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Featured Article...
 For over 50 years, Mercedes-Benz has exposed its vehicles to a vigorous test track known as Heide-dauerlauf*. Located in Germany, this route provided Mercedes with a means of testing the life of a vehicle and its components in an accelerated manner*. In the modern era, Mercedes has re-created the conditions of this track at their facilities in Stuttgart and Sindelfingen*. Each vehicle is instrumented with accelerometers, and a courageous driver endures the vibrations of the test track at a regulated speed as acceleration is recorded at various locations*. This acceleration data is then delivered to the test lab where specialized software and equipment is used to reproduce the same vibrations.
MGA has performed Heide-dauerlauf or "Heide" testing on various seat programs for 6 years for various automotive suppliers. Currently, MGA-MI is capable of performing this vibration test on eight different test rigs. Each rig, known as a Multi-Axis Simulation Table (MAST), is capable of reproducing the six degree-of-freedom vibrations seen on the Heide track. The MGA facility in Troy, MI uses MTS FlexTest™ IIm and IIs software to operate each of the MAST systems. RPC Pro™ (MTS) is used to match the road load data provided by the customer.
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Salt Fog Testing Taken to the Next Level
 Salt Fog is a very common test used to gage corrosion resistance in products. A less common (and much more rigorous) method is the SO2 injected salt fog. SO2 is produced in volcanoes and various industrial processes. Since coal and petroleum often contain sulfur compounds, their combustion generates sulfur dioxide. Sulfur dioxide acts as an acid when combined with moisture, and it accelerates the corrosion process initiated by the standard salt fog test that MGA offers.
Are you certain of the corrosion resistance that your product is providing to your customers? Even a well designed and handsomely built component can be overshadowed by an unsightly corrosion problem. The SO2 injected salt fog test (found in ASTM G85) can be performed in MGA's Technical Services Laboratory in Akron, NY.
For more information on this type of testing, please contact Steve Richardson at (716) 542-5515 or send an e-mail to steven.richardson@mgaresearch.com.
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Battery Failures - Part 2
Nail Penetration
Battery failures can be extremely dangerous. In the previous issue, we took a closer look at the External Short Circuit test and the way it is performed. Now we will be looking at a second type of battery failure: Nail Penetration. Nail Penetration does not necessarily need to be caused by a nail. It refers to the type of failure that is produced when an object (usually metallic) punctures the case of the battery and allows it to short circuit internally. This testing is uniquely relevant to hybrid-vehicle batteries because there are many metallic components around the battery that could puncture its casing during a collision. Because of this, nail penetration has been included in the SAE J2464 standard for testing electric vehicle batteries. This type of failure could drain the battery of its charge, or cause it to heat up and explode. To test batteries for this condition, we use an appropriate sized metallic rod that is driven through the battery by a hydraulic cylinder. The cylinder is hooked up to a controller that allows us to vary the speed of puncture as well as how deep into the battery it is inserted. For thin batteries and cells, the puncture is usually all the way through, but for larger batteries and extremely large packs, the rod can be stopped at any point. Read More... |
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MGA-South Carolina Offers Full Vehicle Environmental Testing
The MGA-South Carolina facility, located in Greer, continues  in the expansion of its capabilities and customer base. In meeting our customer's testing requirements, including those of BMW and other major suppliers in the area, a full vehicle environmental chamber is now on-line. It is capable of conducting a wide range of industry standard tests. The temperature profiles used in these tests typically depend upon the placement of the part within the vehicle, as well as its potential to be affected by direct sunlight. The new chamber has a temperature range of -30°C to +95°C and humidity control. The large drive-in chamber has a floor space of 19' x 11' x 8', and can accommodate full vehicles or multiple test samples on fixtures. Bringing equipment on-line to support the local OEMs and suppliers in South Carolina is the reason we decided to locate to this area. For more information regarding our capabilities, please contact Natalee Ramsden ( natalee.ramsden@mgaresearch.com) or Jennifer Hill ( jennifer.hill@mgaresearch.com) at (864) 848-3088. . |
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Rotational Latch Testing
