Zellmer IIT 2009 Crash Test Handout

Harald Zellmer, Crash Test Facilities, New Delhi, December 2009
Crash Test Facility Design

Harald Zellmer
Autoliv B.V. & Co. KG, Elmshorn, Germany
International Course on Transportation Planning

and Safety
New Delhi
December 2009
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 2009- 2 Crash Test Facility Design
1
Crash-Methods
Accident Reconstruction
Costs
Standard Full-Scale-Crash
Legal and customer requirements

Body-In-White
Real life
Sled Test
Component Test
[ANG-TT/HZ] [´28.08.00] [AKAD03]
Introduction
Crash test modes
2
Full-Scale Crash Test
USA legal: FMVSS 208
H-III 50% & 5% Dummy
56 km/h concrete barrier (0°- 30°)
3
Europe: ECE R-94
56 km/h offset deformable barrier

40% "Offset"
2 Dummys HIII 50%
Euro
NCAP
http://www.euroncap.com/
4
Euro
NCAP
Euro
NCAP
5
Japan-NCAP
Frontal 55 km/h Frontal 64 km/h
Side 55 km/h
Test Modes Frontal Impact Sensor Tests
[ANG-TT/HZ] [´28.08.00] [AKAD03]

6
Test Modes Side Impact
FMVSS 214 Side Pole- Car
ECE R 95 Car to Car Car Pole
[ANG-TT/HZ] [´28.08.00] [AKAD03]

Body-in-White Test
[ANG-TT/HZ] [´28.08.00] [AKAD03]

7
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 ..
[ANG-TT/HZ] [´28.08.00] [AKAD03]

Sled Test ECE R-16
[ANG-TT/HZ] [´28.08.00] [AKAD03]

8
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
[ANG-TT/HZ] [´28.08.00] [AKAD03]

ECE-R 16: Acceleration Time History
[ANG-TT/HZ] [´28.08.00] [AKAD03]

9
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
[ANG-TT/HZ] [´28.08.00] [AKAD03]

Introduction
Crash test modes
10
Comparison Test Facilities
Acceleration - Deceleration
Pulse very repeatable Pulse may vary more

Dummy positioning very Dummy positioning influenced
exact by acceleration phase.
Price is very high Price of test facility is 50% of

Only on-board cameras equivalent acceleration facility
possible Full-Size Crashes can be
Dummy end position performed in same test facility
influenced by braking after
test
[ANG-TT/HZ] [03.03.98] [AKAD03]

Propulsion system deceleration sled

• Servo hydraulic motor with energy reservoir
• Fly-Wheel
• Bungee rope
• Electrical motor
Propulsion system acceleration sled
• Pneumatic
• Servo hydraulic
11
Braking Systems for Deceleration Sleds
Bending bar brake

PU-Tube brake
Hydro-brake
PU-Tube Brake
Source: Messring.de
12
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
Hydro-Brake
Source: Messring.de
13
Hydro-Brake
Source: Messring.de
Hydro-Brake
Source: Messring.de
14

High-speed video cameras (min. 1000 f/s)
Lighting system
• Tungsten about 400 kW
• HMI
Data Acquisition System
Dummies
Sensors
• Acceleration
• Belt force transducers
• .....
Introduction
Crash test modes
15
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
Crash Test Facility Elmshorn Layout
Length 70 m, Width 17 m
16
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

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
17

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
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
18
Propulsion System Flywheel

–Manufacturer: Messring
–Model Year 1996
–Velocity Tolerance ± 0,5 km/h
–Maximum Acceleration 0,5 g
–Automatic Control by PLC and PC
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)
19
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
Introduction
Crash test modes
20
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
Autoliv Crash Test Facility Bangalore

SEAT BELT TESTING (BIW) IN DYNAMIC ENVIRONMENT
AIRBAG DEPLOYMENT TESTING IN DYNAMIC ENVIRONMENT
21
Crash Testing and Test Facilities
Introduction
Test Modes
SAFETY CENTER
Autoliv France
22
CRASH TEST FACILITIES

