Products are often subjected to great fluctuations in temperature and humidity. To ensure that they can withstand these challenges, we simulate extreme conditions.
In temperature tests, HELLA products are exposed to temperature fluctuations from -40 °C to 100 °C in climatic chambers which have a volume of 600 to 1,000 liters. In addition, condensation and defogging tests are carried out up to max. 95% air humidity and up to 80 degrees Celsius. In the “shock chamber”, the temperatures change within seconds (intervals of max. 6 seconds) between -40 °C and +100 °C. The heat and cold tests last up to 48 hours.
Splash water (e.g. from vehicles ahead) poses one of the most frequently encountered environmental conditions for our products.
This is why we conduct real-world simulation tests in this regard as well by using universal spray booths. The booths are equipped with devices for rain, splash water, water jets and water mist. In the process, the test products are tested for leak tightness by undergoing the intermittent and splash water test at a pressure of up to 5 bar, and the sprayed water test at a pressure of up to 10 bar.
During high-pressure cleaning, vehicles and vehicle parts can be subjected to extremely high pressures. Pressure levels can reach 120 bar. By comparison: In a normal household, water pressure is typically 0.5 bar to 5 bar.
In a test facility that utilizes extreme water pressure and a water temperature of +85 °Celsius, cleaning in a car wash or with a high-pressure cleaner is reliably simulated.
Bad roads with pot holes, different surfaces such as gravel, pebbles and country roads: Vibrations and jolts are an everyday occurrence for many products.
The wideband random vibration test is used to test the mechanical endurance strength in the vertical and horizontal axes. Here, the frequency range extends from 10 to 1000 Hertz. Defined temperatures of -40 to +80 degrees Celsius also simulate real-world aging processes of plastic. All products are tested for function for up to 24 hours. Furthermore, a mechanical shock test is conducted during this procedure. This simulates the behavior in the event of jolts (products in packaging during shipping) with an acceleration of between 300 and 500 m/s².
Special rally profiles are tested for selected products such as auxiliary headlamps.
Dust frequently poses a negative environmental condition. This also applies to work carried out in a field or at a construction site, for example.
This is why we thoroughly test our products for their dust-sealing properties. During this quality test, unfired Portland cement is used as a test medium. The test is optionally performed in sample function operation, and with overpressure or underpressure exposure of the device under test. The test is assessed by measuring the photometric value before and after the test. Only those products that meet all requirements receive internal quality approval.
Many HELLA products are also subjected to submersion and pressure-seal tests.
An immersion pipe can be submerged to a depth of 1 meter in water. Another test system can reach a depth of 6 meters. Also, an overpressure test up to 1.6 bar is conducted in an immersion pool. All tests are carried out according to HELLA standards and in line with legal requirements.
We also implement our high quality standards for electronics products.
To this end, ongoing tests are carried out starting in the development phase and continue throughout the production phase. Included among the tests for our electronic products are tests for spray and salt water resistance, dust resistance and high-pressure cleaner suitability. Thermal tests for resistance to cold and hot temperatures also play a key role. Comprehensive physical simulations such as drop and vibration tests as well as cold tests and endurance testing verify the operative functionality of the respective product under conditions involving a load.