Pyroshock testing is critical to aerospace engineering due to the high stakes nature of the industry. This testing simulates explosive and powerful events such as space launches and jettisoning used rocket stages. By performing this testing on individual components, it helps to ensure the spacecraft’s success during high stress events. MGA Research is committed to achieving the most accurate and consistent shock pulses through developing new equipment and knowledge of the industry.

In order to expand capabilities, we designed and built two new Pyroshock testing systems. The Clamped Tunable Resonant Bar (CTRB) was engineered for smaller products, while the Hanging Tunable Resonant Beam (HTRB) was developed to accommodate products with increased size and weight requirements. Both systems are complete when paired with our Mobile Propulsion Unit (MPU), implementing over 35 years of impactor expertise, allowing quality and repeatable results.

With a need to house these new systems, MGA Research built a Pyroshock testing laboratory within our New York facility. This state of the art lab is equipped with an isolated conference room to witness testing, while providing privacy for the customer and their project. With support from MGA’s Equipment Group, we can ensure that this facility, as well as our Pyroshock testing, will meet and exceed customer needs and expectations for years to come.

This new laboratory will be debuting with an open house on Friday, January 25th 2013. For more information on the open house or Pyroshock testing please contact Larry Calabrese at (716) 542-5515 or larry.calabrese@mgaresearch.com.

Early and Realistic Evaluation Helps Design

The evaluation of components early in the design process is a key part of the overall development cycle. From an automotive standpoint, OEM’s work with suppliers to establish the vibration/shock environments that components will experience in the field. In many cases, data is collected with early prototype or pre-production vehicles. This data is then utilized to form the basis for tests to simulate a lifetime of exposure. For other industries, there is little to no opportunity to evaluate performance in the final end-stage application. For example, it is not feasible to test many of the components for space vehicles in a full scale manner; i.e. launching them into orbit to test whether they work prior to the official launch. So, the components themselves must be exposed to an environment which simulates the launch conditions as the actual launch may be the first and only exposure.

Innovative Approaches to Shock Events

Over the years, MGA’s team has developed new ways to simulate the high amplitude shock events that are present in various applications. These approaches have been the result of MGA’s strong collaboration between our laboratory personnel and our equipment team. The approach implemented is to draw upon the technologies that have been developed at MGA in the areas of new sled designs, pyroshock devices, dynamic impactors, and large-scale drop towers.  In many cases, these approaches have been combined to produce the desired acceleration shock pulses. A few recent examples include the following:

Battery Shock Testing: MGA is currently in the final stages of development of a new shock system designed for evaluating large format batteries. These systems are based upon advanced impactor technologies developed over the years by MGA. These systems can be operated in the horizontal and vertical shock modes. The units have been sized so that they fit into a battery containment chamber. Many of these chambers have been commissioned throughout various MGA facilities as the need for evaluating of experimental battery testing has grown.

Shown above is MGA's battery shock systems currently being commissioned.

Horizontal Blast Simulation: Recently, MGA engineers tackled the challenge of simulating the blast shock event of an IED exploding on the side of a military vehicle and producing a very high acceleration/short duration pulse on side mounted seats. MGA’s newly developed mini-sled application was utilized to produce the shock with all of the components in the correct, in-vehicle orientation. This new application complements the vertical based blast simulation testing that MGA has been conducting for many years.

Pyroshock: MGA has been conducting Pyroshock testing for many years. This type of testing simulates the conditions evident when a space vehicle or missile is launched. Accelerations of up to 10,000 g’s are sometimes seen in these events. Over the years, MGA has developed new devices and procedures to be able to match a very wide range of pyroshock environments.

MGA offers extensive capabilities in the field of Pyroshock testing. This type of testing simulates the environment encountered by small components in a launch environment.

MGA recently developed an innovative approach towards simulating automotive shock events which routinely occur in the real world. One such event, curb impacts, is one that has challenged vehicle designers for many years. These events can cause significant damage to vehicle suspensions. The staff at MGA has developed a novel approach that simulates this event within a controlled laboratory environment.

Traditional Vibration and Shock Solutions

For the automotive, aerospace, and defence industries, electrodynamic shakers are utilized extensively to evaluate components over a wide range of acceleration levels and frequency ranges. These systems are used to test products from both a vibration durability approach and simulated, repeated shock exposures. Over the years, various standardized procedures have been developed for specific types of components. In regards to ED shaker capabilities, MGA offers test services out of its network of laboratories. A wide range of shakers are available; with force ratings up to 20,000 lbs. All of the systems are integrated with environmental chamber capabilities so that components can be simultaneously exposed to vibration and extreme temperature cycling.

