Bailey Unicorn Alu-Tech caravan completes marathon endurance test

Sunday, June 17, 2012  | Admin


A Bailey Unicorn Alu-Tech caravan has successfully completed a
marathon endurance test on the AL-KO test track in Germany.

Testing was undertaken to assess the suitability of the vehicle
for Australian road conditions which are perceived to be tougher than those in
Europe. Bailey Alu-Tech caravans and motorhomes proto types have already been
subjected to a comprehensive product validation programme including a series of
accelerated life tests at the internationally renowned Millbrook Proving
Ground. However it was felt that additional testing over and above that carried
out on UK products would be required in order to satisfy the demands of the
Australian market.

The test vehicle was a Unicorn Cabrera built to Australian
specification featuring an AL-KO chassis, axle and running gear and the Bailey
Alu-Tech bodyshell. In terms of construction the only significant difference is
that that the caravan it is covered with a GRP outer skin, as featured on our
Orion caravan and Approach SE motorhome ranges, rather than the aluminium skin
currently used on domestic Unicorn models.

All Bailey caravans and motorhomes ranges now are built using
the state of the art Alu-Tech body shell construction system. The result of the
most comprehensive product design programme ever undertaken Alu-tech leisure
vehicles are more robust, more durable and yet lighter than those manufactured
using conventional methods to provide a completely new level of product performance.

This claim was put to the test at the AL-KO test track in
Markbronn Germany - a circuit renowned for its severity and is known in the
industry as the 'caravan graveyard'. The track itself is one kilometre in
length and the features a number of different road surfaces to thoroughly test
vehicle endurance.


The pothole test is designed to prove that the vehicle will meet
the challenges of real-life usage. Potholes are believed to cause up to 1 in 5
mechanical failures of all types of vehicles on UK roads at a cost estimated at
£320 million per year. The potholes vary in size, shape and are up to a maximum
depth of about 78mm. The test simulates repeated forceful impacts placing large
stresses on every part of the vehicle and proves the quality of the design and
engineering of the chassis and body structure of the caravan.

Belgian Pave

This test is designed to prove the quality of the vehicle build
when used on road surfaces more closely linked to general driving conditions
including undulating and uneven road conditions. It ensures that the axle,
suspension and the joint between chassis and bodywork are capable of
withstanding the continual vibration from driving on these types of road

Rumble Strip

The final test is over a roughly undulating surface similar to a
rumble strip. Here the road surface is a series of peaks and hollows at
different distances, widths and heights. This test applies stresses to the
chassis and running gear through continuous vibration which places greater pressure
on the different components of the chassis and tests the integrity of the
joints between chassis members and the bodywork of the caravan.

Test Conditions

After every twenty lap series on the track the caravan was
returned to the workshop to examine all major chassis joints and inspect both
the exterior and interior of the caravan for any changes in condition. Checks
to ensure all bolt torques are maintained were also carried out on a daily
basis with all information recorded in the final test report.

In total the Unicorn
Cabrera successfully completed 1,000 laps of the track which, based on AL-KO
calculations, simulates a performance of 100,000 kms of usage. This is
the first time a UK-made caravan has been tested to this level on this
punishing circuit and is further proof of the superior performance and
durability of a vehicle built using the combination of an AL-KO chassis and an
Alu-Tech bodyshell.