Browse Topic: Test procedures
Modern mission-critical ground vehicle systems must adapt to rapidly evolving threats, deploying changes in months or days while maintaining reliable and safe operation. Historic manual development and testing methods cannot keep pace without compromising safety assurances. Continuous Integration and Continuous Deployment (CI/CD) pipelines offer proven approaches to accelerating development, but implementing them for mission-critical systems requires careful attention to verification rigor. This paper presents a practical framework for implementing CI/CD pipelines across any level of rigor, from rapid prototyping to DO-178C and ISO 26262 certified systems. Drawing on experience from aviation, medical device, and ground vehicle development, the framework provides guidance for each pipeline stage based on the system’s desired level of rigor. This framework includes an examination of the value of Software-in-the-Loop vs Hardware-in-the-Loop testing to optimize development timelines while maintaining software quality.
With the large-scale application of intelligent connected vehicles, the verification of their functional safety and reliability has become a core bottleneck in the industrial development. The traditional real- vehicle road test method can no longer meet the current demand for large-scale test verification due to problems such as high cost, low efficiency, and difficulty in reproducing dangerous scenarios. This paper studies the vehicle-in-the-loop simulation test system based on a digital twin. By constructing a virtual scenario highly consistent with the real world, physical-level multi-source perception signals are simulated and mapped to the system under test to enable high- reliability verification of real vehicles. In terms of lateral and longitudinal control functions, multiple sets of test cases are selected respectively for comparison between road tests and virtual simulation tests. The results show that the accuracy of key indicators is above 90%, which provides practical reference for the subsequent test and verification system of high-level autonomous driving.
Ultrasonic TOFD detection is one of the most important non-destructive testing techniques for welds. However, the complex beam deflection, scattering, and attenuation of ultrasonic waves in the heterogeneous weld structure lead to the weak signal of the defect diffraction wave received by the probe and the low signal-to-noise ratio, which has a negative impact on the engineering application of ultrasonic TOFD detection technology in austenitic stainless steel welds. In this study, a numerical model of the ultrasonic TOFD detection process for austenitic stainless steel welds was established based on the finite element method. Combined with the test method, the interaction mechanism between the ultrasonic wave and weld structure is analyzed, and the probe arrangement method to reduce the interference of weld scattering noise is proposed. The results show that the finite element model can simulate the anisotropic characteristics of ultrasonic waves in austenitic stainless steel welds, including sound field distortion, sound energy scattering, and attenuation. Combined with the detection test, it has been proven that the adverse effect of the weld structure on the TOFD detection signal can be reduced by changing the probe detection surface.
To safely, efficiently, and high-quality complete the mechanical testing of batch-produced manned spacecraft during the China Space Station (CSS) phase, a series of optimization measures were proposed based on system engineering principles. These measures cover the entire mechanical testing process from preparation to implementation, including: establishing a standardized mechanical testing documentation system; reducing the number of mechanical sensors that do not affect result evaluation; pre-identifying and measuring background noise; digitizing test notching and evaluation methods; and standardizing and automating testing procedures. Additionally, targeted measures for test safety and quality control were implemented, including regular inspections of reusable spacecraft components, strict control of test hazards and operational risks, and standardized management of ground support equipment (GSE) through regular inspections. The proposed optimization and control measures have been validated through applications in batch-produced manned spacecraft during the CSS phase. The results show that: the generalization rate of mechanical testing documentation exceeds 80%; the number of mechanical sensors has been reduced by more than 10%; the test preparation period has been shortened by over 4 days; test efficiency has been improved by 30%; the single-direction test duration has been reduced by more than 50%; and the total test cycle has been shortened by 25%. These results indicate that the proposed optimization and control measures are reasonable and feasible, which effectively reduces redundant test operations and items, lowers potential test risks, improves test efficiency, shortens the overall test cycle, enhances test safety, and ensures the high-quality completion of mechanical testing for batch-produced manned spacecraft.
Full, industry standard test procedures for measuring the charging performance of a vehicle can be found in ISO/SAE 12906. This document describes the lessons learned during the development of that document, including false assumptions that are common in vehicle charging tests. The purpose of this document to better explain the need for the specific procedures in ISO/SAE 12906. Furthermore, by communicating the false assumptions and complications of historic charging tests, it is also hoped that others wishing to create test procedures different from ISO/SAE 12906 can do so without making the same mistakes of the past.
This test method provides a procedure for measuring no-load rotational breakaway torque of self-lubricating spherical bearings.
To address the detection and monitoring needs of fatigue damage in ferromagnetic materials, this paper proposes a nondestructive testing method based on the evolution of magnetic hysteresis characteristics. By constructing a hysteresis loop measurement system, the variation patterns of coercivity (Hc) in Q235 steel specimens under cyclic loading were investigated, revealing three-phase characteristics of fatigue damage: the initial linear growth phase (N ≤ 8,000), the rapid rise phase (8,000 < N ≤ 12,000), and the stable oscillation phase (N > 12,000). Experimental results demonstrate that the relationship between coercivity and damage degree (D) can effectively characterize the processes of crack initiation, propagation, and instability, with significant inflection points observed at D = 0.6 and D = 0.8. The quantitative model based on coercivity provides a novel method for early warning and condition assessment of fatigue damage, offering advantages such as non-contact operation and high sensitivity. This study provides theoretical foundations and technical support for the health monitoring of engineering structures.