Autoliv France
• FACILITIES
PLATEFORME
PLATEFORME
CATAPULTE 2 ROLLOVER
DITCH
ZONE A ZONE B EXTERIEURE
P ZONE DE
ATELIER P
C RECEPTION
A PREPARATION C
MANNEQUINS
B ROLLOVER ATELIER
PREPARATION 2
MES CATAPULTE 4
URE BOX 1
BUREAUX
CATAPULTE 1
BOX 2 BOX 3 Locaux
CATAPULTE 3 Tech.
HALL
TEST POTENTIAL
• SIMULATION SLED TESTING Autoliv France
FRONTAL IMPACT SLED TEST
HYGE max intrusion 1,6 m
23
HyGe-Sled Autoliv North America
[ANG-TT/HZ] [03.03.98] [AKAD03]

HyGe-Sled Autoliv North America
[ANG-TT/HZ] [03.03.98] [AKAD03]

24
More Crash Test Facilities
TÜV Rheinland TNO Automotive International b.v. BMW Munich, Germany

Helmond/Netherlands Full scale crash-test facility with moveable block
ADAC, Germany Honda, USA
Source: Messring More at: www.sledtest.de/html/crash_facilities.html
Introduction
Crash test modes
25
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
END
26

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Harald Zellmer, Crash Test Facilities, New Delhi, December 2009

Crash Test Facility Design

Autoliv B.V. & Co. KG, Elmshorn, Germany

International Course on Transportation Planning

Crash Test Facility Design

Legal and customer requirements

Crash Test Facility Design

Full-Scale Crash Test

USA legal: FMVSS 208

H-III 50% & 5% Dummy

56 km/h concrete barrier (0°- 30°)

Europe: ECE R-94

56 km/h offset deformable barrier

Frontal 55 km/h Frontal 64 km/h

Test Modes Frontal Impact Sensor Tests

[ANG-TT/HZ] [´28.08.00] [AKAD03]

Test Modes Side Impact

FMVSS 214 Side Pole- Car

ECE R 95 Car to Car Car Pole

[ANG-TT/HZ] [´28.08.00] [AKAD03]

[ANG-TT/HZ] [´28.08.00] [AKAD03]

Simulation of Full-Size Crash Tests in stiff body shell

Cost reduced alternative for

[ANG-TT/HZ] [´28.08.00] [AKAD03]

Sled Test ECE R-16

[ANG-TT/HZ] [´28.08.00] [AKAD03]

ECE-R 16 Test Set up

Stiff seat and B-pillar

Collision speed: 50 km/h ± 1 km/h

Acceleration time-history in defined corridor

Belt anchorage position as in the car

[ANG-TT/HZ] [´28.08.00] [AKAD03]

ECE-R 16: Acceleration Time History

[ANG-TT/HZ] [´28.08.00] [AKAD03]

ECE-R 16: Requirements

No damage to the belt system

Buckle opening force < 60 N

Pelvis forward displacement: 80 mm - 200 mm

Chest forward displacement: 100 mm - 300 mm

[ANG-TT/HZ] [´28.08.00] [AKAD03]

Crash Test Facility Design

Comparison Test Facilities

Pulse very repeatable Pulse may vary more

Price is very high Price of test facility is 50% of

[ANG-TT/HZ] [03.03.98] [AKAD03]

Requirements to crash test facilities

Propulsion system deceleration sled

Braking Systems for Deceleration Sleds

Bending bar brake

Bending Bar Brake

Bending Bar Brake consisting of

Requirements to crash test facilities

Crash Test Facility Design

Crash Test Facility Elmshorn Basic Data

Dimension of Test Facility

Flywheel Propulsion system

Crash Test Facility Elmshorn Layout

Crash Test Facility Elmshorn

Full Scale Tests

Track 60 m long, 5 m - 8m wide

Crash Test Facility Elmshorn

Crash Test Facility Elmshorn

Sled with ECE R 16 Seat

Hydraulic PU-Tube Braking System