Pitfalls of Accelerated Validation Test on Automotive Components

Starting the production of automotive components on schedule is a big challenge faced by tier 1 suppliers. Both design validation (DV, on prototypes) and product validation (PV, on serial parts) heavily rely on sign-off testing activities. Indeed, the execution of an inappropriate validation test often results in the over testing of the component, thus increasing the probability of incurring into unrepresentative failure modes. The consequent corrective actions would significantly increase manufacturers’ R&D and operational costs, resulting in over-designed products. On the other hand, the outcome of unsuitable validation tests might as well be the under testing of the component, with potentially severe consequences on the durability once the product is in-service. This paper gathers some of the most common pitfalls encountered during the development and implementation of accelerated validation tests. The avoidance of such pitfalls will give a better chance of successfully launching new products without incurring in unexpected costs and difficulties. The proposed practical examples deal in particular with components that are responsible for the thermal management of the vehicle.