Test Methods

1

Peter Heinrich engineering/business/consulting

Test Methods

2

How to find the right test method

Damage

technical product

Test Methods

3

How to find the right test method

Damage impact matrix

Pos. 1 wear

Pos. 1 deposits

Pos. 1 ...

Pos. 2 …

Pos. 3

impact

Damage

pro

du

ct le

vel

test

test

ing

leve

l

Test Methods

4

How to find the right test method

Input

Damage impact matrix

Pos. 1 wear

Pos. 1 deposits

Pos. 1 ...

Pos. 2 …

Pos. 3

Speed yes no yes no no

Temperature Yes Yes Yes Yes Yes

Pressure yes ? yes no no

Humidy yes no yes no no

Operation time

yes ? yes yes yes

Fuel/oil Yes Yes Yes yes yes

…

… … … … …

- Mission profile - Environment - User - ?

Output

- Main test sequence - Specific test sequence - HALT-Tests - QALT-Tests -…

pro

du

ct le

vel

test

ing

leve

l

Test Methods

5

How to find the right test method

Damage impact matrix

Pos. 1 wear

Pos. 1 deposits

Pos. 1 ...

Pos. 2 …

Pos. 3 …

Pos. 4

Speed yes no yes no no yes

Temperature Yes Yes Yes Yes Yes Yes

Pressure yes ? yes no no no

Humidy yes no yes no no ?

Operation time

yes ? yes yes yes yes

Fuel/oil Yes Yes Yes yes yes Yes

…

… … … … …

-Main test sequence -Same impact parameters -Same impact direction

-Specific test sequence -Same impact parameters -Different impact direction

-Single HALT-Tests - One parameter not know ( full factor testing matrix)

-Multiple HALT-Tests - >=2 parameters not know ( part factor testing matrix)

- QALT-Tests -Specific overload test; knowledge about existing borders

test

ing

leve

l

Test Methods

6

How to find the right test method

Damage impact matrix

Pos. 1 wear

Pos. 1 deposits

Pos. 1 ...

Pos. 2 …

Pos. 3 …

Pos. 4

Speed yes no yes no no yes

Temperature Yes Yes Yes Yes Yes Yes

Pressure yes ? yes no no no

Humidy yes no yes no no ?

Operation time

yes ? yes yes yes yes

Fuel/oil Yes Yes Yes yes yes Yes

…

… … … … …

-Main test sequence -Same impact parameters -Same impact direction

-Specific test sequence -Same impact parameters -Different impact direction

-Single HALT-Tests - One parameter not know ( full factor testing matrix)

-Multiple HALT-Tests - >=2 parameters not know ( part factor testing matrix)

- QALT-Tests -Specific overload test; knowledge about existing borders

test

ing

leve

l

Test Methods

7

How to find the right test method

Damage impact matrix

Pos. 1 wear

Pos. 1 deposits

Pos. 1 ...

Pos. 2 …

Pos. 3 …

Pos. 4

Speed yes no yes no no yes

Temperature Yes Yes Yes Yes Yes Yes

Pressure yes ? yes no no no

Humidy yes no yes no no ?

Operation time

yes ? yes yes yes yes

Fuel/oil Yes Yes Yes yes yes Yes

…

… … … … …

-Main test sequence -Same impact parameters -Same impact direction

-Specific test sequence -Same impact parameters -Different impact direction

-Single HALT-Tests - One parameter not know ( full factor testing matrix)

-Multiple HALT-Tests - >=2 parameters not know ( part factor testing matrix)

- QALT-Tests -Specific overload test; knowledge about existing borders

test

ing

leve

l

Test Methods

8

How to find the right test method

Damage impact matrix

Pos. 1 wear

Pos. 1 deposits

Pos. 1 ...

Pos. 2 …

Pos. 3 …

Pos. 4

Speed yes no yes no no yes

Temperature Yes Yes Yes Yes Yes Yes

Pressure yes ? yes no no no

Humidy yes no yes no no ?

Operation time

yes ? yes yes yes yes

Fuel/oil Yes Yes Yes yes yes Yes

…

… … … … …

-Main test sequence -Same impact parameters -Same impact direction

-Specific test sequence -Same impact parameters -Different impact direction

-Single HALT-Tests - One parameter not know ( full factor testing matrix)

-Multiple HALT-Tests - >=2 parameters not know ( part factor testing matrix)

- QALT-Tests -Specific overload test; knowledge about existing borders

test

ing

leve

l

Test Methods

9

How to find the right test method

Damage impact matrix

Pos. 1 wear

Pos. 1 deposits

Pos. 1 ...

Pos. 2 …

Pos. 3 …

Pos. 4

Speed yes no yes no no yes

Temperature Yes Yes Yes Yes Yes Yes

Pressure yes ? yes no no no

Humidy yes no yes no no ?

