Vehicle body panel deflection testing device and method

Abstract

The invention provides a vehicle body panel flexure testing device and a vehicle body panel flexure testing method. A test device and method may include a frame, a force applicator, and a force sensor. The frame includes a first handle, a second handle, and a body. The handle extends from a perimeter of the body and is configured to be grasped by a hand of an operator. The body includes a housing portion and a support portion. The housing portion is configured to hold a display device such that a display screen of the display device is visible from a rear side of the main body. The support portion is disposed on a front side of the main body. The force applicator extends forward away from the support portion. The force sensor is mounted to the support portion and couples the force applicator to the support portion. The force sensor is configured to detect a push force and / or a pull force applied to a location on an object via the force applicator.

Description

Technical Field

[0001] The present disclosure relates to a test apparatus and method for determining the flexure of a vehicle body panel. Background Art

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] Vehicle body panels are typically tested to determine their elasticity in response to flexure or deformation caused by push and / or pull loads. Typically, more than one location on the panel is tested, and a vehicle includes many such panels. Each test typically requires a fair amount of setup, including positioning a dial indicator on a complex frame and securing the frame to the ground or the vehicle, and then operating a manual force gauge. This setup is typically repeated for each location tested on the vehicle and can be very time-consuming and may be prone to variation between each setup.

[0004] The teachings of the present disclosure address these and other problems with vehicle body panel flexure testing. Summary of the Invention

[0005] This section provides a general overview of the present disclosure and is not a full disclosure of its entire scope or all of its features.

[0006] In one form, the present disclosure provides a test apparatus including a frame, a force applicator, and a force sensor. The frame includes a first handle, a second handle, and a body. The first handle and the second handle extend from a perimeter of the body and are configured to be grasped by opposite hands of an operator. The body includes a housing portion and a support portion. The housing portion is configured to hold a display device such that a display screen of the display device is visible from a rear side of the body. The support portion is disposed on a front side of the body. The force applicator extends away from the support portion in a forward direction. The force sensor is mounted to the support portion and couples the force applicator to the support portion. The force sensor is configured to detect a push force and / or a pull force applied to a position on an object via the force applicator.

[0007] According to various forms of the test device of the above paragraphs that can be incorporated individually or in any combination thereof: The test device further includes a data acquisition module mounted to the support portion, the data acquisition module being in electrical communication with the force sensor to receive a signal from the force sensor indicating the thrust and / or pull force; The test device further includes at least one non-contact sensor, the at least one non-contact sensor being supported by the body and configured to measure the distance to the position on the object; The at least one non-contact sensor includes a stereo camera; The body defines an aperture that opens through the front side and the rear side of the body and is aligned with the housing portion and is configured to provide a line of sight between the non-contact sensor on the rear side of the display device and the position on the object; The support portion includes a reinforcing member longitudinally extending in a lateral direction perpendicular to the forward direction, the reinforcing member having a total length in the lateral direction, a total width in the forward direction, and a total thickness in a direction perpendicular to the lateral direction and the forward direction, wherein the total length is greater than the total width and the total width is greater than the total thickness; The force sensor is mounted to the reinforcing member; The test device further includes a data acquisition module mounted to the reinforcing member, the data acquisition module being in electrical communication with the force sensor to receive a signal from the force sensor indicating the thrust and / or pull force; The housing portion includes four corner brackets, each corner bracket being configured to engage both sides of a corresponding corner of the display device; The first handle is located on the left side of the body, and the second handle is located on the right side of the body; The weight of the frame is less than or equal to 2 kg.

[0008] In another form, the present disclosure provides a test device that includes a frame, a force applicator, a force sensor, and a data acquisition module. The frame includes a first handle, a second handle, and a body. The first handle and the second handle extend from the perimeter of the body and are configured to be grasped by the opposite hands of an operator. The body includes a housing portion and a support portion. The housing portion is configured to hold a display device such that the display screen of the display device is visible from the rear side of the body. The support portion is disposed on the front side of the body. The force applicator extends away from the support portion in a forward direction. The force sensor is mounted to the support portion and couples the force applicator to the support portion. The force sensor is configured to detect a thrust and / or a pull force applied to a position on an object via the force applicator. The data acquisition module is mounted to the support portion. The data acquisition module is in electrical communication with the force sensor to receive a signal from the force sensor indicating the thrust and / or the pull force.

