Duration And Reliability Laboratories

DURATION AND RELIABILITY LABORATORIES

MM PWT develops physical components for (gasoline and diesel) engine control systems and for (conventional and dual clutch) transmissions control systems.  During the development phase, both full compliance with functional requirements and with the requested quality and reliability objectives must be verified and demonstrated. The components validation activities of Magneti Marelli Powertrain are carried out by applying specific test plans, conducted on representative samples of the various development phases of the products.

The validation process of Magneti Marelli Powertrain applies to three different product/process development phases:

·         Initial prototypes à verification of design solutions à Design Validation 1  (*)

• Final prototypes (final project + representative process of the series) à Design Validation 2 (**)
• Production samples  à Product Validation  (**)

(*) specific or special tests are defined from time to time in DV1 depending on the test objective 

(**) In DV2 and PV test mode, the quantities of samples to be tested and the test sequence are defined in accordance with the provisions and requirements of customer specifications

Main contents of DV2 and PV plans:

Long-term operation test (up to 2000 hours) under extreme environmental and operational conditions (maximum performances, extreme temperatures, etc.)

• “Statistical” test sample (more than 5 pieces per test)
• Mechanical stresses related to the actual application (sine or random vibrations combined with temperature, thermal shocks, humidity, etc.)
• Resistance test to environmental conditions (dust, water, saline fog, engine fluids, etc.)

Main laboratory equipment:

• No.  9 vibrating benches combined with thermal cell (two of which enabled to also work with gasoline in the circuits with pressure of up to 200 bar)
• No. 22  climate chambers (-60/+180 °C; Relative Humidity check)
• No.  5 thermal shock chambers (-60/+180 °C, transition time <10 seconds)
• No.  2 saline fog chambers
• No.  1 chamber for water tightness test (testable protection levels: IPX5/IPX6/IPX6K/IP9K)
• No.  1 Camber for dust test
• No. 1 X-ray machine