URS Labs in Automotive, Electrical, Electronics, IT Products and Components testing

URS, in India, has grown up with new vertical as Testing Facility for Automotive, Electrical, Electronics, IT Products and Components. URS has further been declared as Notified Body with EU for Construction Directive 98/214/EC with Technical Specification EN 1090 and NB No 2710.

Brief of current URS portfolio in Automotive, Testing and Component Certification is as below:

1) AUTOMOTIVE PRODUCTS TESTING

This includes – IP Ratings- IP 01 to IP 68, Vibration Tests, surge, high voltage and impulse tests, Climatic Tests/environmental tests (thermal ageing & Thermal Shock), DB Test, salt spray test(corrosion resistance), Shock Test for all Type of Automotive Products such as Antennas, head lights, spark plug, engines,  starter motors, gears, wheels, dashboard equipment etc.

2) AUTOMOTIVE SYSTEM CERTIFICATION

URS is IATF recognized certification body for Auditing and Certification for Automotive Supply Chain customers against IATF 16949. URS employs IATF Auditors with sound automotive background and long & versatile Auditing experience. A large Automotive Customer base of URS has enriched this vertical a lot.

E-Vehicle : An electric vehicle, also called an EV, uses one or more electric motors or traction motors for propulsion. An electric vehicle may be powered through a collector system by electricity from off-vehicle sources, or may be self-contained with a battery, solar panels or an electric generator to convert fuel to electricity.

EVs first came into existence in the mid-19th century, when electricity was among the preferred methods for motor vehicle propulsion, providing a level of comfort and ease of operation that could not be achieved by the gasoline cars of the time. Modern internal combustion engines have been the dominant propulsion method for motor vehicles for almost 100 years, but electric power has remained commonplace in other vehicle types, such as trains and smaller vehicles of all types.

In the 21st century, EVs saw a resurgence due to technological developments, and an increased focus on renewable energy. Government incentives to increase adoptions were introduced.

E-vehicle Components Testing: –

URS Products and Testing Pvt. Ltd. having complete range of testing facilities under Electrical & Electronics test Lab. Testing in automotive is a process of validating components and vehicles as per National and International specifications. URS has functional laboratories to test component as per IEC/EN/IS/JIS/ISO/ASTM Standards & Customer specification. All the facilities are manned by trained engineers to handle customer queries and requests.

Following are the components and test facilities are available under URS LABS

Lithium-ion battery:

Most electric vehicles use lithium ion batteries. Lithium ion batteries have higher energy density, longer life span and higher power density than most other practical batteries. Complicating factors include safety, durability, thermal breakdown and cost.  Li-ion batteries should be used within safe temperature and voltage ranges in order to operate safely and efficiently

Increasing the battery’s lifespan decreases effective costs. One technique is to operate a subset of the battery cells at a time and switching these subsets.

URS PRODUCTS & TESTING PVT LTD having full furnished test LAB for testing of Rechargeable Batteries for the following test: -.

  • Efficiency Test of Batteries
  • Short Circuit Protection Test
  • Over Charge Test
  • Over Discharge Test
  • Vibration & Shock Test
  • Crushing Test of Cells
  • Continuous Charging Test
  • Transportation Test
  • Incorrect Installation Test
  • Battery Life Test
  • Altitude Simulation Test
  • Thermal Shock Test
  • Temperature Cycling Test

Electric motor:

The power of a vehicle’s electric motor, as in other vehicles, is measured in kilowatts (kW). 100 kW is roughly equal to 134 horsepower, but electric motors can deliver their maximum torque over a wide RPM range. This means that the performance of a vehicle with a 100 kW electric motor exceeds that of a vehicle with a 100 kW internal combustion engine, which can only deliver its maximum torque within a limited range of engine speed.

Energy is lost during the process of converting the electrical energy to mechanical energy. Approximately 90% of the energy from the battery is converted to mechanical energy, the losses being in the motor and drivetrain

URS PRODUCTS & TESTING PVT LTD having full furnished test LAB for testing of Electric Motor for the following test

  • Vibration and Shock Test
  • Thermal Ageing Test
  • Durability Test
  • Insulation Resistance Test and High Voltage Test
  • Input Rating test

Testing Facilities for Electronics Components used in E- Vehicles: –

URS PRODUCTS & TESTING PVT LTD having full furnished test LAB for testing of Electrical and Electronics Components used in Automotive: –

  • Mobile Chargers used in Vehicles
  • Music System used in Vehicles
  • Amplifiers Used in Vehicles
  • Wiring harness used in Vehicles
  • Connectors Used in Vehicles
  • Navigation System used in vehicles
  • Sensors used in vehicles
  • Cameras used in vehicles
  • Display unit used in vehicles

ENVIRONMENTAL TESTING FACILITIES: –

URS LABS having full furnished test LAB for testing of Automotive components to check the reliability and durability of the Vehicle parts against the different environmental conditions: –

Type of Environmental Test for Automotive components

Automotive Durability Testing

Engage in the development and production of a robust, strong, durable automotive product by Automotive Durability Testing:

It is important to test the structure and strength of an automotive product, from its components all the way through to the finished product, to ensure the safety and performance. URS Products and Testing Pvt Ltd performs a wide range of mechanical, electrical and electro-mechanical Automotive Durability Testing—including cyclic corrosion and cyclic fatigue, electrodynamics vibration, solar irradiation, standard corrosion, and more—to both industry-specific standards and customer-specific requirements

Automotive Environmental Testing

Ageing Tests are particularly referred to as ‘Life Test’, it is concerning for the determination of ‘Life-Span’ of any products in respect of being checking-out the period of time for which the product can actually survive the outcomes at different environmental conditions with different rate of temperature change.