Andy Gould - Troy, MI (andrew.gould@mgaresearch.com)
At MGA, we enhanced our capabilities to conduct Rotational Latch and Striker testing on vehicular door systems. These tests are done to evaluate the ability of a door to remain closed in a dynamic crash environment. Although the NHTSA has a federal requirement (FMVSS 206 - Door Locks and Door Retention Components), many automobile manufacturers have developed their own internal requirement to augment the federal regulation. The tests are performed using two specific fixture designs which allow the striker to load into the stationary and fixed latch by rotating about the X or Z axis. A Universal Test Machine (UTM) is used to conduct these tests by applying loads at a fixed displacement rate. Data processing and analysis is convenient since it provides the customer the opportunity to determine failure modes, as well as verifying passing results, following each individual test. Read More... |
Up Close & Personnel
When associates or customers call headquarters in New York, they are greeted with the pleasant voice of Ellen Joachimiak. Ellen has been a part of MGA's family for over 23 years. With the exception of our officers, she holds the honor of being MGA's longest standing associate. From typewriters to computers, she has grown and adapted as MGA grows and adapts to the changing needs of its customers. She is the embodiment of MGA's core values of honesty, integrity, and excellence in work. No matter how stressful a day may get, Ellen always greets you with a smile.
Among her numerous duties, she manages all of MGA's account payables and executive itineraries. She is an expert in both domestic and international shipping as well as customs procedures. Ellen is also the first line of contact to our customers ensuring they receive superior service. She is a core team member with answers for seemingly everything.
In her spare time, Ellen is an active grandma and crochet master. She enjoys vacations at her cabin with her husband and children.
With the ebbs and flows of corporate climate, Ellen is MGA's icon of not only dependability, but also adaptability.
 Ellen Joachimiak | |
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Touching Base
with Dr. Patrick Miller - Akron, NY
Automobile Sales
Those connected with the automotive industry anxiously await monthly automobile sales figures. During recent months, the media has been reporting sales down 40 percent or so from the same month a year earlier. These numbers are then projected to annual sales rates of 9 to 10 million vehicles. Some of the more dire forecasts suggest a fundamental structural change in vehicle sales where yearly sales of 10 million will become the norm. Sometimes the current situation is even related to the Great Depression of the 1930s.
It seems to me that we should relax a little and take a deep breath. Let's review the situation during the Great Depression. Auto sales then peaked at 5 million units in 1929. The sales steadily declined to a little over one million in 1933. To have a similar situation today, annual sales would have to reduce to about 5 million units in the next couple of years. No one is suggesting such a reduction, so let's set aside Great Depression talk and consider some of today's relevant facts.
The population of the United States is about 300 million people, and the number of registered vehicles is about 250 million. On the surface, the number of vehicles for the population might seem to be excessive. But, vehicle ownership is a fundamental part of our lifestyles. Approximately two-thirds of the population is of working age and about 90 percent of these travels to and from work using motor vehicles. Those not working, such as retired people, enjoy a lifestyle that is highly dependent upon vehicle ownership. The situation with respect to driving-aged students is similar. Visit any college or even a high school and try to find a parking space when the school is in session.
It is unlikely that any part of the population will soon change their current vehicle-ownership related lifestyles. For these reasons, it is safe to assume that even in a worst-case situation, the number of total vehicles will not significantly decrease in the foreseeable future.
Any forecast of the future should consider not only the current sales but also how many vehicles must be replaced during the year. The annual scrappage rate is now between 5 and 6 percent of the total number of vehicles. A scrap rate of 6 percent results in annual sales of 15 million vehicles just to maintain the current vehicle population, while a rate of 5 percent requires new car sales of 12 million. This means the market is likely to be at least 12 to 15 million vehicles annually. Furthermore, the country has a growing population that is expected, during the next 40 years, to increase to about 440 million. With this growing population, future sales will likely return to at least the traditional 16 to 17 million range.
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