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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

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 2009- 2 Crash Test Facility Design

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

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]
AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 3 Crash Test Facility Design

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 2009- 4 Crash Test Facility Design

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

Full-Scale Crash Test

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 5 Crash Test Facility Design

USA legal: FMVSS 208

 H-III 50% & 5% Dummy

 56 km/h concrete barrier (0°- 30°)

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 6 Crash Test Facility Design

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

Europe: ECE R-94

56 km/h offset deformable barrier


40% "Offset"
2 Dummys HIII 50%

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 7 Crash Test Facility Design

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

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 8 Crash Test Facility Design

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

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

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 9 Crash Test Facility Design

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

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 10 Crash Test Facility Design

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

Japan-NCAP

Frontal 55 km/h Frontal 64 km/h

Side 55 km/h

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 11 Crash Test Facility Design

Test Modes Frontal Impact Sensor Tests

[ANG-TT/HZ] [´28.08.00] [AKAD03]


AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 12 Crash Test Facility Design

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

Test Modes Side Impact

FMVSS 214 Side Pole- Car

ECE R 95 Car to Car Car Pole

[ANG-TT/HZ] [´28.08.00] [AKAD03]


AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 13 Crash Test Facility Design

Body-in-White Test

[ANG-TT/HZ] [´28.08.00] [AKAD03]


AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 14 Crash Test Facility Design

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

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]


AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 15 Crash Test Facility Design

Sled Test ECE R-16

[ANG-TT/HZ] [´28.08.00] [AKAD03]


AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 16 Crash Test Facility Design

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

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]


AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 17 Crash Test Facility Design

ECE-R 16: Acceleration Time History

[ANG-TT/HZ] [´28.08.00] [AKAD03]


AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 18 Crash Test Facility Design

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

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]


AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 19 Crash Test Facility Design

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 2009- 20 Crash Test Facility Design

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

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]


AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 21 Crash Test Facility Design

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 2009- 22 Crash Test Facility Design

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

Braking Systems for Deceleration Sleds

Bending bar brake


PU-Tube brake
Hydro-brake

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 23 Crash Test Facility Design

PU-Tube Brake

Source: Messring.de

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 24 Crash Test Facility Design

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

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 2009- 25 Crash Test Facility Design

Hydro-Brake

Source: Messring.de

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 26 Crash Test Facility Design

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

Hydro-Brake

Source: Messring.de

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 27 Crash Test Facility Design

Hydro-Brake

Source: Messring.de

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 28 Crash Test Facility Design

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

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 2009- 29 Crash Test Facility Design

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 2009- 30 Crash Test Facility Design

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

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

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

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

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

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 34 Crash Test Facility Design

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

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

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 35 Crash Test Facility Design

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 2009- 36 Crash Test Facility Design

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

Crash Test Facility Elmshorn

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

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 37 Crash Test Facility Design

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)

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 38 Crash Test Facility Design

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

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

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 39 Crash Test Facility Design

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 2009- 40 Crash Test Facility Design

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

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 / Dr. H. Zellmer / New Delhi 2009- 41 Crash Test Facility Design

Autoliv Crash Test Facility Bangalore


SEAT BELT TESTING (BIW) IN DYNAMIC ENVIRONMENT

AIRBAG DEPLOYMENT TESTING IN DYNAMIC ENVIRONMENT

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

Crash Testing and Test Facilities

Introduction
Test Modes

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 43 Crash Test Facility Design

SAFETY CENTER
Autoliv France

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 44 Crash Test Facility Design

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

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

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 45 Crash Test Facility Design

TEST POTENTIAL
• SIMULATION SLED TESTING Autoliv France
 FRONTAL IMPACT SLED TEST

HYGE max intrusion 1,6 m

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

HyGe-Sled Autoliv North America

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


AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 47 Crash Test Facility Design

HyGe-Sled Autoliv North America

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


AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 48 Crash Test Facility Design

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

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

AUTOLIV / Dr. H. Zellmer / New Delhi 2009- 49 Crash Test Facility Design

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 2009- 50 Crash Test Facility Design

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

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

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Crash Test Facility Design

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