Tests We Offer:

  • Accelerated Aging
  • Altitude Testing
  • Accelerated Weathering – Xenon, Carbon Arc, Fluorescent UV
  • Thermal Aging
  • Thermal/Humidity Cycling
  • Thermal Shock
  • Humidity – Condensing/Noncondensing
  • Sun load Testing
  • Salt Spray/Humidity/CASS
  • Cyclic Corrosion
  • Dimensional Stability
  • Corrosiveness to Steel
  • Moisture Absorption
  • Chemical Resistance
  • Chemical Immersion
  • Effect of Cleaners
  • Degree of Blistering
  • Impact Testing
  • Low Temperature Flexibility
  • Environmental Electrical Life test

Standards We Use for Test

Specific tests performed Test method/  Standard against  which tests are performed
Salt Spray Test:

The salt spray (or salt fog) test is a standardized and popular corrosion test method, used to check corrosion resistance of materials and surface coatings. Usually, the materials to be tested are metallic(although stone, ceramics, and polymers may also be tested) and finished with a surface coating which is intended to provide a degree of corrosion protection to the underlying metal. Salt spray testing is an accelerated corrosion test that produces a corrosive attack to coated samples in order to evaluate (mostly comparatively) the suitability of the coating for use as a protective finish. The appearance of corrosion products (rust or other oxides) is evaluated after a pre-determined period of time. Test duration depends on the corrosion resistance of the coating; generally, the more corrosion resistant the coating is, the longer the period of testing before the appearance of corrosion/ rust. The salt spray test is one of the most widespread and long-established corrosion tests. ASTM B117 was the first internationally recognized salt spray standard, originally published in 1939. Other important relevant standards are ISO9227, JIS Z 2371 and ASTM G85

ASTM B117-16, JISZ2371: 2015, ISO-9227: 2017,

ISO-10289: 1999, IEC 60068-2-11: 1981, IS 5528: 1985, DIN 50021: 1988:-

Salt spray testing is popular because it is relatively inexpensive, quick, well standardized, and reasonably repeatable. Although there may be a weak correlation between the duration in salt spray test and the expected life of a coating in certain coatings such as hot dip galvanized steel, this test has gained worldwide popularity due to low cost and quick results. Most Salt Spray Chambers today are being used NOT to predict the corrosion resistance of a coating, but to maintain coating processes such as pre-treatment and painting, electroplating, galvanizing, and the like, on a comparative basis. For example, pre-treated + painted components must pass 96 hours Neutral Salt Spray, to be accepted for production. Failure to meet this requirement implies instability in the chemical process of the pre-treatment, or the paint quality, which must be addressed immediately, so that the upcoming batches are of the desired quality. The longer the accelerated corrosion test, the longer the process remains out of control, and larger is the loss in the form of non-conforming batches. The principle application of the salt spray test is therefore enabling quick comparisons to be made between actual and expected corrosion resistance. Most commonly, the time taken for oxides to appear on the samples under test is compared to expectations, to determine whether the test is passed or failed. For this reason, the salt spray test is most often deployed in a quality audit role, where, for example, it can be used to check the effectiveness of a production process, such as the surface coating of a metallic part. The salt spray test has little application in predicting how materials or surface coatings will resist corrosion in the real-world, because it does not create, replicate or accelerate real-world corrosive conditions. Cyclic corrosion testing is better suited to this.

Cold Test:

The object of the cold test is limited to the determination of the ability of components, equipment or other articles to be used o- stored at low temperature. These cold tests do not enable the ability of item. to withstand or operate during temperature variations to be assessed. In this case, it would be necessary to use change of temperature test’

IS 9000 (Part 2/Sec I to IV): 1977 Reaffirmed:2010

IEC 60068-2-1: 2007, JASO D 001:1994 :

The differences in environmental testing procedures for component type items and equipment type items are fast disappearing in the context of technological developments. It is, therefore, felt necessary to pave uniform testing procedures wherever possible. These series of standard. on environmental testing procedures has been prepared with this objective

Dry Heat Test:

The object of the dry heat test is limited to the determination of heat ability of components, equipment or other articles to be used or stored at high temperature. These dry heat tests do not enable the ability of items to withstand or operate during temperature variations to be assessed

IEC 60068-2-2 :1974,IS 9000 (Part 3/Sec I to V):1977 Reaffirmed:2010,JASO D 001:1994:

a) Dry heat tests for non-heat dissipating items:

i) with sudden change of temperature

ii) with gradual change of temperature

b) Dry heat tests for heat dissipating items:

i) with sudden change of temperature

ii) with gradual change of temperature

DAMP HEAT (STEADY STATE), DAMP HEAT (CYCLIC TEST)

Damp heat test on automotive components is perform to determine the suit- ability of electronic and electrical items for use and storage under conditions of high relative humidity and normal temperature

IEC 60068-2-78:2001

IS 9000 (Part 4):2008

Reaffirmed:2015

JASO D 001:1994

Composite Temperature/Humidity cycle Test

A composite temperature/humidity cyclic test

(moisture resistance test) is designed to reveal defects in test items caused by breathing as distinct from the absorption of moisture.