[0009] According to various forms of the test device of the above paragraphs that can be incorporated individually or in any combination thereof: The test device further includes at least one non-contact sensor supported by the body and configured to measure the distance to the position on the object; the support portion includes a reinforcing member longitudinally extending in a lateral direction perpendicular to the forward direction, the reinforcing member having a total length in the lateral direction, a total width in the forward direction, and a total thickness in a direction perpendicular to the lateral direction and the forward direction, wherein the total length is greater than the total width and the total width is greater than the total thickness, and wherein the force sensor is mounted to the reinforcing member.

[0010] In yet another form, the present disclosure provides a method of testing a vehicle panel, the method including supporting a force applicator, a force sensor, a data acquisition module, at least one non-contact sensor, and a display device on a frame, wherein the frame includes a body including a housing portion and a support portion, wherein the display device is mounted to the housing portion such that a display screen of the display device is visible from a rear side of the body, wherein the support portion is disposed on a front side of the body, and wherein the force applicator is mounted to the support portion and extends from the support portion in a forward direction. The method includes positioning the frame such that the force applicator contacts the vehicle panel. The method includes moving the frame relative to the vehicle panel until the vehicle panel deforms or until a force detected by the force sensor reaches a predetermined threshold force. The method includes measuring an amount of deflection of the vehicle panel using the non-contact sensor during the step of moving the frame relative to the vehicle panel.

[0011] According to various forms of the method of the above paragraphs that can be incorporated individually or in any combination thereof: The step of moving the frame relative to the vehicle panel includes pushing the frame toward the vehicle panel using the force applicator to press the vehicle panel; the step of moving the frame relative to the vehicle panel includes pulling the frame away from the vehicle panel using the force applicator to pull the vehicle panel; the at least one non-contact sensor includes a stereo camera; the stereo camera communicates with the display device, and the display device is configured to display at least one of the following: an image from the stereo camera, a video from the stereo camera, and distance data based on an input from the stereo camera; the method further includes placing coordinate markers on the vehicle panel, and wherein the at least one non-contact sensor is configured to detect the coordinate markers.

[0012] Based on the description provided herein, additional applicable fields will become apparent. It should be understood that the description and specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] To better understand the present disclosure, various forms of the present disclosure will now be described by way of example with reference to the accompanying drawings, in which:

[0014] Figure 1 is an exploded perspective view of a test device according to the present disclosure;

[0015] Figure 2 is Figure 1 a perspective view of a part of the test device of

[0016] Figure 3 is Figure 1 a perspective view of the test device of

[0017] Figure 4 is Figure 1 a rear view of the test device of

[0018] Figure 5 is a perspective view of a vehicle including a panel for testing with a test device according to the present disclosure and having Figure 1 to be used;

[0019] Figure 6 is Figure 5 a plan view of a part of the panel of

[0020] Figure 7 is Figure 5 a cross-sectional view of the panel of Figure 1 showing the test device according to the present disclosure in a first position;

[0021] Figure 8 is Figure 5 a cross-sectional view of the panel of Figure 1 showing the test device according to the present disclosure in a second position; and

[0022] Figure 9 is Figure 5 a cross-sectional view of the panel of Figure 1 showing the test device according to the present disclosure in a third position.

[0023] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0024] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0025] Refer to Figure 1, a test device 100 is shown. The test device 100 includes a frame 110, a force applicator 114, and a force sensor 118. The test device 100 may further include a data acquisition module 122 mounted to the frame 110. The test device 100 further includes at least one non-contact sensor 126 mounted to the frame 110. The test device 100 may optionally further include a display device 128. The test device 100 may optionally further include a microphone 130.

[0026] Reference Figure 1 and Figure 2 , the frame 110 includes a first handle 132, a second handle 134, and a body 138. The first handle 132 and the second handle 134 extend from the periphery of the body 138 and are configured to be grasped by opposite hands of an operator (a person; not shown). The first handle 132 extends from the left side of the body 138 and is thus also referred to herein as the left handle 132. The second handle 134 extends from the right side of the body 138 and is thus also referred to herein as the right handle 134.

[0027] The body 138 includes a housing portion 142 and a support portion 146. The housing portion 142 is configured to hold the display device 128 in a space 148 defined by the housing portion 142. The housing portion 142 opens through the rear side of the body 138 such that the display screen 150 ( Figure 4 ) of the display device 128 is visible from the rear of the body 138. The housing portion 142 may be configured to allow the display device 128 to be removably mounted to the housing portion 142. In the provided example, the housing portion 142 is configured to allow the display device 128 to be inserted into the space 148 from the rear of the body 138.