The photo on the left shows the existing vibration test lab while the photo on the right shows the new lab as it is being commissioned. These labs consist of a wide array of traditional ElectroDynamic Shaker and Shock test solutions.

Shown above are the examples of the more traditional vibration/shock capabilities offered at MGA. On the left, is a large ElectroDynamic Shaker integrated with a slip table. On the right, a component-level shock machine is presented.. Shown above are example shock pulses that can be produced. MGA has produced shock pulses as high as 500 g's in magnitude for a single impact event.

Shown above are example shock pulses that can be produced. MGA has produced shock pulses as high as 500 g's in magnitude for a single impact event.

Overall, MGA offers numerous, state-of-the-art solutions to your vibration and shock needs. If you are interested in learning more about these capabilities, please contact Andy Gould at (248) 577-9810 or by email at andrew.gould@mgaresearch.com. 

Automotive interiors are increasingly adding touch screen interfaces like the one shown above.

MGA Offers a Comprehensive “Tool Box” of Solutions

Over the years, MGA’s team has developed comprehensive facilities designed to evaluate virtually all aspects of interior components and full cockpits.  MGA’s capabilities are designed to evaluate a wide range of issues that are critical to the overall cabin environment. All of these systems have been the result of MGA’s strong collaborative approach between our laboratory personnel and our equipment team.  Examples of some of the more important trends and issues facing interior suppliers include the following:

Safety:  From a crashworthiness perspective, seats and airbags each contribute heavily toward the overall safety of the vehicle.  From a seat perspective, various industry and regulatory standards must be met without compromising the comfort, features, and durability of the seat system.  MGA has been conducting safety tests on seating systems for over 30 years.  These tests include static, dynamic impact, and crash sled evaluations.  Another safety component that is integrated but not visual to the interior is airbags.  Some vehicles now offer as many as 10 airbags integrated into various key locations of a vehicle.  All airbags must be seamlessly integrated into an interior so that styling and space is preserved.  As airbags have been added, MGA has brought on-line additional capacity to meet the needs of the industry.  Currently MGA offers 3 full-scale, state-of-the-art deployment rooms out of the Troy, Michigan laboratories to support the local industry.  These facilities each feature full drive-in chambers, new high-speed video cameras, and synchronized deployment controllers.  From a legal compliance perspective, MGA has conducted suppression and low risk deployment testing for the NHTSA and OEM’s  in conjunction with federal vehicle crash testing at our Wisconsin facility for many years.

Airbags are being added at many locations within the vehicle interior and engineers need to seamlessly integrate these safety devices into designs.

Shown above is one of the MGA Airbag Deployment bays at the Troy, Michigan facility.

Durability:  The durability aspects of complete interiors and components is critical to the overall performance of the vehicle.  The key to durability testing is to be able to simulate many years of use or exposure in a compressed time frame within the lab. Durability can be evaluated numerous ways – effects of extreme temperatures, mechanical/electrical life cycling of components, fatigue or vibration exposure, etc.  For each of these and other critical issues, MGA has commissioned a vast tool box of facilities.  This includes 35 walk-in or larger environmental chambers, 13 Multi-Axis Simulation Tables, 12 large Electro-Dynamic shakers, 12 Seat Ingress-Egress robots, 12 Seat Jounce-Squirm systems, and many other custom systems.  Much of the expanded capacity that has been brought on-line recently has been to meet the challenges faced by developing new and innovative features against the backdrop of a shortened overall vehicle development time-line.

Smaller components such as the vent shown above are sometimes difficult to package into the instrument panel.

 

One trend evident in interiors is the move away from hard plastic components to softer touch surfaces like the passenger compartment shown above.

 

MGA offers full service Materials Testing laboratories at 2 of its facilities.

Repeated use or life cycle of components is critical to evaluate longer term functionality issues.

Quality:  In regard to a consumer’s perception of a particular vehicle, the quality aspects of it’s complete interior, including components, is often most important.  For example, hard trim is usually considered inferior to softer touch surfaces.  Another example is how well all of the interior components integrate and fit together at the joints and intersections.  One other critical quality issue is cabin noise.  If squeaks or rattles are evident, this will severely limit a consumers preference for the vehicle.  For many of these and other issues, MGA has brought on-line numerous, custom laboratory solutions.  MGA currently offers two state-of-the-art dedicated Material’s testing facilities.  The capabilities of these labs are well suited to evaluate new material performance in regards to characteristics such as strength, impact, colouring, fade, spill resistance, etc.  In regards to squeak and rattle, MGA has a facility designed specifically to evaluate interior component noise issues.  This facility features a semi-anechoic chamber with an ultra quiet ED shaker inside.  Sensitive microphones, combined with state-of-the-art noise evaluation software, results in engineers being able to evaluate sounds both subjectively and objectively with collected data.

