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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Harald Zellmer, Crash Test Facilities, 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
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Crash Test Facility Design
Crash-Methods
Real life
Body-In-White
Sled Test
Component Test
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Crash Test Facility Design
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Legal and customer requirements
Standard Full-Scale-Crash
Costs
Accident Reconstruction
Harald Zellmer, Crash Test Facilities, 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
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Crash Test Facility Design
Full-Scale Crash Test
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
USA legal: FMVSS 208
H-III 50% & 5% Dummy
56 km/h concrete barrier (0°- 30°)
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Crash Test Facility Design
Europe: ECE R-94
56 km/h offset deformable barrier
40% "Offset"
2 Dummys HIII 50%
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
Euro
NCAP
http://www.euroncap.com/
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Crash Test Facility Design
Euro
NCAP
http://www.euroncap.com/
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
Euro
NCAP
http://www.euroncap.com/
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Crash Test Facility Design
Japan-NCAP
Frontal 55 km/h
Frontal 64 km/h
Side 55 km/h
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
Test Modes Frontal Impact Sensor Tests
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Crash Test Facility Design
Test Modes Side Impact
FMVSS 214
Side Pole- Car
ECE R 95
Car to Car
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Crash Test Facility Design
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Car Pole
Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
Body-in-White Test
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Crash Test Facility Design
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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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
Sled Test ECE R-16
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Crash Test Facility Design
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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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
ECE-R 16: Acceleration Time History
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Crash Test Facility Design
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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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, 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
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Crash Test Facility Design
Comparison Test Facilities
Acceleration
-
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
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
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
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Crash Test Facility Design
Braking Systems for Deceleration Sleds
Bending bar brake
PU-Tube brake
Hydro-brake
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
PU-Tube Brake
Source: Messring.de
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Crash Test Facility Design
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
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
Hydro-Brake
Source: Messring.de
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Crash Test Facility Design
Hydro-Brake
Source: Messring.de
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
Hydro-Brake
Source: Messring.de
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Crash Test Facility Design
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
• .....
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, 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
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Crash Test Facility Design
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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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
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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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
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 Design
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 Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
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
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Crash Test Facility Design
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
Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
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 Design
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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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, 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
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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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
Autoliv Crash Test Facility Bangalore
SEAT BELT TESTING (BIW) IN DYNAMIC ENVIRONMENT
AIRBAG DEPLOYMENT TESTING IN DYNAMIC ENVIRONMENT
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Crash Test Facility Design
Crash Testing and Test Facilities
Introduction
Test Modes
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
SAFETY CENTER
Autoliv France
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Crash Test Facility Design
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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
Crash Test Facility Design
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ATELIER
PREPARATION 2
Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
TEST POTENTIAL
• SIMULATION SLED TESTING
Autoliv France
FRONTAL IMPACT SLED TEST
HYGE max intrusion 1,6 m
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Crash Test Facility Design
HyGe-Sled Autoliv North America
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, New Delhi, December 2010
HyGe-Sled Autoliv North America
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Crash Test Facility Design
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
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Crash Test Facility Design
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Harald Zellmer, Crash Test Facilities, 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
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
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