[0028] In the provided example, the housing portion 142 includes four corner brackets (i.e., an upper left corner bracket 154a, a lower left corner bracket 154b, an upper right corner bracket 154c, and a lower right corner bracket 154d, which are collectively referred to herein as corner brackets 154) and at least one front surface 158. Once positioned in the space 148, the at least one front surface 158 inhibits further forward movement of the display device 128. In the provided example, a separate front surface 158 is located at each corner bracket 154, but other configurations may be used. Each corner bracket 154 is configured to wrap around a corresponding corner of the display device 128 to contact both sides of the periphery of the display device 128 to position the display device 128 in the left, right, up, and down directions of the frame 110.. The display device 128 may be fixed to the housing portion 142 in the space 148 in any suitable manner.

[0029] In one form, the resilient pads 162 are disposed in one or more of the corner brackets 154 and are sized and positioned such that pressing the display device 128 into the space 148 deforms the resilient pads 162. The resilient pads 162 can then hold the display device 128 in the space 148 by friction and / or pressure from their resiliency (such as by biasing the display device 128 towards other corner brackets 154 and / or at least one front surface 158 for example). In another form, a strip (not shown specifically) can secure the display device 128 to the housing portion 142. In yet another form, fasteners (not shown) can secure the display device 128 to the housing portion 142.

[0030] In the example provided, the housing portion 142 also includes a top transverse member 166 and a bottom transverse member 170. The top transverse member 166 spans in the transverse direction (i.e., from left to right) to connect the top portions of the upper left corner bracket 154a to the top portions of the upper right corner bracket 154c. The bottom transverse member 170 spans in the transverse direction to connect the bottom portions of the lower left corner bracket 154b to the bottom portions of the lower right corner bracket 154d.

[0031] In the example provided, the first handle 132 is directly coupled to the upper left corner bracket 154a and the lower left corner bracket 154b and is spaced apart from the body 138 therebetween. In the example provided, the second handle 134 is attached to the upper right corner bracket 154c and the lower right corner bracket 154d and is spaced apart from the body 138 therebetween.

[0032] The support portion 146 is located in front of the top transverse member 166 and the bottom transverse member 170 and is positioned vertically (i.e., in the up and down direction) between the top transverse member 166 and the bottom transverse member 170. The support portion 146 is coupled to the corner brackets 154 and spans between the corner brackets.

[0033] In the provided example, the support portion 146 includes a base member 174 and a reinforcement member 178. The base member 174 can be a substantially flat plate such that the length of the base member 174 in the lateral direction (i.e., left - right direction) is greater than the height in the vertical direction (i.e., up - down direction), and has a depth (i.e., in the front - back direction) that is less than the length or height. In one form, when viewed from the front or the back, the base member 174 has a substantially rectangular shape. The base member 174 is coupled to the lower front portion of the upper left corner bracket 154a and the lower front portion of the upper right corner bracket 154c, and spans therebetween in the lateral direction. The base member 174 is coupled to the upper front portion of the lower left corner bracket 154b and the upper front portion of the lower right corner bracket 154d, and spans therebetween in the lateral direction. In other words, the base member 174 can be a substantially flat plate having a planar front surface 182 and a planar back surface 186 that are perpendicular to the front - back direction. The planar back surface 186 can optionally include reinforcing ribs 188 that are configured to reinforce (i.e., strengthen) the base member 174 in the front - back direction. In the provided example, the reinforcing ribs 188 extend longitudinally in the lateral direction (left - right) of the frame 110 to overlap with the upper left corner bracket 154a and the lower left corner bracket 154b on the left side in the lateral direction, and overlap with the upper right corner bracket 154c and the lower right corner bracket 154d on the right side in the lateral direction.

[0034] The reinforcement member 178 is coupled to the base member 174 and provides structural reinforcement to the base member 174 to reinforce (i.e., strengthen) the base member 174 in the front - back direction. In the provided example, the reinforcement member 178 is a substantially flat plate such that the length of the reinforcement member 178 in the lateral direction (i.e., left - right direction) is greater than the depth (i.e., front - back direction), and its height (i.e., up - down direction) is less than the depth. In one form, when viewed from above or below, the reinforcement member 178 can have a substantially rectangular shape, and when viewed from the left or right, the reinforcement member can have a substantially rectangular cross - section. In other words, the reinforcement member 178 can be a substantially flat plate having a planar top surface 190 and a planar bottom surface 194 that are perpendicular to the up - down direction. The rear portion of the reinforcement member 178 is coupled to the front surface 182, and the reinforcement member 178 extends forward therefrom.