The functional aspects of a component are important. Above, the efforts to deploy a cup-holder are evaluated.

MGA offers state-of-the-art solutions to evaluate Squeak and Rattle issues. Shown above is the sound chamber and ultra-quiet shaker used to evaluate interior components both subjectively and objectively.

Overall, this comprehensive suite of interior evaluation solutions provides the industry with a method to quickly and easily evaluate new concepts at an early stage of development as well as validate production intent components.  If you are interested in learning more about these capabilities, please contact Daniel Merritt (dan.merritt@mgaresearch.com) at (248) 577-5001.

How is the Automotive Industry Reducing Vehicle Weight?

Car buyers in the US prefer larger vehicles compared to other regions of the world.  The preference for larger vehicles poses significant challenges to engineers in meeting upcoming fuel economy standards, which require a fleet average of 54.5 miles per gallon by 2025.   In addition to reducing weight, engineers are developing more efficient engines, utilizing electric/hybrid propulsion systems, and optimizing other factors such as wind resistance, wheel efficiency, etc. to increase fuel economy. In regard to vehicle weight savings, there are a number of alternatives currently being developed.

Among the options under consideration include high strength steel, the use of aluminium in key areas, high strength plastics for certain applications, advanced composites, and alternative glazing.  A number of factors go into what is the best choice; safety, performance, quality, durability, cost, etc.  One of the more critical aspects for certain parts of an automobile is when alternative approaches are considered for structures or components that are designed to manage impact energy.  For example, the front sections of vehicles are designed to effectively absorb the energy of a frontal crash.  Steel historically is very well-suited to absorb crash energy.  If the steel is replaced with another type of material or lighter weight/higher strength steel, engineers must be certain that the crash energy management is not compromised.  This is just one example of the many problems that vehicle designers face when looking at the weight savings/energy management issue.

For the interior of a vehicle, engineers are looking at advanced plastic solutions for certain components which are critical from a safety standpoint.  For example, an automotive seat back, which plays a vital role in certain crash modes, is typically made from steel.  Work is underway to utilize newly develiped plastic solutions for an entire single-piece, seat back component.

MGA’s Energy Management Evaluation Tool Box

Shown above is a new drop tower developed specifically for large mass impact tests.

Over the years, MGA’s team has developed a comprehensive suite of evaluation tools that have helped the industry evaluate new weight reduction approaches.  These systems include specialized quasi-static load devices, component-level dynamic impact devices, large mass horizontal impact systems, vertical drop towers, and customized full-vehicle crash applications. All of these solutions have been the result of MGA’s strong collaborative approach between our laboratory personnel and our equipment team.

Each of these systems has been developed for specific applications.  For example, a new high-mass drop tower was commissioned to specifically evaluate advanced front structural sections which are designed to crumple in a manner which absorbs the energy during a frontal crash.  The ability to evaluate these systems on a component-level is very helpful to the development process from the standpoint of cost savings, the ability to correlate with FEA, and the option to carefully look at the performance of the part with high speed video, data, etc.

Shown above is a new system developed by MGA which can be used to dynamically evaluate the energy absorption properties of advanced materials, structures, etc.

Another state-of-the-art system recently brought on-line was a smaller scale, high-speed sled system.  This system was originally developed by MGA to evaluate smaller components over a wider frequency range than traditional sleds.  The system has custom pulse capabilities utilizing a metering pin approach.  Concerning energy management, this sled will be used to evaluate components dynamically which require a higher mass (1200 lbs) combined with higher impact velocities.  The system works very well for this application.

The two latest additions described here are part of a full range of dynamic impact capabilities.  This includes the traditional dynamic impactor series utilized primarily for interior impact applications, the new smaller scale sled, various drop towers, and full vehicle crash capabilities.  This array of capabilities results in the ability to combine virtually any size mass with any velocity to produce a specified energy level. 

Overall, this comprehensive suite of solutions provides the industry with a method to quickly and easily evaluate new concepts at an early stage of development.  If you are interested in learning more about these capabilities, please contact Kevin Oliverio (Kevin.Oliverio@mgaresearch.com) at (248) 577-5001.