Operation time

yes ? yes yes yes yes

Fuel/oil Yes Yes Yes yes yes Yes

…

… … … … …

-Main test sequence -Same impact parameters -Same impact direction

-Specific test sequence -Same impact parameters -Different impact direction

-Single HALT-Tests - One parameter not know ( full factor testing matrix)

-Multiple HALT-Tests - >=2 parameters not know ( part factor testing matrix)

- QALT-Tests -Specific overload test; knowledge about existing borders

test

ing

leve

l

Test Methods

10

How to find the right test method

Damage impact matrix

Pos. 1 wear

Pos. 1 ...

Pos. 2 …

Speed yes yes no

Temperature Yes Yes Yes

Pressure yes yes no

Humidy yes yes no

Operation time

yes yes yes

Fuel/oil Yes Yes yes

…

… … …

-Main test sequence -Same impact parameters -Same impact direction

tractor field

tractor road

excavator

wheel loader

tractor field

tractor road

excavator

wheel loader

BMW 330 d

0,00%

10,00%

20,00%

30,00%

40,00%

50,00%

60,00%

70,00%

80,00%

90,00%

0 10 20 30 40 50 60 70 80

temperature CP inlet [°C]

tim

es

ha

re

city

rural

highway

• Good

• Acceptable

• Poor

• no data

source: SGS world wide fuel surveys 2006 - 2008, SGS surveys USA and RussiaAAM surveys North America

Fuel from filling station

SGS/AAM data

Corrosion Protection

Map displays the current situation. Changes may occur due to changing fuel standards.

e.g. Biodiesel content or desulfurization

- Mission profil

- Environment - User - ?

test

ing

leve

l

Test Methods

11

How to find the right test method -Main test sequence -Same impact parameters -Same impact direction

tractor field

tractor road

excavator

wheel loader

tractor field

tractor road

excavator

wheel loaderBMW 330 d

0,00%

10,00%

20,00%

30,00%

40,00%

50,00%

60,00%

70,00%

80,00%

90,00%

0 10 20 30 40 50 60 70 80

temperature CP inlet [°C]

tim

es

hare

city

rural

highway

- Mission profil

- Environment

Speed

Temperature

Pressure

Humidy

Operation time

Fuel/oil

…

Input Output

• Good

• Acceptable

• Poor

• no data

source: SGS world wide fuel surveys 2006 - 2008, SGS surveys USA and RussiaAAM surveys North America

Fuel from filling station

SGS/AAM data

Corrosion Protection

Map displays the current situation. Changes may occur due to changing fuel standards.

e.g. Biodiesel content or desulfurization- User - ?

test

ing

leve

l

Test Methods

12

How to find the right test method -Main test sequence -Same impact parameters -Same impact direction

tractor field

tractor road

excavator

wheel loader

tractor field

tractor road

excavator

wheel loaderBMW 330 d

0,00%

10,00%

20,00%

30,00%

40,00%

50,00%

60,00%

70,00%

80,00%

90,00%

0 10 20 30 40 50 60 70 80

temperature CP inlet [°C]

tim

es

hare

city

rural

highway

• Good

• Acceptable

• Poor

• no data

source: SGS world wide fuel surveys 2006 - 2008, SGS surveys USA and RussiaAAM surveys North America

Fuel from filling station

SGS/AAM data

Corrosion Protection

Map displays the current situation. Changes may occur due to changing fuel standards.

e.g. Biodiesel content or desulfurization

- Mission profil

- Environment

- User - ?

Input Output

-Static parameter -Semi-static parameter

-dynamic parameter

With single correlation (r >= 0.85)

With multiple correlation (r >= 0.85)

test

ing

leve

l

Test Methods

13

How to find the right test method -Main test sequence -Same impact parameters -Same impact direction

Output

-Sta

tic

-Sem

i-st

atic

-dyn

amic

single correlation

multiple correlation time

FFT no correlation

Test sequence anlyses

Increased stress

test

ing

leve

l

Test Methods

14

How to find the right test method -specific test sequence -Same impact parameters -Different impact direction

Output

-Sta

tic

-Sem

i-st

atic

-dyn

amic

single correlation

multiple correlation

FFT no correlation

Test sequence anlyses

time

Increased stress

test

ing

leve

l

Test Methods

15

How to find the right test method

Damage impact matrix

Pos. 4

Speed yes

Temperature Yes

Pressure no

Humidy ?

Operation time

yes

Fuel/oil Yes

…

-Main test sequence -Same impact parameters -Same impact direction

-Specific test sequence -Same impact parameters -Different impact direction

-Single HALT-Tests - One parameter not know ( full factor testing matrix)

-Multiple HALT-Tests - >=2 parameters not know ( part factor testing matrix)

- QALT-Tests -Specific overload test; knowledge about existing borders

test

ing

leve

l

Test Methods

16

How to find the right test method -Single HALT Test - one impact parameter not known

Output

-Sta

tic

-Sem

i-st

atic

-dyn

amic

single correlation

multiple correlation

FFT no correlation

Test sequence anlyses

time

-Un

kow

n

imp

act

Step 1 Step 2 Step n

test

ing

leve

l

Test Methods

17

How to find the right test method -Single HALT Test - one impact parameter not known

Output

-Un

kow

n im

pac

t

Step 1 Step 2 Step n

par

amet

er

limits

specification

field use

technical