Zwick Roell—A trusted partner for testing in the automotive industry

Find the right solutions

The demand for testing in the automotive industry spans from testing the materials to complete components. Most vehicle components must be designed for mechanical loading over the service life of the vehicle and reliably fulfill the component requirements.

Intelligent testing solutions—The right product for any application

Zwick Roell's wide range of testing machines is modularly designed and can be optimally adapted to your testing requirements. We offer testing solutions for standard-compliant tests via universal testing machines for a number of test tasks to fully automated complex testing systems. All Zwick Roell testing systems deliver reliable test results, easy operation, and high availability.

From drives to electronics—Testing solutions for all segments

We not only provide testing systems for fundamental challenges such as the use of materials and joining technology, we offer comprehensive testing solutions for all relevant vehicle segments, from drives to the chassis, body, interior, and safety, to electronics/mechatronics. We work closely with our customers in the development electrical drives and battery technologies.

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Precise determination of deformation characteristics in the testing of components for the automotive industry

Components testing is an important part of the test arrangement in the automotive industry. In addition to force characteristics, the deformation must also be recorded with great precision. During a compression test on components it is often the case that deformation cannot directly measured with extensometers because of the geometry of the accessories. testXpert III testing software offers an attractive solution for this known as the correction curve.
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Deformation and force characteristic values for many of these components, for example springs and brake linings, must be determined with high precision. During tensile tests on standard specimens, precise determination of deformation is achieved by using extensometers to measure change in length. However, accessory geometry does not permit correct use of an extensometer in compression tests on components, with the result that crosshead travel is often used in practice to measure component deformation. The problem then arises that even materials testing machines with a very high level of stiffness are liable to self-deformation as force increases. This can lead to significant distortion of deformation characteristic values, particularly when stiff components are being tested.

Automatic correction for machine deformation

testXpert III testing software offers the unique option of eliminating materials testing machine self-deformation while achieving high-precision measurement of components, without the need for additional extensometers. 

  • The "Determine correction curve" test program allows testing system self-deformation to be measured quickly and easily for each test arrangement.
  • For this, a force-deformation curve is recorded once with no component present. In other words, the compression platens are loaded up to machine nominal force and the resulting curve is saved in the system as a correction curve. 
  • The assignment of the correction curve to the corresponding test arrangement is saved as a system configuration in "Set up testing system", so that even with different test arrangements the right correction curve will always be loaded.
  • In the actual test, deformation correction takes place online. The amount of correction is automatically equal to the deformation of the correction curve at the corresponding force. This enables determination of extremely precise deformation values, including in compression tests on components for which an extensometer cannot be used. 
  • Another important point is that deformation correction takes place directly in the electronics. Control directly to this channel is possible, enabling precise travel to the set targets for the deformation, when testing springs for example. In systems lacking this function the deformation target would not be attained, resulting in inaccurate determination of the relevant force characteristic values.

Traceability of Specimen Behavior with Video Capturing

  • Videos synchronized exactly with the test enable visual analysis of specimen behavior during testing.
  • Additional single frames from the video can be generated for interesting points in the test sequence.
  • The point of break can be repositioned after the test.
  • At the end of the test the user also has the option of visually retracing the specimen behavior.

More examples of Video Capturing

Always One Step Ahead

Unique test and evaluation requirements are possible with testXpert III: we get started where the others leave off!

  • testXpert III offers a Master Test Program already prepared for all types of tests, allowing you to configure your test sequence to meet your needs.
  • The user interface adapts to your individual requirements so that you see exactly the graphics, results tables, tolerance displays, input dialogs and layout elements that are required for your testing situation.
  • The comprehensive results and statistics tables can be expanded as required.
  • Long-term evaluations and informative histograms are already integrated in testXpert III .
  • testXpert III uses ZIMT, a flexible programming language for creating any number of complex processes, including calculation, and evaluation processes.
  • Zwick can provide customizations tailored to your specific applications.
  • Existing sensor technology is easily integrated into testXpert III; even measurement channels from external measurement amplifiers can be imported in synchronized form.
  • Complex data can be displayed and interpreted easily and clearly with the Layout Editor (customized views are possible).

Customized Test Sequences with the Graphical Sequence Editor

The Graphical Sequence Editor gives you all the flexibility and freedom you need. It is the perfect tool for creating individual test sequences of any type, allowing you to freely combine test events, parameters and results according to your requirements.

  • Operation of the Graphical Sequence Editor is configured to your individual needs by means of drag and drop.
  • Simulation of the created test sequence ensures that the testing steps are set up logically and that the materials testing machine nor the specimens get damaged.
  • Freely programmable test sequences are a requirement, particularly in research applications. The Graphical Sequence Editor is the perfect tool for n creating non-standardized test sequences. 

Testing Software for Temperature Chambers

The materials testing machine including temperature chamber features convenient, intuitive operation via the testXpert III testing software. The control layout adapts interactively to the test sequence and provides direct feedback, allowing the fan speed of the temperature chamber to be conveniently adjusted. ensuring reliable test results even with fragile specimens such as films.

System Monitoring

testControl II system monitoring provides the user/laboratory manager with detailed information on the current status and level of utilization of the testing equipment. This enables further increases in testing equipment availability and greatly simplifies maintenance planning and spares/replacement procurement.
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