Innovative Multi-Axial Testing approach for Enhanced Reliability of Cooling Modules in Commercial Vehicles

This paper presents an innovative in-lab accelerated testing approach for chassis-mounted components, with a particular focus on the cooling module of commercial vehicles. The proposed method simulates real-time data acquired from field operations and replicates all critical chassis modes, including torsion. Additionally, real-time coolant circulation at specified pressure and temperature maintenance are feasible during durability testing, enhancing the realism of the test environment. The cooling modules, comprising the radiator, intercooler, and charge air cooler (CAC), often experience failures due to various multi-axial inputs and chassis modes. This paper introduces an innovative methodology for replicating field conditions in the lab, utilizing seven servo-hydraulic actuators to simulate multi-axial inputs. The accuracy of in-lab simulation for the acceleration levels at input and response locations of the cooling module exceeds 90%. This makes it a preferred choice for test engineers to simulate field failures or validate designs well in advance of final production, thereby avoiding issues at later stages of vehicle launch. This approach offers the flexibility to accelerate the test duration while ensuring the retention of over 90% of the damage observed in real-world conditions. By utilizing the same chassis frame and mounting locations, the test maintains consistent boundary conditions, providing reliable and accurate results. This method significantly enhances the efficiency and effectiveness of testing processes for commercial vehicle components, ensuring robust and reliable performance.