MGA began providing dynamic test services to the Aerospace industry 20 years ago, and today continues to expand its services to meet our customer’s needs.  Recently a new test facility was established in the Northern Virginia area complete with an accelerator sled system.  This new facility allows MGA to provide greater flexibility to meet our customer’s test program timeframes through operating two sled facilities capable of achieving the requirements for 14CFR23.562, 14CFR25.562, 14CFR27.562, 14CFR29.562, and TSO C127a for aircraft seats (the other one in Burlington, WI).  Currently, MGA is assisting seat manufacturers with side facing divans that now require the use of the ES2re side impact Anthropomorphic Test Device.  MGA’s expertise in automotive safety provides several years of experience with this new tool to the Aerospace industry.

Casually named our “HIC on a Stick”, MGA’s Head Delethalization testing device has been online in our South Carolina laboratory for 3 years.  In the Aerospace industry, dynamic sled testing simulating a crash event is typically employed to evaluate the head impact properties of the back of an airliner seat.  In certain cases, a component-level test is used to evaluate the head impact protection properties in a commercial airliner environment.  Delethalization testing provides the aerospace industry with the opportunity to test their designs utilizing a simpler, component-level approach.  The test is used to demonstrate compliance with FAA Regulation 25.785. The regulation simply states that a passenger making proper use of the equipment provided shall not receive serious injury as a result of an emergency landing. This test simulates what an individual may encounter in the event of an emergency landing and impacting the rear of the seat back, wall, or other items immediately in front of them.

The system includes an instrumented Hybrid II dummy head attached to an inverted pendulum test device. Data acquisition includes 3 channels of acceleration data to provide the necessary means to study the impact in detail. The primary result of the test is the Head Injury Criterion (or HIC), which is calculated from the resultant head acceleration data.  Test speeds can be finely tuned to achieve the desired specification for a successful test. High speed video is recorded, and video analysis provides an in-depth visualization of the impact to examine the energy management and damage to the tested component.  MGA is currently in the process of upgrading our system to help provide the best service to our customers.

MGA has been providing customers with Buoyancy testing for many years.  Just recently, we have added services to allow our customers to evaluate TSO-C72c requirements.  The purpose of TSO-C72c is to specify performance standards for individual flotation devices for the aerospace industry. In accordance with the standard, the preconditioned flotation devices must be capable of providing not less than 14 pounds of buoyancy in +85ºC fresh water for at least 8 hours. These flotation devices may include seat cushions, head rests, arm rests, pillows or any similar piece of aircraft equipment. As foam density varies, the buoyancy forces will change.

 Custom life cycle testing is used to test the durability of various aircraft components.  MGA’s hybrid pneumatic and power life-cycle controllers are used to mimic the physical moments of mechanical systems in order to fatigue a part for its full useful life. As cycling continues, the item is monitored for any sort of malfunctions including squeaks and rattles, abnormal displacements, increased efforts, etc.

Coming soon to our South Carolina laboratory is a comprehensive new facility to handle fire related testing.  Three new test systems are being installed to meet the needs of a growing aerospace cluster in the Carolina region.  A number of specific test systems are included in the facility.  A Heat Release test system is used to measure the rate at which heat energy is released by a material when burned.  The National Bureau of Standards (NBS) Smoke Chamber is used to measure smoke characteristics of components, as well as measure the toxicity of the smoke being produced.  The Oil Burner system evaluates the resistance to burning of components exposed to a high-intensity flame.  It can also be used to evaluate the burn through characteristics of materials.  MGA’s expertise, combined with the facility, is well suited to conduct normal industry testing specified by the Aircraft Materials Fire Test Handbook, ASTM E906, ASTM E662, ASTM F814, BSS 7238, BSS 7303, AITM 2.0007, FAR 25.853, as well as many other standard specifications.  In addition to these new systems coming online shortly, MGA performs horizontal and vertical flammability testing according to FAR 25.853.

MGA has supported the aerospace industry for many years with various test methods and meeting many standards.  With the addition of the Boeing assembly plant in Charleston, the Carolina region has seen an increase of suppliers.  This, along with stricter guidelines continuously being implemented has made MGA ever more prevalent in helping the industry reach its goals.

While da Vinci was the first to dream up flight, he will certainly not be the last imagining the next great breakthrough for the aerospace industry.  MGA is always on the outlook for new services and upgrading our existing products to ensure that we are on the cutting edge. For more information on MGA’s aerospace testing capabilities, please contact Mark Nowakowski (mark.nowakowski@mgaresearch.com) at (864) 848-3088.