[0035] The reinforcement member 178 can span most of the length of the base member 174 laterally (i.e., left - right). In the provided example, the reinforcement member 178 spans from left to right to overlap with the upper left corner bracket 154a and the lower left corner bracket 154b on the left side in the lateral direction, and overlap with the upper right corner bracket 154c and the lower right corner bracket 154d on the right side in the lateral direction.

[0036] In the provided example, the frame 110 may also optionally include a lower reinforcement member 200. In the provided example, the lower reinforcement member 200 is a substantially flat beam such that the length of the lower support member 200 in the lateral direction (i.e., left - right direction) is greater than the depth (i.e., front - back direction). In one form, the lower reinforcement member 200 has a height equal to the depth (i.e., up - down direction). In another form, the height of the lower reinforcement member 200 is less than the depth. In another form, the height of the lower reinforcement member 200 may be greater than the depth. In one form, when viewed from above or below, the lower reinforcement member 200 may have a substantially rectangular shape, and when viewed from the left or right, the reinforcement member may have a substantially rectangular or square cross - section. In other words, the lower reinforcement member 200 may be a substantially flat plate or beam having a planar top surface 214 perpendicular to the up - down direction. The rear portion of the lower reinforcement member 200 is coupled to the front surface 182 and extends forward therefrom.

[0037] The lower support member 200 may extend laterally (i.e., left - right) across most of the length of the base member 174. In one form, the lower reinforcement member 200 may extend across the same length as the reinforcement member 178, but other configurations may be used. In the provided example, the lower reinforcement member 200 extends from left to right to overlap with the upper left corner bracket 154a and the lower left corner bracket 154b in the lateral direction on the left side, and overlap with the upper right corner bracket 154c and the lower right corner bracket 154d in the lateral direction on the right side.

[0038] The frame 110 may be formed of any suitable material, such as polymers, composite materials, metals, plastics. In one form, the entire frame 110 is formed of the same material and is 3D printed (i.e., additive manufacturing) or molded. The frame 110 may be integrally formed as a single piece, or may be formed as multiple pieces joined together using any suitable method (e.g., welding, fasteners, adhesives). In another form, the reinforcement member 178 and / or the base member 174 may be a different material from the rest of the frame 110.

[0039] The force sensor 118 is mounted to the support portion 146 and is centered in the lateral direction. In the provided example, the force sensor 118 contacts and is attached to the planar bottom surface 194 of the reinforcement member 178 (e.g., via an adhesive, fasteners, or a bracket, not shown). The force sensor 118 may also contact the front surface 182 of the base member 174. In the provided example, the force sensor 118 is vertically located between the reinforcement member 178 and the lower reinforcement member 200.

[0040] The data acquisition module 122 is mounted to the support portion 146. In the provided example, the data acquisition module 122 is centered in the lateral direction, but other configurations may be used. In the provided example, the data acquisition module 122 contacts and is attached to the planar top surface 190 of the reinforcing member 178. In the provided example, the data acquisition module 122 is fixed to the planar top surface 190 via an optional support bracket 210 of the support portion 146. Alternatively or additionally, the data acquisition module 122 may be attached via another suitable attachment means (e.g., via an adhesive, a fastener).

[0041] The planar top surface 190 may optionally define an upper recess 198, and the bottom of the data acquisition module 122 may be received in the upper recess. The support bracket 210 may extend from the base member 174 and / or the reinforcing member 178 and contact the top surface of the data acquisition module 122. In the provided example, the support bracket 210 also contacts the left and right surfaces of the data acquisition module 122.

[0042] In an alternative configuration not specifically shown, the planar bottom surface 194 may define a recess in which the force sensor 118 may be received. In yet another configuration, the force sensor 118 and the data acquisition module 122 may be swapped such that the force sensor 118 is mounted to the planar top surface 190 and the data acquisition module 122 is mounted to the planar bottom surface 194.

[0043] The force applicator 114 is attached to the force sensor 118 and extends forward therefrom. The force applicator 114 is configured to engage a surface 220 ( Figures 5 to 7 ) and transmit a force to the force sensor 118 along the force axis 218 (corresponding to the front-rear direction) in the axial direction.

