Testing : Key Life Testing

What is Key Life Testing?

Key Life Testing (KLT) was introduced in the early 1990’s by Ford Motor Company.  It is a system or sub-system based test designed to demonstrate failure modes within the expected useful life e.g. 10 years/150,000 miles.

The testing is based on product specific data and correlates closely to the actual range of usage conditions.

Why do Key Life Testing?

The concept was driven by:

• The need to reduce expensive prototype vehicle costs
• Shift of responsibility from component to system suppliers
• A desire to improve early problem recognition within the Product Development life cycle
• A need to improve system reliability and quality
• Bringing system/sub-system sign-off into the controlled environment of the Test Lab
• Incorporates non-wear out failure modes such as ‘Squeak & Rattle’ which have a critical effect on customer satisfaction

Key Life Testing at MIRA

MIRA is one of the most experienced providers of Key Life Testing.  Using special purpose rigs we are able to subject systems to combined factors:

• Environmental conditions

  • Temperature
  • Solar load
  • Humidity
  • Pressure
  • Air-flow

• Vibration

  • Road Load Data or sine

• Customer Usage Profile

  • Functional operation
  • Physical loads
  • Electrical loads
  • Repetitions of input

Typical Systems

Interior systems

• Instrument Panels, Centre Consoles, Door Trim, Climate Control

MIRA's Climate Control System Key Life Test Rig

MIRA's Climate Control System Key Life Test Rig enables a fascia and partial body buck with the complete climate control system installed to be operated whilst being subjected to simulated real world operation.  The refrigerant circuit is charged as it would be on a vehicle but the compressor is driven by an electric motor.  Mounted in an environmental chamber and upon a vibration table the system can be subjected to changing environmental conditions and simulated road vibrations.  The heat exchangers and system blowers are operated using the relevant fluids, flow rates, pressures and temperatures.

Electronics

• Radios, Cassettes, Single & Multi CD Players, MP3 Players, Rear Seat Entertainment

In addition to vibration this instrument cluster is being exercised electronically

Powertrain Systems

• Electronic Throttles, Air Fuel Charge Assemblies

Benefits of Key Life Testing

One of the major benefits of Key Life Testing is that it can identify issues and failures that might otherwise be missed until the product is in service leading to:

• Reduced warranty costs
• Improved product quality
• Improved customer satisfaction
• Greater confidence in the product

Because it facilitates durability sign-off  of a whole system it can also provide:

• Increased confidentiality
• Reduced overall test costs
• More effective use of programme time
• Repeatability

Complementary Services and Facilities

Key Life Testing is part of MIRA's comprehensive range of product development services.  Further details of which can be found using the following links:

Durability Consultancy

Durability Testing

Testing - Environmental Main

MIRA - Testing Facilities - Durability and Fatigue
Extensive Proving Ground test circuits

Corrosion Chamber

Dimensional Measurement Equipment
Road Load Data Acquisition & Analysis Equipment
Virtual Test Rigs and Virtual Proving Ground
FEA Modeling& Simulation Systems