• Business
    • Biz Tech
  • Cloud
  • Social Media
  • Alternatives
    • Movie Streaming Sites
      • 1MoviesHD
      • Hurawatch
      • Ifvod
      • Bflix
      • Couchtuner
    • Anime Streaming Sites
      • Animesuge
      • Animekisa
      • Animedao
      • Anilinkz
    • Manga Sites
      • Asurascans
      • Comick.fun
      • Webtoon XYZ
    • Sports Streaming Sites
      • Streameast
    • Photos & Graphics
  • Software
  • Gaming

Subscribe to Updates

Get the latest creative news from FooBar about art, design and business.

What's Hot

How to Boost Instagram Followers?

Mar 30, 2023

From Spender to Saver – Building a Healthy Savings Account

Mar 30, 2023

How to Automate Your Software Documentation Process

Mar 30, 2023
Facebook Twitter Instagram
  • Home
  • About Us
  • Privacy Policy
  • Advertise
  • Write For Us
  • Contact Us
Facebook Twitter
Digital Edge
  • Business
    • Biz Tech
  • Cloud
  • Social Media
  • Alternatives
    • Movie Streaming Sites
      • 1MoviesHD
      • Hurawatch
      • Ifvod
      • Bflix
      • Couchtuner
    • Anime Streaming Sites
      • Animesuge
      • Animekisa
      • Animedao
      • Anilinkz
    • Manga Sites
      • Asurascans
      • Comick.fun
      • Webtoon XYZ
    • Sports Streaming Sites
      • Streameast
    • Photos & Graphics
  • Software
  • Gaming
Digital Edge
Home»Guide»All That We Know About Automotive Prototype Testing Engineer
Guide

All That We Know About Automotive Prototype Testing Engineer

Michael JenningsBy Michael JenningsMay 10, 2022Updated:May 18, 2022No Comments5 Mins Read

Cars are considered to be in the top 10 of the most complex mechanisms the humankind ever created. This makes car development and manufacturing processes extremely complex. Car safety and performance requirements are rising with every model. New sensors are being installed to monitor the condition of different modules. New materials and designs are being implemented to increase car power, speed, and safety. All of the things developed need to be tested. At some point, the amount and complexity of tests became so large that a new professional was required.

What Are The Duties Of The Testing Engineer?

A testing engineer is a professional that develops and conducts prototype tests on every level of the manufacturing cycle. He is also responsible for car performance tests on other stages of its lifecycle. Some of the skills required to develop the tests include extensive knowledge in the strength of materials, both static and dynamic. Metrology methods and an experience with measuring tools is absolutely necessary as well as science experimental knowledge.

Key Areas Of Automotive Prototype Testing

It is absolutely vital to test all of the main elements that determine the car performance

  • Engine is the most complex and vital element of the car. It is tested on a number of levels starting from its materials. Special conditions are created that are close to the real ones in order to test the yield strength of the chosen materials. After that, when the prototype of the engine is ready, it is loaded with the fuel and the fluids necessary for its operation and with a lot of sensors to test the way it behaves at different conditions. It is then put into action to determine what kind of loads it can withstand. Next stage is installing the engine into an existing car frame and conducting test drives. The final part of engine testing includes checking its performance in a full-scale new car prototype where every part belongs to the developed model.
  • Chassis is one of the car elements that withstands the most severe pressures. This is why it is tested for dynamic and static yield strength.Chassis need to endure colossal forces and stay rigid. This is why when a chassis prototype is created, its first tests include bending, stretching and vibrating. After the prototype is found strong enough, it is installed into an actual car model and crash tests are performed.

  • Car frame is the element of the car that holds all other assemblies together and protects the driver from harm if a car crash happens. This is why crash tests are the most important ones for a frame. A number of designs is created and the tests are modeled using finite element analysis. Then, the best designs are manufactured into prototypes and supplied with mechanisms that enable it to drive and actual car crash tests are performed using a manikin.
  • Steering is the system that allows the driver to turn and control his car. It is directly connected to the chassis and has a hydraulic cylinder in order to decrease the force required to turn the wheels. This is the main testing parameter of the steering system. A dynamometer is installed into the prototype and a special machine is used to turn the wheels while maximum force is measured. Another vital point in a steering system is the air-tightness of the hydraulic cylinder.