[0044] In the provided example, the force applicator 114 includes a shaft 222 and may optionally include an end piece 226. The shaft 222 is a rigid material. The proximal end of the shaft 222 is coupled to the force sensor 118, and the shaft 222 extends forward therefrom to the distal end. The end piece 226 is coupled to the distal end of the shaft 222. The end piece 226 has a forward surface 230 that is configured to contact the surface 220 ( Figures 5 to 7 ) to which the force is to be applied. In an alternative form not specifically shown, the end piece 226 may be excluded, and the end of the shaft 222 directly contacts the surface 220 ( Figures 5 to 7 ) to which the force is to be applied. In another alternative not specifically shown, the end piece 226 may be separate from the shaft 222 and connected (e.g., by magnetism, an adhesive, or suction) to the surface 220 ( Figures 5 to 7 ), and the end of the shaft 222 may contact the end piece 226 to apply a force to the surface 220 ( Figures 5 to 7)。In one form, the end member 226 can be a circular disk-shaped body centered on the shaft 222, but other shapes can be used. In one form, the forward surface 230 is a flat surface perpendicular to the force axis 218, but other configurations can be used, such as a convex surface or a concave surface.

[0045] The end member 226 can be formed of any suitable material, including but not limited to plastics, polymers, metals, composite materials. In one form, the forward surface 230 of the end member 226 is defined by a pad (not specifically shown) attached to the remainder of the end member 226. Such a pad can be configured to inhibit the surface 220 to which the scraping force will be applied ( Figures 5 to 7 ), such as a layer of fabric, rubber or elastic material, and / or configured to conform to the surface 220 (e.g., if the surface 220 is non-planar). In one form, the end member 226 can include a magnet configured to be attracted to the surface 220 to which the force will be applied ( Figures 5 to 7 ), such that a pulling force can be applied thereto. In another form, the end member 226 can include a suction cup that defines the forward surface 230 such that a pulling force can be applied to the surface 220 to which the force will be applied ( Figures 5 to 7 ).

[0046] The force sensor 118 can be any suitable type of sensor configured to detect a pushing force and / or a pulling force applied thereto via the force applicator 114, such as, for example, a force transducer.

[0047] Reference Figure 3 , the data acquisition module 122 communicates with the force sensor 118, such as via a wired connection or a wireless connection. The data acquisition module 122 is configured to receive signals from the force sensor 118 indicating the force applied along the force axis 218. The data acquisition module 122 can convert those signals into data. In one form, the data acquisition module 122 can also communicate (e.g., wired or wireless) with an external device 234, such as a computer, a tablet, a phone, or a network device, to, for example, transmit data thereto in real time. Additionally or alternatively, the data acquisition module 122 can optionally communicate with the display device 128. In another form, the data acquisition module 122 can store data to be transmitted to the external device 234 at a later time.

[0048] The at least one non-contact sensor 126 can be any suitable type of one or more non-contact sensors configured to detect the surface 220 without the sensor contacting the surface 220 when a force is applied to the surface 220 via the force applicator 114 ( Figure 5) amount of deflection. In one form, the non-contact sensor 126 includes a stereo camera (also known as a stereo camera or 3D camera) having two or more lenses spaced a predetermined distance apart and configured to detect the three-dimensional positioning of the imaged features. In another form, other sensors may be used, such as, for example, lasers (e.g., lidar), radar, microwave, or sonar. The non-contact sensor 126 is mounted to the frame 110 and is positioned facing the forward direction to detect the deflection of the surface 220 when the surface 220 is pressed or pulled via the force applicator 114.

[0049] In the provided example, the non-contact sensor 126 is laterally positioned between the left corner brackets (i.e., the upper left corner bracket 154a, the lower left corner bracket 154b) and the right corner brackets (i.e., the upper right corner bracket 154c, the lower right corner bracket 154d). In the provided example, the non-contact sensor 126 is positioned below the base member 174 and above the bottom lateral member 170. Thus, the non-contact sensor is visible from the front of the frame 110 through the lower aperture 246 defined by the lower left corner bracket 154b, the lower right corner bracket 154d, the base member 174, and the bottom lateral member 170. The upper left corner bracket 154a, the upper right corner bracket 154c, the base member 174, and the top lateral member 166 may also define an upper aperture 250 that opens through the front of the frame 110. In an alternative form (not shown), the non-contact sensor 126 may be located above the base member 174 and below the top lateral member 166 such that the non-contact sensor 126 is visible from the front of the frame 110 through the upper aperture 250.

