Crash Test Facility Design

Harald Zellmer, Crash Test Facilities, New Delhi, December 2010

Crash Test Facility Design Harald Zellmer Autoliv B.V. & Co. KG, Elmshorn, Germany

International Course on Transportation Planning and Safety New Delhi December 2010

Crash Test Facility Design Introduction Crash test modes Requirements to crash test facilities Crash test facility Autoliv Elmshorn Examples of crash test facilities

AUTOLIV / Dr. H. Zellmer / New Delhi 2010

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Crash Test Facility Design

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Crash-Methods

Real life

Body-In-White Sled Test

Component Test [ANG-TT/HZ] [´28.08.00] [AKAD03] AUTOLIV / Dr. H. Zellmer / New Delhi 2010

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Legal and customer requirements

Standard Full-Scale-Crash

Costs

Accident Reconstruction




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Full-Scale Crash Test


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USA legal: FMVSS 208

H-III 50% & 5% Dummy

56 km/h concrete barrier (0°- 30°)


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Europe: ECE R-94

56 km/h offset deformable barrier 40% "Offset" 2 Dummys HIII 50%


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Euro NCAP http://www.euroncap.com/


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Japan-NCAP

Frontal 55 km/h

Frontal 64 km/h

Side 55 km/h AUTOLIV / Dr. H. Zellmer / New Delhi 2010

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Test Modes Frontal Impact Sensor Tests

[ANG-TT/HZ] [´28.08.00] [AKAD03] AUTOLIV / Dr. H. Zellmer / New Delhi 2010

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Test Modes Side Impact FMVSS 214

Side Pole- Car

ECE R 95

Car to Car


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Car Pole


Body-in-White Test


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Body-in-White Test

Simulation of Full-Size Crash Tests in stiff body shell

Cost reduced alternative for

Tuning of restraint system Out-of-Position airbag deployment Performance of components in the car interior as seats, instrument panels ..


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Sled Test ECE R-16


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ECE-R 16 Test Set up

Stiff seat and B-pillar TNO 10 - manekin Collision speed: 50 km/h ± 1 km/h Stopping distance: 40 cm ± 5 cm Acceleration time-history in defined corridor Belt anchorage position as in the car


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ECE-R 16: Acceleration Time History


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ECE-R 16: Requirements

No damage to the belt system

Buckle opening force < 60 N

Pelvis forward displacement: 80 mm - 200 mm with pretensioner: 40 mm - 200 mm Chest forward displacement: 100 mm - 300 mm with pretensioner: 50 mm - 300 mm


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Comparison Test Facilities Acceleration

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Pulse very repeatable Dummy positioning very exact Price is very high Only on-board cameras possible Dummy end position influenced by braking after test

Deceleration

Pulse may vary more Dummy positioning influenced by acceleration phase. Price of test facility is 50% of equivalent acceleration facility Full-Size Crashes can be performed in same test facility

[ANG-TT/HZ] [03.03.98] [AKAD03] AUTOLIV / Dr. H. Zellmer / New Delhi 2010

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Requirements to crash test facilities Propulsion system deceleration sled

• Servo hydraulic motor with energy reservoir • Fly-Wheel • Bungee rope • Electrical motor Propulsion system acceleration sled

• Pneumatic • Servo hydraulic AUTOLIV / Dr. H. Zellmer / New Delhi 2010

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Braking Systems for Deceleration Sleds Bending bar brake PU-Tube brake Hydro-brake


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PU-Tube Brake

Source: Messring.de AUTOLIV / Dr. H. Zellmer / New Delhi 2010

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Bending Bar Brake

Bending Bar Brake consisting of sheet metal brake system with roller guides and height adjustable sheet metal rests on both sides, including all fastening elements, max. stopping force app. 1 MN. Source: Messring.de AUTOLIV / Dr. H. Zellmer / New Delhi 2010

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Hydro-Brake


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Hydro-Brake


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Hydro-Brake


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Requirements to crash test facilities High-speed video cameras (min. 1000 f/s) Lighting system

• Tungsten about 400 kW • HMI Data Acquisition System Dummies Sensors

• Acceleration • Belt force transducers • ..... AUTOLIV / Dr. H. Zellmer / New Delhi 2010

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Crash Test Facility Elmshorn Basic Data

Test Area I Full Size Crash tests Body In White Test Area II Body In White Sled Tests Test Area III Sled Tests

Dimension of Test Facility Area 1200m² Length 70m Width 17m Flywheel Propulsion system

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Crash Test Facility Elmshorn Layout Length 70 m, Width 17 m

Crash Test Facility Elmshorn Test Area I BiW And Fullsize Crash Tests Body-in-White Tests Quick-out Platforms Maximum Mass of BIW 1200 kg Bending Bar Brake System Full Scale Tests Frontal : FMVSS 208 & ECE-R-94 Side : FMVSS 214 and ECE-R-95 Rear : ECE-R-32 and ECE R 34