IS:9000 (Part VI)-1978

(Reaffirmed 2010)

Cl 5.1.1

Thermal Shock / Rapid change of temperature with prescribed time of transfer:

A change of temperature test is intended to determine the effect on the test item of a change of temperature or a succession of changes of temperature.

IEC-60068-2-14:1984

IS 9000

(P14 & Sec.1):1988

Reaffirmed:2015

SAE J1455:1984,

JASO D 001:1994

ISO 16750-4:2003

Temperature Cycling

This test simulates varying temperatures during electrical operation of a system/component, for example during use at fast-changing ambient temperature. If the system/component is exposed to hot-soak temperatures (e.g. engine-mounted systems/components), an additional short temperature peak is added during the high temperature phase of the profile to ensure proper functioning during short temperature peaks. The electrical operation is switched off during phases of decreasing temperature in order to avoid electrical heat dissipation of the DUT which would inhibit the reaching of Tmin inside it. Failure mode is electrical malfunction during temperature change.

ISO 16750-4:2010

This part of ISO 16750 describes the climatic loads that can affect of electric and electronic systems and components in respect of their mounting location directly on or in road vehicles and specifies the corresponding tests and requirements.

Change of temp. with specified change of temp., Thermal Cycling SAE J1455:1994

IEC-60068-2-14:2009

IS 9000

(Part 14 / Sec. 2):1988

Reaffirmed:2015

Vibration Testing Sine, Random and Shock:

Vibration testing, vibration analysis and mechanical shock help attune automotive products for structural soundness and paramount vehicle perception using methods such as resonant searches and dwells, fixture resonance evaluation, custom fixture design and fabrication, reproduction of sample road and/or event data, shock response spectrum (SRS) testing,

JIS D 1601:1995, IEC-60068-2-64:2008

SAE J1455:2006, SAE J1211:2009

IS 9000 (Part VIII):1981 Reaffirmed:2015

IEC 60068-2-6:2007, IEC-60068-2-27:2008

ISO 16750-3:2012, JASO D 001-1994,

IEC 613732:2010 :

The vibration ( sinusoidal ) test is applicable to Automotive components which, during transportation or in service, may be subjected to conditions involving vibration of a harmonic pattern, generated primarily by rotating, pulsating or oscillating forces, such as occur in ships, aircraft, land vehicles, rotorcraft and space applications or are caused by machinery and seismic phenomena. It consists, basically, of subjecting an item to sinusoidal vibration over a given frequency range or at discrete frequencies for a given period of time.

 

Automotive Battery and Electric Vehicle Testing

The rapidly emerging Electric Vehicle, Hybrid Electric Vehicle and Plug-in Hybrid Electric Vehicle markets are poised for continued growth and change. Testing of these products make significant investments in alignment with the evolving needs of your business. We offer lab capacity for EV, HEV, PHEV and automotive battery testing services on a global scale to certify your charging stations and electrical components for worldwide distribution

Most electric vehicles use lithium ion batteries. Lithium ion batteries have higher energy density, longer life span and higher power density than most other practical batteries. Complicating factors include safety, durability, thermal breakdown and cost. Li-ion batteries should be used within safe temperature and voltage ranges in order to operate safely and efficiently

Increasing the battery’s lifespan decreases effective costs. One technique is to operate a subset of the battery cells at a time and switching these subsets

Automotive Headlamps & Luminaire Testing:

If you are manufacture vehicle headlamps, tail lamps, turn signals, reflectors, center high-mount stop lights (CHMSLs), warning lights, or interior lighting, we conduct testing to verify your product to industry and OEM standards:

Accelerated Testing

Chemical Resistance

Compliance Consulting

Electrical Testing

Environmental Testing

Physical & Mechanical Testing

Vibration Testing

 

 

High Voltage, Insulation Resistance, Impulse and Surge Test:

The most sensitively protected testing includes    Impulse, Surge and High Voltage tests, carried out at the most priority level to check the danger against over voltages

Automotive Headlamps & Luminaire Testing

If you are manufacture vehicle headlamps, tail lamps, turn signals, reflectors, center high-mount stop lights (CHMSLs), warning lights, or interior lighting, we conduct testing to verify your product to industry and OEM standards for the following Test

  • Accelerated Testing
  • Chemical Resistance
  • Compliance Consulting
  • Electrical Testing
  • Environmental Testing
  • Physical & Mechanical Testing
  • Vibration Testing
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