[0050] The non-contact sensor 126 communicates with the device and is configured to send a signal to the device indicating the deflection of the surface 220. In one form, the device is the data acquisition module 122, and the non-contact sensor 126 sends these signals to the data acquisition module 122. In this form, the data acquisition module 122 may analyze and / or interpret those signals and send the corresponding signals and / or data to an external device 234. In the provided example, the non-contact sensor 126 is attached to or otherwise disposed on the forward surface of the display device 128, and the display device 128 can receive signals from the non-contact sensor 126.

[0051] Reference Figure 4 , the display device 128 may be configured to display on its display screen 150 an image and / or data representing the deflection of the surface 220 ( Figure 5 ) and the display device 128 may also transmit the deflection data to the external device 234 via a wired or wireless connection (Figure 3 )。In one form, the display device 128 transfers data directly to the external device 234. In another form, the display device 128 can transfer data to the data acquisition module 122( Figure 1 and Figure 3 ), and the data acquisition module can transfer the data to the external device 234. The display screen 150 can optionally be a touch screen.

[0052] Referring Figure 5 , the surface 220 can be prepared by placing the positioning features 510 on the surface 220 near the location 514 that will be contacted and flexed by the end member 226( Figure 1 ). These positioning features 510 can be calibration or coordinate markers. In the example provided, these features 510 are attachments (e.g., stickers, decals, magnets) that are removably applied to the surface 220 and act as coordinate markers. In another form, the feature 510 can be a permanent feature of the surface 220. The location 514 that will be contacted and flexed by the end member 226 can also be marked, and in the example provided is marked with a plus sign, but any other marking can be used, such as but not limited to "x", bull's-eye, dot, or circle.

[0053] In the example provided, the surface 220 is an exterior body panel of the vehicle 518, but other types of surfaces on or off the vehicle can be tested. In the example provided, the surface 220 is a fender or front quarter panel of the vehicle 518, but other body panels (e.g., door panel, hood) can be tested.

[0054] Referring Figure 6 , some examples of the feature 510 are shown in more detail. The feature 510 can include a shape and / or color that are of known dimensions and are placed within the field of view of the sensor 126( Figure 1 ) when the end member 226( Figure 1 ) engages the surface 220. The sensor 126 is configured to detect the feature 510, and the display device 128( Figure 1 ) and / or the external device 234 can be configured to use the feature 510 to determine the position of the test device 100( Figure 1 ) relative to the surface 220, and accurately determine the flexure of the surface 220 when it is pushed or pulled via the force applicator 114.

[0055] Referring Figure 7 , the test device 100 is schematically shown in a stationary state in contact with the surface 220 before any force is applied. In this state, an operator (not shown) holds the first handle 132( Figure 1 ) and the second handle 134( Figure 1)Position the test device 100 such that the end piece 226 contacts the surface 220 and the force axis 218 is perpendicular to the surface 220.

[0056] Reference Figure 8 , a user (not shown) may move the test device 100 forward from the Figure 7 position shown to flex the surface 220 in the forward direction until a predetermined force value is achieved. Then, the user may release the force (i.e., return the test device 100 in the backward direction) and remove the test device 100 from the surface 220.

[0057] Reference Figure 9 , a user (not shown) may move the test device 100 backward from the Figure 7 position shown to flex the surface 220 in the backward direction until a predetermined force value is achieved. To create this tensile force, the end piece 226 may be coupled to the surface 220 via, for example, an adhesive, a suction cup, a magnet, a fastener, or other means. Then, the user may release the force (i.e., return the test device 100 in the forward direction) and remove the test device 100 from the surface 220.

[0058] When applying a thrust ( Figure 8 ) or a tensile force ( Figure 9 ), the display device 128 ( Figure 3 ) may be configured to display an indication of the force being applied and / or display or audibly indicate when the predetermined force has been achieved. When flexing the surface 220 forward ( Figure 8 [[ID=2F]]) or backward ( Figure 9 ), the non-contact sensor 126 detects the flexure of the surface 220 from its original position ( Figure 7 ) during the application of the force (i.e., Figure 7 the distance 710 shown, or Figure 8 the distance 810 shown). The non-contact sensor 126 ( Figure 3 ) may detect the maximum flexure, i.e., at the predetermined force value. The non-contact sensor 126 may also detect any remaining flexure after the test device 100 is removed from the surface 220.

[0059] The predetermined force may be any suitable value and may be based on the material properties of the surface 220, the position on the vehicle 518 ( Figure 5 ), the geometry of the surface 220, the thickness of the surface 220, the type of panel that the surface 220 forms, and the expected real-world forces that the surface 220 may encounter, among other factors. In one form, the predetermined force may be greater than or equal to 500 Newtons. In another form, the predetermined force may be less than 500 Newtons.

