Automotive & motorsport
verification or validation via testing operations. Tests can be categorised as necessary for design verification or product validation. Any testing outside of these parameters is categorised as engineering validation
and will not be viewed as an official part of the formal results. The test plan must describe all the components and their normal functions/modes of operation, broken down by:
Inputs/outputs required to trigger the device‘s normal modes of operation, plus any relevant details on modes that isolate broadband or narrowband noise.
Methods of measuring component response to input/output actions to establish a baseline for normal operation, such as +/- tolerances
Signals defined by pin-out diagrams
Defined orthogonal orientations for the device (depicted with photographs or diagrams)
Information on power or ground lines requiring transient tests
Performance requirements based on the four performance-level definitions as described in ISO 11451-1 Annex A (whether normal operation is required during and/or after each test, and to what extent)
Other details that may be incorporated include information about how a component was manufactured, supplier data, environmental conditions for tests, pass/fail criteria, severity levels, and relevant safety procedures.
TESTING PROCESS STEPS
Upon receipt of the OEM’s approval number, you may inform your partner laboratory, and testing can begin. Ideally, the testing process will go exactly as described in the test plan, and the product will meet all of the standards imposed upon it.
It may be necessary to make adjustments in real time based on unforeseen parameter changes. If the OEM is informed of your intention to adjust the testing process as outlined in the plan, and the manufacturer signs off on the change, it is permissible to change the plan. For example, a motor for a power window is expected to be run continuously clockwise as part of a test in the plan. But this might not be possible because it’s attached to a fixture and therefore can’t travel very far until it hits a hard stop and must be reset. The OEM must be informed of the issue and told why a change is necessary.
Another example could be that the required orientation of the device during testing prevents the wire harness requirements from being met. In either case, the OEM must both be informed of the issue and told why a change is necessary. Close communication between the testing laboratory, supplier, and OEM is critical. In many cases, an OEM will require continuous updates on test passage or failure, sometimes as immediately as 24 hours or less after each test is conducted. After being informed of a test pass/ fail status, you may have a few more days before associated car manufacturers demand more detailed reports on the individual tests. You will also have to consider various other tight deadlines throughout the course of the project, including macro- deadlines such as time-to-market.
CHOOSING A TEST LABORATORY Your test laboratory, whether you have a laboratory in-house or use a third-party facility,
must meet ISO/IEC 17025 minimum requirements. This standard enables laboratories to demonstrate that they operate competently and generate valid results. It also helps facilitate cooperation between laboratories and other bodies by generating wider acceptance of results between countries. Test reports and certificates can be accepted from one country to another without the need for further testing which improves international trade. For automotive OEMs and suppliers it can be very valuable if a laboratory is able to provide end-to-end solutions throughout the entire automotive value chain as it streamlines the testing process. A single laboratory can handle all testing needs, from components to full vehicle systems, so there is no need to coordinate multiple testing providers. Unified testing also improves data reliability and minimises the risk of miscommunication, overlooked tests, or non-compliance. They can also provide insights into how different components interact within the vehicle to ensure interoperability and system-level reliability. This all helps to minimise time to market, especially as any compliance or performance issues can be identified and resolved faster, helping OEMs meet production and launch timelines. By bundling services and avoiding test duplication, costs can also be minimised. If you are working with a third-party laboratory instead of in-house, determine these key factors in advance:
Equipment: Who provides equipment for generating signals during the test process?
Review: Laboratory personnel can review the unfinished plan and make suggestions but cannot conduct any advanced testing.
Monitoring protocols: What response monitoring protocols will be used (particularly for any tests conducted in an EMC chamber)?
Information: Suppliers should provide software, equipment or any other informational/operational collateral necessary for the laboratory to understand the component and properly conduct testing.
EMC testing is crucial for automotive components and final vehicles as it ensures that all electronic systems and components operate as required despite electromagnetic disturbances, while also preventing the vehicle from generating excessive interference. With the growing complexity of modern vehicles, EMC testing is an increasingly important factor for performance, safety, compliance, and reliability.
TÜV SÜD
www.tuvsud.com/uk Instrumentation Monthly February 2025 65
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