Track 1 Session 11

10:20 to 11:20 a.m. Friday March 30, 2012

Design of Prototype Test Procedures (DPP): Concept and Case Study

Within the early development phases of automotive components, the knowledge of the failure behaviour and damage causes regarding the components’ complete life cycle is important. This session presents an innovative concept for the design of prototype test procedures to early simulate and measure complex wearout mechanisms on automotive interior and exterior components, as caused by a driver, with the goal to predict the long-term failure behaviour. This concept’s innovative approach is based on the integrated process design of prototype tests with the interdisciplinary interaction of robotics to represent the realistic wearout mechanisms, the metrology to detect the extent of damages, as well as the reliability analysis based on (non-)parametric statistical models for the mapping and prediction of the failure behaviour during the complete life cycle. Based on the described approach, a reduction of prototype numbers and test times, as well as a reduction of development time and cost, can be expected, while providing a high quality of the knowledge and prediction of the component’s failure behaviour. In this presentation, the resulting "Design of Prototype Test Procedures (DPP)" concept and its application case study "surface damage door paint" are described and explained.

Key Words: Reliability Analysis; Prototype Testing; Robotics, Metrology, Nonparametric Statistic

Stefan Bracke

University of Wuppertal


Ralf Breede

Cologne University of Applied Sciences