Track 60 m long, 5 m - 8m wide Mass up to 2500 kg Velocity up to 80 km/h Filmpit (13m long, 2m wide) Lighting System up to 400 kW

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Crash Test Facility Elmshorn Test Area II BIW and Sled Tests BIW Tests Quick-out Platforms Maximum Mass Of BIW 1000 kg Sled Tests - 2 ECE-R-16 Seats - universal fixture system for B-Pillar and seat mounting simulation

Velocity up to 70 km/h Lighting System up to 90 kW Servo-Hydraulic Brake System


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Crash Test Facility Elmshorn Test Area III Sled Tests according to ECE-R 16 Sled with ECE R 16 Seat Hydraulic PU-Tube Braking System Sled Pulse according to ECE-R-16 or AKLV (German WG of Car Manufactures)

Measuring of Dummy Displacement with string potentiometer


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Crash Test Facility Elmshorn Dummies Dummys permanent at Facility 3 Hybrid III 50% 2 Hybrid III 95% Male 2 Hybrid III 5% Female 2 Hybrid II 50% 6 TNO 10 1 BioRID Rev. G 1 Hybrid III 50% with TRID Neck TNO Child Dummies –0 & 9 Month –3, 6 & 10 Years Side Impact Dummies and more Frontal Impact Dummies pooled with AUTOLIV Dachau and available in short term AUTOLIV / Dr. H. Zellmer / New Delhi 2010

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Crash Test Facility Elmshorn Propulsion System


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Flywheel –Manufacturer: Messring –Model Year 1996 –Velocity Tolerance ± 0,5 km/h –Maximum Acceleration 0,5 g –Automatic Control by PLC and PC


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Crash Test Facility Elmshorn Data Acquisition On-board Transient Recorder −Type: Messring NA 33 −Resolution 16 bit −4 individual Units −192 Analogue-Channels −24 Digital-Channels −Sampling-Rate up to 100 kHz −Programmable Amplifiers and Filters −Digital Filter according to SAE J211(95)


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Crash Test Facility Elmshorn Visualisation 12 HS-Cameras On-board or Off-board

– 6 Kodak ROC HS-Video 1000 f/s – 2 Kodak HG-TX HS-Video 1000 f/s – 4 Kodak HGLE max. 1504x1128 oder max. 100.000f/s


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Autoliv IFB

Autoliv Crash Test Facility Bangalore Over view:- Driven by bungee force - Pay load up to 1000Kg - Max speed ~60Kmph - 12 Channel high speed data acquisition - High speed digital video Salient Features: - PU brake for modified half sine wave deceleration profile - Bending bar technique for vehicle crash pulse - Programmable squib for pyrotechnique device firing


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Autoliv Crash Test Facility Bangalore SEAT BELT TESTING (BIW) IN DYNAMIC ENVIRONMENT

AIRBAG DEPLOYMENT TESTING IN DYNAMIC ENVIRONMENT


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Crash Testing and Test Facilities Introduction Test Modes


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SAFETY CENTER

Autoliv France



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CRASH TEST FACILITIES Autoliv France

• FACILITIES

PLATEFORME ROLLOVER EXTERIEURE

CATAPULTE 2 ZONE A

ZONE B P C A

MANNEQUINS

MES URE

ATELIER PREPARATION

ZONE DE RECEPTION ROLLOVER

P C B

CATAPULTE 4

BOX 1

BUREAUX CATAPULTE 1 BOX 2

BOX 3

CATAPULTE 3

Locaux Tech.

HALL


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PLATEFORME DITCH


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ATELIER PREPARATION 2


TEST POTENTIAL • SIMULATION SLED TESTING

Autoliv France

FRONTAL IMPACT SLED TEST HYGE max intrusion 1,6 m


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HyGe-Sled Autoliv North America


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HyGe-Sled Autoliv North America


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More Crash Test Facilities

TÜV Rheinland TNO Automotive International b.v. Helmond/Netherlands

BMW Munich, Germany Full scale crash-test facility with moveable block

ADAC, Germany

Honda, USA

Source: Messring More at: www.sledtest.de/html/crash_facilities.html AUTOLIV / Dr. H. Zellmer / New Delhi 2010

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Useful Links NHTSA Crashtest Database: www-nrd.nhtsa.dot.gov/database/nrd-11/veh_db.html Crash Test Facilities: www.sledtest.de/index.html www.iihs.org/brochures/pdf/vrc_brochure.pdf www.autoliv.com/wps/wcm/connect/autoliv/Home/What+We+Do/Crash%20testing

Further Links: www.sledtest.de/html/crash_links2.html http://www.esi-group.com/products/crash-impact-safety/virtual-performancesolution-1/video_a8


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Crash Test Facility Design

Crash Test Facility Design

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