 The grand opening of the Facilities & Equipment Center was held on October 26, 2011 and was a huge success. Over 75 MGA customers and industry leaders were in attendance for the event.  While attendees were arriving, everyone was encouraged to browse the equipment displays and socialize with representatives from the diverse array of companies in attendance. On display were several pieces of equipment including a FMVSS 207/210 seat anchorage system, a FMVSS 202a head restraint system, and jounce and squirm machine. In addition, associates from several MGA facilities were onsite to answer equipment and testing related questions.  Networking and socializing continued throughout a catered luncheon which provided people with an opportunity to sit, relax, and eat before the presentations began.

The luncheon was followed by a short introduction by Lauren Viera of MGA-MI welcoming everyone to the grand opening. 

The first presentation was given by Mike Miller who is the V.P. of MGA and Director of the MGA-MI Operations. Miller’s presentation focused on MGA’s equipment development philosophy.  He discussed the foundation behind our development process and how this strategy supports our World-Wide customer base.  For many in attendance, this presentation was an eye opener.  It turns out that even though many customers have visited our facilities, some were unaware that we design and build this equipment. The presentation also highlighted the internal development process prior to releasing our equipment for purchase.  Mike stated that MGA products are never released to the public until we are satisfied with their durability, performance, quality, and safety in our own labs.

Following Miller’s presentation, DJ Whiteside, the Dynamic Team Leader at MGA-MI, gave a presentation on the new FMVSS 226 Ejection Mitigation standard and test procedure.  The presentation defined the purpose of the regulation and provided a breakdown of the technical requirements and the developmental history of the standard.  Many in the audience were surprised to learn that MGA was an integral part of developing equipment that helped NHTSA bring this standard to life.  DJ also explained how the FMVSS 226 impactor system functions and how the design meets the critical requirements in the regulation.

After the presentation, a live impact test demonstration was performed in order to showcase the latest versions of the MGA FMVSS 226 impactor, mobile propulsion system, and 3-axis adjustable load frame.  The demonstration walked the audience through the test procedure and gave them chance to see a live test in action.  High-speed video and acceleration data was collected to show the severity of the test and why ejection mitigation is becoming such an important concern for manufacturers.

Mike Janovicz from MGA-WI discussed MGA’s approach to product innovation.  His presentation began with a simple question: “How many of you in the audience know that MGA is involved with battery testing?”  Of those in attendance, only two raised their hands and are current battery testing customers of MGA. Many of the audience members were surprised to know that MGA has been testing batteries for almost 30 years! Mike’s presentation also highlighted several innovative battery testing products which are currently in development.  Several of these systems were on display at the grand opening. These products, along with several others, will be upcoming additions to our annual Facilities & Equipment Catalog once they meet our internal expectations. 

After the presentations, the floor was opened up for a Q&A session. Of the many questions asked during the event, one of the more popular was “How soon can we take delivery of this equipment?”  The MGA Facilities & Equipment Center is designed to not only showcase new equipment; it also provides an excellent venue for onsite training and a place to assemble an inventory of key equipment components found in our catalog.  With essential hardware and equipment in inventory at the equipment center, MGA will be able to meet most customer requests for equipment within very short lead times.

 The day ended with a walking tour highlighting the Facilities & Equipment Center’s training classrooms and office suites along with the MGA-MI hydraulic durability, simulation, static, and impact labs.  The day’s activities gave the participants an opportunity to view MGA testing equipment, and talk with industry colleagues.   Participants left with a better understanding of the rate that the development of innovative equipment plays in our mission to respond to customer needs.  Participants also left with a copy of the MGA Facilities and Equipment Catalogue.  You may also obtain a complimentary copy of the catalogue by contacting Lauren Viera (lauren.viera@mgaresearch.com) or call 248-577-5001 x 301.

MGA has been performing BSR testing for many years, and this experience has helped us develop a keen ear for determining what sounds might be considered a problem, and what sounds would not.  However there are times, more often than not, when subjective evaluations are not enough to make a judgment.  With these situations a “quiet room”, with calibrated microphones specifically built to record the most sensitive sounds, is used.  The data measured from this system can be presented in various units such as decibels (dB) or sones.  The ability to compare exact values as opposed to listening to differences with the human ear is incredibly helpful with comparison studies and development.

If you are interested in additional information or a quote for BSR or vibration testing, please contact Andrew Gould by email at (andrew.gould@mgaresearch.com) or by phone at (248) 925-8092.