Testing equipment for bumpers

The front and rear bumpers in modern vehicles contain a large number of safety, comfort and assistance systems. In addition to classic lighting, various combinations of sensors, actuators and other electronic parts are also used there.

With an assembly and test station developed and manufactured by the ITgroup you can secure your quality standards and meet all verification and documentation duties toward your end customers. Our development work is based on providing test equipment and methods that are specially tailored to your circumstances and requirements. We offer various bumper handling options ranging from manual, semi-automatic through to completely automatic solutions. The components can be checked with respect to presence, function and other necessary criteria.

Go directly to our innovative system examples.


Bumper test - Simple test recording
Bumper test - PDC 173
Bumper test - PDC 197

Customize iT - modular test equipment for bumpers

We solve your test task. Fast. Reliable. Extendable. Inexpensive.

The modular system allows the intelligent combination of our proven modules to create customised overall systems. The high-quality construction allows subsequent expansion and sustainable reuse in follow-up projects. More than 250 test systems for bumpers delivered to our customers’ sites across the globe speak for themselves.

Thanks to our many years of experience in developing test equipment for system suppliers of the sensors installed in bumpers, we have in-depth know-how of electronic components. Our team of specialists uses this expertise and in-depth technical know-how to create reliable solutions to meet your various requirements. Starting with the connection to your production flow system through optical controls and damage-free part handling and also photo documentation.

Test scopes

  • E-check and variant control
  • Visual inspection
    • Installation, variants, colour
    • Photo documentation
  • Parking assistance (ultrasound sensors)
    • Distance sensor (PDC/APS)
    • Park Control Assistant (PLA)
  • Lights
    • (Fog) headlight - halogen, xenon, LED
    • Actuator cornering light
    • Registration plate lights
    • Rear spotlights
    • Rear fog lamp
    • Indicator
    • Sidemarker
  • Radar
    • Short range radar NBR
    • Mid Range Radar MRR
    • Long Range Radar LRR
    • Adaptive Cruise Control ACC
    • Forward Collision Warning FCW
    • Lane change assistant SWA
    • Blind Spot Monitoring BSM, BSM+, iBSM
  • LTE/Bluetooth Antenna
  • Cool air regulation
  • Headlight cleaning system (SRA)
  • Cameras
    • Front camera
    • Reversing camera
    • Surround view camera SVC
    • Area View Camera AVC
    • Top View Camera TVC
    • Night Vision Camera NVC
  • Various sensors
    • Pedestrian protection sensor, hose (FGS/P-SAT)
    • Acceleration sensors (G-SAT)
    • Hands-free access (HFA), Virtual pedal (VIP)
    • Garage door opener (UGDO)
    • Laser scanner
    • Temperature sensor
    • LIDAR
  • Variant features
    • Emblem, radiator grille, trims
    • Painting
    • Differentiation cable harness/cable set
    • Licence plate holder
  • Assembly scopes
    • Attachment clips
    • Holding clips
    • Screws
    • Spring nut
    • Expanding rivets, rivets

Customize iT

Module 1: Contacting

The key point of the test is the connector or socket of the cable harness that is designed by the manufacturer for a very limited number of connection cycles.

For this reason, the necessary counterpart, our contacting adapter, is of central importance for this application to guarantee a reliable and sustainable test.

» Show module

Module 2: Fixture

Customers have various wishes with respect to fixtures. Some customers want the test equipment integrated directly into the assembly device, other customers require a separate test station. A completely automated and independent test line is highly suitable for volume models thank to the extremely low cycle times. The range of models we supply has proven itself in a wide variety of production lines for many years.

» Show module

Module 3: Test equipment

The amount of electronics in the bumper is continuously increasing thanks to stricter safety standards and the emergence of autonomous driving.
Although the parts required for this have all undergone 100% testing before they are sent to the TIER 1 suppliers and OEMs, sensitive parts can become faulty during installation or when painted. These impairments can lead to cost-intensive recall actions especially with respect to safety-relevant parts. For this reason, retesting of the components to eliminate faults and for customer documentation is extremely important.
A simple installation and presence check is often insufficient. The manufacturers of the individual components stipulate precisely how components need to be tested. Our modular test equipment will help you by covering all necessary test scenarios.

» Show module

Module 4: Software

Our software is the central switch point of your test station. It ensures that the test processes function correctly and that the measured values are processed. It guides the operator through the test process and visualises the test results. All settings and processes are menu-controlled and can be configured freely. This means that the software for controlling test processes, and handling through to robot control can be extended in a modular fashion.

» Show module


  • 2020
    Release of the modular kit in the bumper area
  • 2019
    250th bumper test equipment
  • 2018
    200th bumper test equipment
  • 2014
    First bumper test cell with robot (PDC-134)
  • 2014
    150th bumper test equipment
  • 2011
    100th bumper test equipment
  • 2008
    First automated bumper test line (PDC-61)
  • 2008
    50th bumper test equipment
  • 2002
    10th bumper test equipment
  • 1998
    First bumper test equipment