[0060] The flexure data may be displayed on the display screen 150 ( Figure 4)upwardly and / or transmitted to an external device 234( Figure 3 ).

[0061] In one form, the external device 234( Figure 3 ) can analyze the flexure data and determine whether it falls within a predetermined acceptable tolerance. If the flexure data is outside the acceptable tolerance, the external device 234 can output an indication that the panel (i.e., surface 220) has not passed the test. The indication can be a visual indication, an audible indication, a flag in a database (e.g., a maintenance ticket), which can trigger further actions (e.g., repair of surface 220, further inspection, change in the manufacturing process of surface 220).

[0062] The microphone 130( Figure 3 ) can optionally record sound (i.e., audio data) during the flexure and release process. This audio data can also be transmitted to the external device 234( Figure 3 ). The external device 234 can analyze the audio data and compare it with known audio data (e.g., stored on the external device 234 or retrieved from another device). If the recorded audio data matches known unacceptable audio data (within a predetermined tolerance), the external device 234 can output an indication that the panel (i.e., surface 220) has not passed the test. The indication can be a visual indication, an audible indication, a flag in a database (e.g., a maintenance ticket), which can trigger further actions (e.g., repair of surface 220, further inspection, change in the manufacturing process of surface 220). In other words, if the panel makes an unacceptable sound (e.g., a pinging sound) during flexure or release, the surface 220 can be marked as not passing the test.

[0063] Thus, the test device 100 and test method of the present disclosure allow for quick and accurate testing of many locations on a vehicle without the need for complex test fixture setups.

[0064] Unless expressly indicated otherwise herein, all numerical values indicating mechanical / thermal properties, percentage compositions, dimensions, and / or tolerances or other characteristics should be understood to be modified by the word "about" or "approximately" when describing the scope of the present disclosure. This modification is desired for various reasons, including: industrial practice; material, manufacturing, and assembly tolerances; and test capabilities.

[0065] As used herein, the phrase "at least one of A, B, and C" should be construed to represent the logic (A or B or C) using non-exclusive logic "or" and should not be construed to mean "at least one of A, at least one of B, and at least one of C".

[0066] In the present application, the terms "controller" and / or "module" may refer to, be part of, or include the following: application specific integrated circuit (ASIC); digital, analog, or mixed analog / digital discrete circuits; digital, analog, or mixed analog / digital integrated circuits; combinational logic circuits; field programmable gate array (FPGA); processor circuits (shared, dedicated, or grouped) that execute code; memory circuits (shared, dedicated, or grouped) that store code executed by the processor circuits; other suitable hardware components that provide the described functionality (e.g., operational amplifier circuit integrators as part of a heat flux data module); or a combination of some or all of the above, such as in a system-on-chip.

[0067] The term memory is a subset of the term computer-readable medium. As used herein, the term computer-readable medium does not cover transitory electrical or electromagnetic signals propagated through a medium (such as on a carrier wave); thus, the term computer-readable medium can be considered tangible and non-transitory. Non-limiting examples of non-transitory tangible computer-readable media are non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or mask read-only circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), magnetic storage media (such as analog or digital magnetic tape or hard disk drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0068] The devices and methods described in the present application may be implemented in part or in whole by a special purpose computer created by configuring a general purpose computer to execute one or more specific functions embodied in a computer program. Functional blocks, flowchart components, and other elements described above serve as software specifications that can be translated into a computer program by routine work of a technician or programmer.

[0069] The description of the present disclosure is merely exemplary in nature, and thus, variations that do not depart from the essence of the present disclosure are intended to be within the scope of the present disclosure. Such variations should not be regarded as departing from the spirit and scope of the present disclosure.

[0070] According to an embodiment, the first handle is located on the left side of the main body, and the second handle is located on the right side of the main body.

[0071] According to an embodiment, the weight of the frame is less than or equal to 2 kg.

[0072] According to the present invention, there is provided a testing device having: a frame including a first handle, a second handle and a body, the first handle and the second handle extending from a perimeter of the body and configured to be grasped by opposite hands of an operator, wherein the body includes a housing portion and a support portion, the housing portion being configured to hold a display device such that a display screen of the display device is visible from a rear side of the body, wherein the support portion is disposed on a front side of the body; a force applicator extending away from the support portion in a forward direction; a force sensor mounted to the support portion and coupling the force applicator to the support portion, the force sensor being configured to detect a thrust force and / or a pulling force applied to a position on an object via the force applicator; and a data acquisition module mounted to the support portion and in electrical communication with the force sensor to receive a signal from the force sensor indicating the thrust force and / or the pulling force.

