High precision vibration jigs with a minimum natural frequency of 1200 Hz
Research by Jaroslav Miklušák (MECASYS), Ján Habovštiak, Jozef Medvecký, Pavol Gužík (MECASYS Design Labs), Jozef Vnenčák - MECASYS CAM Program
Summary
In the development of modern automotive mirrors, testing their stability in harsh conditions is crucial.
The client, a leading manufacturer of automotive components, was looking for a partner to help them solve a testing reliability issue. MECASYS took up the challenge and offered a comprehensive solution - high-precision vibration jigs with a minimum natural frequency of 1,200 Hz that allow simulation of real driving conditions and guarantee accurate, repeatable test results.
Description of the problem
With the increasing complexity of automotive mirrors and their integrated functions (auto-dimming, heating, blind spot monitoring, digital mirrors and more), the demands on their stability and vibration resistance are increasing.
The client was faced with uncertain test results that led to repeated costly tests and potential design flaws.
The main challenge was to develop formulations that would ensure not only the accuracy but also the repeatability of the assays without the need for additional modifications, while allowing for fast and efficient integration into existing test facilities.
High minimum natural frequency of the preparation (1 200 Hz):
MECASYS has designed fixtures whose natural frequencies significantly exceed the test frequencies. This ensured that the fixtures would not resonate and the test results would not be distorted. This approach extended the life of the fixtures and allowed repeated testing without risk of damage1.
Production accuracy:
Each component has been manufactured with extreme precision using CNC machining and 3D printing for prototyping. The MECASYS team has ensured that even the smallest deviation will not affect the test results and the client will get the most reliable data on the first try1.
Reliability under repeated loads:
The fixtures are designed to withstand repeated dynamic loads without damage. The higher natural frequency serves as a safety factor to ensure fixture stability and longevity, which is critical for testing complex mirrors with advanced features1.
Integration into existing facilities:
MECASYS successfully integrated the new fixtures into the client's equipment, ensuring that the tests ran smoothly without disrupting other processes. This ability to adapt and react quickly to specific requirements is one of the company's main advantages.
Minimize first-attempt errors:
Every stage of the project, from design to production, was carried out with the utmost attention to detail. This minimised errors and the cost of re-testing, saving the client time and money.
Efficient production and fast delivery:
Despite the high demands on precision and quality, the preparations were delivered in a short time. MECASYS was able to plan and control production efficiently, ensuring that the client could continue testing without downtime.
Technological and development context
Modern rear-view mirrors are equipped with a number of features that increase their complexity and testing requirements. MECASYS was aware that test fixtures had to be designed to take all these aspects into account - from vibration resistance to compatibility with modern sensors and electronics. The use of advanced simulation tools and 3D modelling in SolidWorks allowed the rigidity, weight and geometry of the jigs to be optimised, increasing their stability and reliability.
Solution
MECASYS has designed and manufactured vibration fixtures with a minimum natural frequency of 1 200 Hz. The jigs were designed in SolidWorks, optimized using advanced simulation tools and prototyped using 3D printing. Final production was carried out by CNC machining, ensuring maximum precision and reliability.
The formulations were successfully integrated into the client's test facilities and enabled the simulation of the entire mirror life cycle in an accelerated mode (1-2 days).
Results and benefits
By implementing the measuring jigs designed by MECASYS, the client achieved a significant improvement in the quality and stability of the production process. Thanks to the precision-engineered and modularly designed jigs, all dimensional requirements within tolerances of 0.01 mm were met while optimizing internal processes.
Key benefits include:
1. Accuracy within 0.01 mm: all geometric parameters were stably achieved without the need for additional corrections.
2. Measurement repeatability: thanks to CMM inspection and MSA analysis, the ability of the formulations to provide consistent results in batch production has been confirmed.
3. Error reduction: accurate measurement and validated part clamping eliminated dimensional variations in output.
4. Fast deployment: digital design and verification in a 3D environment enabled smooth implementation without production downtime.
5. Inspection cost savings: continuous CMM measurements and shared documentation have eliminated the need for repeated initial inspection by the customer.
6. Readiness for future development: the modular architecture of the fixtures allows for flexible adaptation when products or checkpoints change.
These results have not only strengthened the reliability of the production process, but also the client's confidence in MECASYS' technical solutions.
Conclusion
MECASYS delivered a comprehensive bespoke solution that met all of the client's requirements.
Vibration fixtures with a minimum natural frequency of 1,200 Hz ensured accurate and robust verification of the stability of the rear-view mirrors, thereby increasing the efficiency and quality of the manufacturing and testing processes. This case confirms once again that MECASYS is able to respond to tough challenges, offer innovative solutions and ensure their fast and flawless implementation.
For the customer we have achieved
- Accurate and reliable test results:
The fixtures enabled accurate measurements of mirror stability while simulating real-world driving conditions, providing the client with reliable data for further development.
- Reduced cost of re-testing:
Minimized errors in testing processes resulted in cost and time savings.
- Improving the quality and durability of mirrors:
The stability of the test conditions contributed to the higher quality and durability of the final products.
- Fast integration and efficient test execution:
The fixtures were fully compatible with existing devices, allowing rapid implementation and continued testing without downtime.
Your needs, Our expertise
If you are looking for a partner that can turn your challenges into quality and reliable solutions, contact MECASYS. We are ready to help you develop, manufacture and integrate specialized products that will increase the reliability and efficiency of your testing processes. With MECASYS, you get a partner who understands your needs and can turn them into success.
MECASYS designs and delivers customized fixtures for you - reliably, flexibly and in accordance with the demanding requirements of your production.
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