conducted during initial, interim and after test. The hot simulation test ensures that there is not any functional and structural failure in door systems like latch actuators, seals, PKE, door switches, locks, power window mechanisms. Further, ensures that there is not any cracks, breakage, rust, wear and tear in any of the components during and after the test. No traces of dust ingress inside the cabin or in the tested sample. There must not be any seepage or leakage observed in the passenger compartment during and after the test. All the parameters, door and mechanism operating efforts, gaps and flushness must be within the specification during and after 1,00,000 cycles.
Shower system is provided with at least 40 shower nozzles in the test chamber capable of discharging water at rate of 1.1 liter per min per nozzle at 2 bar pressure for 20 min. Sealing test is conducted to evaluate the deterioration in sealing performance of vehicle during initial, interim and post completion of door slam durability test for 1,00,000 cycles. Shower test is generally, conducted to simulate field failures in door latch actuators, PKE switches, door switches, locks, power window mechanisms and rusting due to water ingress. Test is conducted for checking the waterproofing capacity of passenger compartment, performance and functionality of seals, electrical, mechanical components by placing the vehicle in shower. Also, the test assists to verify the water ingress inside the HV system kits (E-box, B-box, wiring harness -LV & HV, E-motor, NC/ FC ports). During 20 min of shower test, engine runs in idle for first 5 min of duration, followed by increased RPM (75% of rated RPM) for next 10 min and final 5 min in varying throttle. The test ensures that there shall not be any water entry of any mode into the enclosed volume such as compartment for driver/crew/passengers, boot (luggage compartment) and enclosed loading compartment. Also, ensures that there shall not be any failure in door latch actuators, PKE switches, door switches, locks, power window mechanisms and rusting due to water ingress. Test ensures, no water clogging is permitted at doors (inside door trim pad) and plenum applique.
Dust spray system is provided with plurality of dust spray nozzles in the test chamber capable of discharging dust at 1 bar pressure for 2 minutes. The test includes spraying dust on latch fish mouth, glass run channels, window regulator rail, handles, hinges, door check and known dust exposure parts at every scheduled recorded measurement stoppage. The test includes filling 1g Arizona and 2ml salt + water 5% NaCl in the spray container. Connecting the pneumatic line to the dust spray nozzle through a pressure control valve and setting the initial pressure to Zero bar. Further, the test includes enclosing the region to be tested by pasting polyethylene and gradually increasing the pressure to 1 bar to ensure proper dust spray at every scheduled recorded measurement stoppage. Dust is sprayed at 1 bar pressure for 2 minutes during initial, interim and after door slam test. The dust spray test ensures that there should not be any dust entry inside the enclosed, head lamp, tail lamp, inside cabin, and the vehicle meet the performance and functional test requirements.
The test can be stopped for interim performance measurement and visual observation and/or for any physical failure.
The table below shows the decreased time achieved by the new test cycle by employing new test chamber according to the present invention. The testing hours has been considerably decreased from 1197hrs to 830hrs for conducting a cycle including closure hot slam test, shower test, dust test and corrosion test.
Table 1: Comparison showing number of hours for known cycle and new test cycle
Known Cycle New Test Cycle
Name of the Test Test system Type of test Testing Hours Name of the Test Test system Type of test Testing Hours
Closures Hot slam test Part level Durability 652 Door slam Test with Hot, Rain, Corrosion and Dust simulation Trimmed BIW or Vehicle (Full system level) Durability & Performance (Initial, intermittent, and Final performance) 830
Shower test Vehicle level Performance 165
Dust Test Vehicle level Performance 28
Corrosion test Part level Durability 352

The present invention provides facility for testing the automotive vehicle for 1,00,000 cycles of slam tests with combination of hot, ambient, rain, corrosion, and dust simulations. The test chamber can simulate the new combination of all environmental (80%) conditions in test chamber to find the premature failures in vehicles doors and its mechanism. Combined environmental conditions able to identify new failure modes and assist for robust and optimized design. Moreover, product application specific RWUP conditions can be simulated in the test rig. Such a test chamber is cost effective and allows for productive testing.
Considering the different environmental conditions providing single chamber for all test conditions is extreme challenging. However, the present invention provides the test facility in single chamber with different systems therein, which provides optimized and realistic test condition with respect to real world usage patten.
While the preferred embodiment of the invention has been illustrated and described herein, it is to be understood that the invention is not limited to the precise construction herein disclosed, and the right is reserved to all changes and modifications coming within the scope of the invention.
Although there has been shown and described the preferred embodiment of the present invention, it will be readily apparent to those skilled in the art that modifications may be made thereto which do not exceed the scope of the appended claims. Therefore, the scope of the invention is only to be limited by the following claims.
, Claims:
1. A facility (100) for testing an automotive vehicle (102), comprising:
a test chamber (104) configured to accommodate the vehicle (102);
a corrosion system, a hot simulation system, a shower system, and a dust spray system adapted to be accommodated in the test chamber; and
a control unit in communication with the corrosion system, the hot simulation system, the shower system, and the dust spray system, the control unit configured for running and replicating a test cycle comprising a corrosion test, a hot simulation test, a shower test, and a dust spray test in the same test chamber.
