A vehicle, that sets standards
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Pilot project: Bertrandt provides quality engineer with process responsibility (PV-QI)
In February 1999, Bertrandt Munich was given an opportunity to play a positive, pioneering role in driveline project management when we were asked to provide a quality engineer with process responsibility (PV-QI) to liaise between the model line team and the driveline development area (EA) and be responsible for this area’s entire external communication. Among the aims was to ensure process transparency at all times between the technical departments and the model line staff.
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The engineer was also responsible for departmental quality issues, such as implementing and continuous monitoring of a quality control list and checking the synchro checkpoints in the project plan against the relevant reports. In addition, the PV-QI was responsible for change request management.
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Component testing
In 1999 we took over certain aspects of ensuring the function and service life of the front seat models. On behalf of BMW and the seat suppliers, development was supported for over two years in our laboratories and on site at BMW. Our test rigs are identical reproductions of BMW's original machinery, which ensures comparability of the test results at all times. We helped to make substantial improvements in the mechanical seat back width adjustment of the multifunctional seat, which permits optimum adjustment of the side sections of the seat back to the occupant’s body. The proposal to develop an optimised linkage between the upholstered sections and the adjusting segments complied with stringent BMW function and service life requirements and was implemented into series production.
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Endurance testing of the lock systems
We carried out three endurance tests in 2001. The project called for functional testing of the outside door handle by means of a slamming test. An acoustically decoupled lock striker must be just as capable of withstanding such a stress test as the optional keyless entry lock system equipment . All load cycles were carried out under controlled climatic conditions. In addition, we measured lateral door rigidity and door drop.
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Operating strength tests, airbag system verification and passenger identification
The start of the first endurance test coincided with operational stability tests on the front axle. Using the pendulum test rig, we verified the axle’s various design statuses by simulating a kerb impact. With the help of the high-speed camera, intrusion paths and the forces acting on the axles were registered and evaluated. The driver’s and front passenger’s knee airbags were tested in the conventional way. Test runs were first carried out using parts made from prototype tools, later from production tools. This was followed by an environmental simulation which indicated the resistance to ageing. For the head airbag systems, we carried out the test verification programme on behalf of a supplier. We were particularly closely involved in the final development phase of the passenger airbag. At BMW’s premises, our engineers also helped on the development of the occupant identification systems. The BMW 7 Series is widely regarded as a highly innovative car and is a pioneer in the area of occupant identification.
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