In response to the current airworthiness regulations’ inability to cover the stall flight test requirements under icing conditions of civil aircraft with high-angle-of-attack restriction function and the lack of relevant flight test technologies in China, a study was conducted on the differences in airworthiness provisions for stall characteristics under icing conditions of such aircraft. Key technologies, including simulated ice accretion stall flight test methods, ice installation strategies, and data analysis techniques, are proposed and successfully applied to a specific civil aircraft. The results demonstrate that the methodologies proposed in this paper can effectively support simulated ice accretion stall tests, providing valuable insights for other similar aircraft.
This SAE Standard establishes a test method and a definition for disclosing the performance of suction/blower fans when applied to self-propelled sweepers that solely use a pneumatic conveyance means for the collection and transfer of “sweepings” into a collection hopper.
As acoustic requirements for NVH trim components become increasingly constrained by mass, cost, and sustainability targets, traditional approaches to inner dash design based on spatially averaged Transmission Loss (TL) metrics are reaching their practical limits. In fully built vehicles, the acoustic performance of the inner dash is governed by its global insulation capability but also by strong spatial heterogeneity and its interaction with spatially distributed noise sources such as the power unit, gearbox, and tyre-road excitation. This paper presents a test-based methodology for the spatial optimisation of inner dash acoustic performance using reciprocal holography. By applying a calibrated sound power source within the vehicle cabin and measuring the reciprocal response in the engine bay and wheel-arch regions, a high-resolution spatial Transmission Loss “hologram” of the inner dash is obtained under in-situ conditions. The resulting spatial data enables the identification of localised acoustic weak points that are not observable using conventional testing methods. To bridge the gap between passive component characterisation and real-world vehicle operation, the spatial TL hologram is subsequently evaluated using representative operational source sound power data to prioritise acoustically relevant regions. This enables the transmitted acoustic energy to be evaluated under realistic driving conditions. The holographic data is then coupled with a parametric acoustic model of the inner dash system, allowing localised mass redistribution to be optimised using a genetic algorithm while respecting packaging and manufacturing constraints.
Noise phenomena in automobiles caused by the stick-slip effect are increasingly among the most frequent reasons for customer complaints and therefore represent a critical vehicle quality attribute. To proactively address such issues, stick-slip testing of contacting material pairs is commonly applied during development. However, the predictive capability of current stick-slip test methods remains limited, particularly when highly flexible materials and realistic, stochastic excitation conditions are involved. The flexibility of sealing systems often allows the actual relative motion at the contact interface to be accommodated through adhesion and elastic deformation, thereby delaying or even preventing sliding. To date, this effect has not been represented by any characteristic parameter in conventional stick-slip testing. Instead, existing evaluations focus exclusively on the analysis of occurring stick-slip oscillations. For the initiation of stick-slip phenomena, however, not only the mean displacement between two stick-slip oscillations during the sliding phase is relevant, but also the relative displacement required to initiate the first slip event of the sealing contact. With the algorithm developed in this work, which reproducibly determines the distance to first slip based on changes in the friction force slope, this methodological gap is now closed. The displacement to first slip depends on numerous influencing factors, including profile geometry, normal load, sliding velocity, excitation profile, and environmental conditions, and was previously inaccessible by both experimental and numerical approaches. In particular, the onset of slip in sealing contacts can now be determined under stochastic excitation of the friction pairing, thereby closely reflecting real operating conditions. As a result, the prevention of noise phenomena can be significantly strengthened at an early stage of vehicle development.
This test method outlines the standard procedure for measuring the radial and axial internal clearance of rolling element bearings used in airframe controls.
AMS6885/2 gives specific information about the qualification program for unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. The prepreg system shall include an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
This digital standard is a requirements extract of AS5127D Aerospace Standard Test Methods for Aerospace Sealants Methods for Preparing Aerospace Sealant Test Specimens. This file contains a general requirements extraction as well as files that are optimized for use with Doors Classic, Siemens Polarian, and PTC.
The payload fairing of a launch vehicle is subjected to extremely high acoustic loads, with peak levels occurring during lift-off and transonic aerodynamic regimes. The external acoustic field penetrates the fairing, producing intense internal sound pressure levels that can challenge the integrity of spacecraft components. Accurate characterization of the vibroacoustic behavior of the payload fairing and its enclosed cavity is therefore essential to ensure spacecraft survivability. The internal acoustic field is governed by the coupled dynamics of the fairing structure and the spacecraft configuration, making it critical to quantify the acoustic environment for different payload arrangements. This study presents a detailed vibroacoustic analysis of a payload fairing with multiple spacecraft configurations to evaluate the resulting internal sound pressure distribution. Vibroacoustic finite element analysis is employed in the low frequency range, while statistical energy analysis is utilized for mid and high frequency ranges. Representative models are developed, and the predicted structural and acoustic responses are validated against experimental acoustic test measurements. The validated models are subsequently extended to other spacecraft configurations to perform sensitivity studies. The influence of various parameters on the internal sound pressure levels is assessed, and the resulting perturbations across frequency bands are quantified. The outcome of this study provides a comprehensive understanding of the internal acoustic environment within payload fairing, aiding in the specification of qualification acoustic test level for spacecraft.
AMS6885/5 is the Material Specification (MS) which defines the requirements of a unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. It also defines the requirements of an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
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