2. The facility (100) as claimed in claim 1, wherein the test chamber (104) formed by an area enclosed by a frame, a door, a top side, a bottom side, a first side wall, a second side wall and a third side wall, the top side, the bottom side, the first side wall, the second side wall and the third side wall are arranged on the frame, the top side is arranged opposite to the bottom side, the first side wall and the second side wall are arranged opposite to each other, the door is arranged on the frame and opposite to the third side wall.
3. The facility (100) as claimed in claim 1 or 2, wherein the corrosion system having a saline solution container (106) mounted on the top side of the test chamber (104), the top side having a lower surface provided with a salt fog discharge line (108) to connect the saline solution container (106), and a salt fog applicator (110).
4. The facility (100) as claimed in any one of the preceding claims, wherein the hot simulation system having at least a fan (112) and a room heater setup (114), the room heater setup (114) having a heating coil (116) and an air blower (118), the room heater setup (114) is positioned behind the side wall such that the air blower (118) passes there through.
5. The facility (100) as claimed in any one of the preceding claims, wherein the shower system having a water container mounted on the top side of the test chamber (104), the lower surface of the top side is provided with a water flow in pipes (120) having a shower nozzle (122) positioned thereon, the water flow in pipes (120) connecting to the water container.
6. The facility (100) as claimed in any one of the preceding claims, wherein the dust spray system having a dust container mounted on the top side of the test chamber (104), the lower surface of the top side is provided with a dust flow in pipes having a dust spray nozzle positioned thereon, the dust flow in pipes connecting to the dust container.
7. The facility (100) for testing a vehicle (102) as claimed in claim 1 or 2, wherein test chamber (104) having an exterior wall and an interior wall insulated with expanded polystyrene (EPS) panel board of at least 50mm thick and laminated with a pre-coated galvanised iron (PCGI).
8. The facility (100) for testing a vehicle (102) as claimed in claim 7, wherein the test chamber (104) having interior walls that are coated with epoxy of grade EPILUX 44 and the bottom side is coated with epoxy of grade RAL 7035.
9. The facility (100) for testing a vehicle (102) as claimed in claim 1 or claim 3, wherein the corrosion system conducts the corrosion test by dissolving 5 ± 1 parts by mass of sodium chloride in 95 parts of water, with humidity in the range of 10 to 95 % ± 4.1% RH.
10. The facility (100) for testing a vehicle (102) as claimed in claim 9, wherein the corrosion test is conducted for 24 hours and component level for 0, 25%, 50% 75% & 100% of slam cycles.
11. The facility (100) for testing a vehicle (102) as claimed in claim 1 or claim 4, wherein the hot simulation system circulates air to conduct hot simulation test in the temperature range of ambient to 80°C ± 3°C discontinuously, with heating-up rate of 1.5°C/min without vehicle, and 1°C/min with vehicle.
12. The facility (100) for testing a vehicle (102) as claimed in claim 1 or claim 5, wherein the shower system conducts the shower test with water discharge rate of 1.1 Liter per min per nozzle at 2 bar pressure for 20min.
13. The facility (100) for testing a vehicle (102) as claimed in claim 1 or claim 6, wherein the dust spray system conducts the dust spray test at 1 bar pressure for 2-3 minutes.
14. The facility (100) for testing a vehicle (102) as claimed in claim 1, further comprises at least a pneumatic actuator (124) provided inside the test chamber (104) for conducting a door slam test.
15. The facility (100) for testing a vehicle (102) as claimed in any one of preceding claims, wherein the test chamber (104) is sealed during the test cycle.
16. The facility (100) for testing a vehicle (102) as claimed in any one of preceding claims, wherein the test chamber (104) has provisions for a pneumatic air supply (130) through pneumatic hose, and pneumatic flow regulator (128).
17. The facility (100) for testing a vehicle as claimed in claim 1 further comprises a control room (126) adjust to one of the side wall, wherein said side wall is provided with monitoring window to monitor test conditions and operate from the control room (126).
18. A method of testing an automotive vehicle (102) in a test facility (100), comprising the steps of:
conducting in a test cycle a corrosion test in a corrosion test system, a hot simulation test in a hot simulation system, a shower test in a shower system, and a dust spray test in a dust spray system; and
controlling the test cycle by a control unit communicating with the corrosion test system, the hot simulation system, the shower system, and the dust spray system,
wherein the corrosion test, the hot simulation test, the shower test, and the dust spray test are conducted in the same test chamber.
19. The method for testing the vehicle (102) as claimed in claim 18, wherein the corrosion test is conducted by dissolving 5 ± 1 parts by mass of sodium chloride in 95 parts of water, with humidity in the range of 10 to 95 % ± 4.1% RH.
20. The facility (100) for testing a vehicle (102) as claimed in claim 19, wherein the corrosion test is conducted for 24 hours and component level for 0, 25%, 50% 75% & 100% of slam cycles.
21. The method for testing the vehicle (102) as claimed in claim 18, wherein the hot simulation system circulates air to conduct hot simulation test in the temperature range of ambient to 80°C ± 3°C discontinuously, with heating-up rate of 1.5°C/min without vehicle, and 1°C/min with vehicle.
22. The method for testing the vehicle (102) as claimed in claim 18, wherein the shower system conducts the shower test with water discharge rate of 1.1 Liter per min per nozzle at 2 bar pressure for 20min.
23. The method for testing the vehicle (102) as claimed in claim 18, wherein the dust spray system conducts the dust spray test at 1 bar pressure for 2-3 minutes.