DEVELOPMENT Test Centre
A world-class test facility, a centre of
excellence, a cutting edge engineering
partner for the global vehicle industry.
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GKN Structures’ test centre offers vehicle
designers and manufacturers a unique facility for
testing a wide range of automotive products from
small components to whole vehicle assessment.
It is equipped not only to carry out advanced
test regimes but also the experienced in-house
engineering team can offer informed feedback to
assist in developing original design concepts for
the production environment.
The GKN Structures’ test capability extends from
simple, single actuator component tests through
to full vehicle multi axis using test track Road Load
Data (RLD). The aim is to replicate vehicle life in
laboratory conditions.
Test evaluation
Test methodology is developed to ensure that
all simulation (CAE) correlates to both the
laboratory test and the track. At the same time,
vehicle life (sign off) and component product life
(to destruction) tests are undertaken in order
to ensure an in depth understanding of each
structure’s durability.
Vehicle testing and testing of structures and
systems – both automotive and non-automotive –
are offered to existing and new customers as part
of our problem solving capability.
Comprehensive testing facility
Standards Compliance
Test centre operations conform to the rigorous
requirements of the TS16949 automotive standard.
The centre is certified to:
• ISO9001 • ISO14001 • OHSAS 18001
Confidentiality
The test centre operates as a ‘closed environment’
engineering service, so when you access our
equipment and expertise your products and data
are managed in strictest confidence.
The comprehensive suite of test and analysis
equipment is complemented by the ability to
design and construct bespoke systems to meet a
range of technical requirements.
Test Capabilities
Centre Development
Sophisticated data and software installations
allow for extensive road and real life simulations as
well as comprehensive analysis and reporting.
As well as serving a number of national and
international customers, the test centre is used
directly by GKN Structures in developing and
proving the systems it designs and manufactures
for many leading names in the automotive,
defence and mass transit markets.
This close link to manufacturing provides test
centre customers with access to a scale and
breadth of expertise not normally found in standalone test centres. It is GKN’s ability to combine
the expertise of testing and analysis specialists
with that of experienced design and production
engineers that allows it to offer a markedly
wider range of intelligent engineering advice
and input.
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This enables GKN Structures not simply to
report on component or vehicle performance
but to advise on ‘Design For Manufacture’ (DFM)
enhancements.
GKN Structures has the capability to test units from
complete cars and smaller commercial vehicles to
small components such as wheels and hubs.
Test capabilities include:
• Single axis cyclic
• Static stiffness/strength/durability
• Monotonic and cyclic material categorisation
• Multi-axis cyclic
• Full vehicle/full axle
• Full vehicle testing on 200 tonne seismic mass
• Remote Parameter Control (RPC)
• Road simulation
• Road Load Data (RLD) acquisition
• RLD analysis
• Component strain data analysis
• Access to test track real life conditions
327 test rig
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State-of-the-art testing capabilities
MTS 329 Road Simulator
Multi Axis Axle Rig
This multi-axial spindle-coupled simulator is
installed on a 200 tonne self-levelling seismic
mass. It is capable of replicating challenging
road surfaces, manoeuvres and events.
The MTS 329 combines advanced durability
testing with the highest levels of laboratory
accuracy when assessing quarter, half and full
vehicle structures. It can be used for testing to
achieve design verification, Computer Aided
Engineering (CAE) correlation, physical material
and part data, conformance of production and
vehicle correlation.
Specifically designed and built in-house for
the static and dynamic testing of tubular deadbeam type axles. This rig can perform a variety of
functions from simple static loading and cyclic
testing to running RLD via RPC software through
three degrees of freedom at each axle end.
100kN Capacity Load Frame
Using Multi-Purpose Test (MPT) software, this
single channel load frame provides a versatile test
and calibration facility for small components and a
variety of materials. Its main function is to provide
monotonic and cyclic material data used in CAE
and development.
Chassis Torsion Rig
This test rig uses an actuator driving a pivoting
beam to impart torque loading to chassis frames.
Measurements of chassis stiffness degradation
over a large number of test cycles are collated to
provide product validation information.
329 test rig
Multi Axis Sub-frame Rig
A purpose built rig used to impart vectored loading
into front and rear sub-frame assemblies using
longitudinal and lateral actuators. This rig was
designed to accommodate OEM engineering
specifications.
1000kN Servo Controlled Press
An adapted proportionally controlled press used
for high compressive static and low cycle dynamic
loading of a variety of components.
High Torque Testing
A half vehicle test facility offering four degrees of
freedom at each of two corners, capable of running
RLD via RPC software. This rig is predominantly
used for testing front and rear sub-frame
assemblies for a variety of motor manufacturers.
It may also be used to test small vehicles, for
example motorcycles.
A single channel rig utilising a linear actuator
driving a lever arm that may be used to test
driveline components such as drive shafts, CVJs,
prop shafts and other power transfer devices in
torsion up to 30kNm.
An industry standard laboratory Vickers hardness
test machine. Used for spot checks on materials
and components. It may also be used for weld
assessment, hardenability measurements and as
an aid to metallurgical analysis.
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Specifically designed and built in-house as a
companion rig to the 327, this two channel rig is
used to test front and rear sub-frame assemblies,
using braking and acceleration loading at the
wheel centre or at the tyre contact patch.
This loading may be correlated with RLD testing on
the 327 to provide a simpler and quicker test.
MTS 327 Road Simulator
Hardness Testing
GKN Test Centre
Brake/Acceleration Rig
1000kN servo controlled press
Low Torque Testing
A single channel rig utilising a rotary actuator that
may be used to test driveline components such
as drive shafts, CVJs, prop shafts and other power
transfer devices in torsion up to 6kNm.
Vehicle chassis under test
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Purpose-designed test equipment
The modular design of GKN
Test Centre equipment enables
adaptation to meet a broad
range of bespoke requirements.
Our specialists can design and
build systems to meet clients’
specific needs whatever the
requirement.
These have included
applications from steering
racks and spring seats to strut
reaction, control arm and engine
roll restrictor tests.
GKN Structures’ broad
based skills and expertise in
automotive, defence and mass
transit markets enable it to
offer customers in all sectors a
sophisticated and professional
design, development and
testing capability, supported
by total commitment to lean
manufacturing excellence.
Heritage, expertise and confidence
When you choose GKN you
are working with a renowned
engineering group.
GKN Structures is a world leader
in the design, development
and manufacture of pressed
steel structural assemblies
and chassis systems for the
automotive market.
GKN plc is a global engineering
business serving the
automotive, aerospace and
land systems markets. It has
operations in more than 30
countries and around 40,000
employees in subsidiaries and
joint ventures. GKN plc
is listed on the London Stock
Exchange (LSE: GKN).
GKN Structures is certified to
ISO14001 and is committed to
protecting the environment in
which we live and work.
It is part of the GKN Land
Systems Division of GKN plc.
GKN Land Systems is a global
organisation with over 5,000
employees worldwide. It is one
of four divisions within GKN plc,
the others being Aerospace,
Driveline and Powder
Metallurgy.
The ability to understand
complex engineering and testing
requirements and convert
these to specific dedicated test
regimes means our test centre
team can deliver real value to
the customer.
From concept design to physical tests
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Getting in contact
To discuss you test requirements call, email or write to us at:
GKN Development Test Centre
PO Box 83
Hadley Castle Works
Telford TF1 6TE
Tel: + 44 (0) 1952 428053
Email: technicalenquiries.structures@gkn.com
www.gknstructures.com
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