[0073] According to an embodiment, the invention is further characterized by at least one non-contact sensor supported by the body and configured to measure a distance to the position on the object.

[0074] According to an embodiment, the support portion includes a reinforcing member longitudinally extending in a lateral direction perpendicular to the forward direction, the reinforcing member having a total length in the lateral direction, a total width in the forward direction, and a total thickness in a direction perpendicular to the lateral direction and the forward direction, wherein the total length is greater than the total width and the total width is greater than the total thickness, and wherein the force sensor is mounted to the reinforcing member.

Claims

1. A testing device, comprising: A frame including a first handle, a second handle, and a main body, the first handle and the second handle extending from a periphery of the main body and configured to be grasped by opposite hands of an operator, wherein the main body includes a housing portion and a support portion, the housing portion being configured to hold a display device such that a display screen of the display device is visible from a rear side of the main body, and wherein the support portion is disposed on a front side of the main body; A force applicator extending away from the support portion in a forward direction; And A force sensor mounted to the support portion and coupling the force applicator to the support portion, the force sensor being configured to detect a pushing force and / or a pulling force applied to a position on an object via the force applicator.

2. The testing device according to claim 1, further comprising a data acquisition module mounted to the support portion, the data acquisition module being in electrical communication with the force sensor to receive a signal indicating the pushing force and / or the pulling force from the force sensor.

3. The testing device according to claim 1, wherein the main body defines an aperture that opens through the front side and the rear side of the main body and is aligned with the housing portion and configured to provide a line of sight between a non-contact sensor on a rear side of the display device and the position on the object.

4. The testing device according to claim 1, wherein the support portion includes a reinforcing member longitudinally extending in a lateral direction perpendicular to the forward direction, the reinforcing member having a total length in the lateral direction, a total width in the forward direction, and a total thickness in a direction perpendicular to the lateral direction and the forward direction, wherein the total length is greater than the total width and the total width is greater than the total thickness.

5. The testing device according to claim 4, wherein the force sensor is mounted to the reinforcing member.

6. The testing device according to claim 5, further comprising a data acquisition module mounted to the reinforcing member, the data acquisition module being in electrical communication with the force sensor to receive a signal indicating the pushing force and / or the pulling force from the force sensor.

7. The testing device according to claim 1, wherein the housing portion includes four corner brackets, each corner bracket being configured to engage both sides of a corresponding corner of the display device.

8. The testing device according to any one of claims 1 to 7, further comprising at least one non-contact sensor supported by the main body and configured to measure a distance to the position on the object.

9. The testing device according to claim 8, wherein the at least one non-contact sensor includes a stereo camera.

10. A method of testing a vehicle panel, the method comprising: A force applicator, a force sensor, a data acquisition module, at least one non-contact sensor, and a display device are supported on a frame, wherein the frame includes a main body, the main body includes a housing portion and a support portion, wherein the display device is mounted to the housing portion such that a display screen of the display device is visible from a rear side of the main body, wherein the support portion is disposed on a front side of the main body, and wherein the force applicator is mounted to the support portion and extends in a forward direction from the support portion; Position the frame such that the force applicator contacts the vehicle panel; Move the frame relative to the vehicle panel until the vehicle panel deforms or until a force detected by the force sensor reaches a predetermined threshold force; And Measure a deflection amount of the vehicle panel using the non-contact sensor during the step of moving the frame relative to the vehicle panel.

11. The method according to claim 10, wherein the at least one non-contact sensor includes a stereo camera.

12. The method according to claim 11, wherein the stereo camera communicates with the display device, and the display device is configured to display at least one of the following: an image from the stereo camera, a video from the stereo camera, and distance data based on an input from the stereo camera.

13. The method according to claim 10, further comprising placing coordinate markers on the vehicle panel, wherein the at least one non-contact sensor is configured to detect the coordinate markers.

14. The method according to any one of claims 10 to 13, wherein the step of moving the frame relative to the vehicle panel includes pushing the frame toward the vehicle panel using the force applicator to press the vehicle panel.

15. The method according to any one of claims 10 to 13, wherein the step of moving the frame relative to the vehicle panel includes pulling the frame away from the vehicle panel using the force applicator to pull the vehicle panel.

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