  • Brakes are performing under severe friction conditions. Brake failures lead to car crashes in almost 95% of the cases and that is why it is so important to check the durability and reliability of those systems. As it is done with most car elements, they are first tested separately on an experimental installation and are then implemented into an actual car prototype. When considering brakes, durability tests are performed, meaning, measuring maximum single time brake performance, and the total time of its operation. Hydraulic systems are also tested for leaking.
  • Wheels are the elements that come into direct contact with the road. They must be durable and withstand hard and sharp objects from piercing the tires. This is why here, material testing takes the main role.

Those are the main car assemblies that need to be tested. They are the ones that withstand the highest loads and must, therefore, be manufactured the way that the final part will be manufactured. In some cases, it may take a lot of time to find an optimal design. This is why usually a number of possible designs is chosen and they are all manufactured simultaneously to be tested later.

Rapid Prototyping For Automotive Testing

After testing the elements that withstand high forces during their performance, some other lightly loaded or not loaded elements need tests. For example, car lighting needs to be tested for the way its frame resists impact or gasoline tanks must be tested for leakage and rigidity. In those cases, it is much more efficient to create a plastic rapid prototype using additive manufacturing (layer-by-layer sintering of materials) or resin casting. Those innovative methods enable engineers to greatly decrease the time between the first design testing and the second one.

Conclusions

Automotive prototype testing engineer is the professional who ensures that every car model is safe, reliable and optimized for the consumer. They conduct tests starting from the earliest stages of the design by using modern numerical tools that enable a simulation of the car performance without any need to create the prototype. However, those calculations are not enough because they do not take everything into account. This is why creating prototypes and testing them is the only method that gives reliable info on the element performance. Testing engineers oversee the manufacturing of prototypes because they may need additional holes or cutouts made in the parts in order to install sensors for the testing processes. They also design and manage the manufacturing of testing installations that enable efficient testing of every car element. Without tests, car failures and victims would be much more frequent than are now.

Michael Jennings

Micheal wrote his first article for Digitaledge.org in 2015 and now calls himself a “tech cupid.” Proud owner of a weird collection of cocktail ingredients and rings, along with a fascination for AI and algorithms. He loves to write about devices that make our life easier and occasionally about movies. “Would love to witness the Zombie Apocalypse before I die.”- Michael

Related Posts

3 Accident Prevention Tips To Avoid Collisions With Trucks

Mar 29, 2023

Myths About Student Loans: What Is True and What Is Not

Feb 22, 2023

Step-by-Step Guide on How to Choose a Good Bank in the USA

Jan 24, 2023
Top Posts

SockShare – Is it Working? 22 Best Alternatives in 2023

Feb 14, 2023

12 Zooqle Alternative Torrent Sites That Work In 2023

Feb 20, 2023

17 Working TheWatchSeries Alternatives in 2023

Feb 6, 2023

Is TVMuse Working? 100% Working TVMuse Alternatives And Mirror Sites In 2023

Feb 18, 2023

15 Games Like Free Cities You Should Check Out

Sep 22, 2022

15 Cucirca Alternatives That Work in 2023

Feb 15, 2023

22 Rainierland Alternatives in 2023

Feb 13, 2023
About Us

Digital Edge is the freshest voice in the field of technology and digital media. Our editorial staff is really passionate in their efforts to curate the latest technological breakthroughs in new and emerging technologies from all over the world to help businesses, IT professionals and consumers to stay abreast with all the latest developments.

We pride ourselves in providing quality content from reputed authors and bloggers as well as from passionate observers like you! If you have a unique voice that you would like to unleash on the rest of the world, then please let us know! Our editors go over everything with a fine tooth comb as a result of which any proverbial cracks are paper-thin from which no inaccuracies ever seep through! However, if there is anything you do not agree with or if you want to comment on the swell job that we are doing, feel free to reach out to us as well. We love hearing from you!

Most Popular

SockShare – Is it Working? 22 Best Alternatives in 2023

Feb 14, 2023336 Views

12 Zooqle Alternative Torrent Sites That Work In 2023

Feb 20, 2023220 Views

17 Working TheWatchSeries Alternatives in 2023

Feb 6, 2023142 Views
Our Picks

How to Boost Instagram Followers?

Mar 30, 2023

From Spender to Saver – Building a Healthy Savings Account

Mar 30, 2023

How to Automate Your Software Documentation Process

Mar 30, 2023
Facebook Twitter
  • Home
  • About Us
  • Privacy Policy
  • Advertise
  • Write For Us
  • Contact Us
© 2023 ThemeSphere. Designed by ThemeSphere.

Type above and press Enter to search. Press Esc to cancel.