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Published by MARTUR / Dergilik, 2018-12-27 03:29:14

Crash Test Eylül 2014

Crash Test Eylül 2014

SEHXOPWO PPRREEVVIIEEWW

CRASH TEST ZONE

Don’t miss the Crash Test Zone at Automotive Testing Expo North America 2014, held at
The Suburban Collection Showplace, Novi, Michigan, USA, from October 28-30, 2014

Once again, Automotive Testing REGISTER ONLINE NOW
Expo North America returns FOR YOUR FREE PASS!
to Michigan in October and, as www.testing-expo.com/usa
always, there will be the Crash Test Zone
forming part of the larger show. On display,
visitors will find the latest innovations in
crash test equipment and services from
around the globe. From cameras to crash
barriers to sensors, you will find everything
for your crash testing needs.
Experts will be on hand from exhibiting
companies including Plascore, NAC Image
Technology, Vision Research and PMG
Technologies. Meanwhile, there are the
free-to-attend presentations in the Open
Technology Forum, where various crash
test relevant discussions will be held by
industry experts.
The wider Automotive Testing Expo
is also set for another record-topping
year with over 260 global exhibitors.
Read on through the following pages
for the highlights that are not to be missed
at The Suburban Collection Showplace
in Novi. We hope to see you there! ‹

Rugged and compact sensor Advanced high-performance camera

Diversified Technical enclosure capable of At NAC Image
Systems (DTS) will withstanding impacts Technology’s booth,
introduce the new ARS3 up to 10,000g. visitors will have
PRO triaxial angular the opportunity
rate sensor, which is The triax to discover the
ideal for high-energy gyroscope measures Memrecam Q1-m
applications such as just 19 x 19 x camera. The Q1 is
vehicle crash safety, 12.5mm and weighs claimed to be the
in-dummy testing, and only 9g (0.35oz). world’s smallest,
human impact studies. For applications self-contained, high
requiring three performance, high-g camera.
Unlike an independent sensors
accelerometer that to measure pitch, It can operate as either a single standalone
measures linear motion, roll and yaw, this camera or in a synchronized multicamera system.
the ARS3 PRO can design eliminates It has a megapixel sensor and provides high-quality
be used to quantify the need for a color images at up to 2,000fps and higher frame
virtually any object’s position in mounting block that consumes rates at reduced resolutions.
space, which starts with angular rate additional space and adds weight.
measurement. The ARS3 PRO makes it The result is a self-contained triaxial Users will benefit from its compact and rugged
easy to accurately measure high rates package that costs 25% less, is 50% design, which means it can withstand a 150g shock.
of angular velocity, even in excessive smaller and 40% lighter than even There’s also built-in memory backup and the 0.75in
shock and vibration environments. three DTS ARS PROs combined in a image format supports standard C-mount and
Rugged and ultra-small, three angular mounting block. custom high-g lenses. The camera also has
rate sensors are packaged in a sealed Visit booth C123 excellent light sensitivity.
Visit booth C100

00490www.AutomotiveTCersatisnhgTTeescthTneoclhongoylIongteyrnInatteiornatl.icoonmal
SEPTEMBER 2014

ESXHPOOWPPRREEVVIEIEWW REGISTER ONLINE NOW!
www.testing-expo.com/usa

Comprehensive test center New NHTSA crash barrier Who to meet

PMG Technologies is Transport Canada’s sole An expert in honeycomb engineering and David Bahadori, director
test and research center. It offers complete vehicle manufacturing, Expo exhibitor Plascore is also a of sales, Microsys
compliance testing according to American (FMVSS) global supplier of crash test barriers and energy
and Canadian (CMVSS) standards, as well as a absorbers.
wide array of research and development tests
and compliance tests geared to foreign markets. Plascore provides a full range of certified
deformable barriers, crushable core, as well as
The center’s crash lab even received Crash custom honeycomb configurations for a wide
Test Facility of the Year in the 2012 Automotive array of energy absorption applications serving
Testing Technology International Awards. many industries. New in 2014, the company has
added the NHTSA Oblique Barrier to its full line of
PMG’s test track design, currently unique in North crash test barriers.
America, offers a wide range of crash configurations
including various moving car-to-car frontal Plascore’s engineers can help customers specify
collisions, as well as perpendicular and oblique a core type to fit their crush strength requirements,
side impact, high-speed rear impact and dynamic or can provide a custom product for a unique
rollover tests, all with unequalled accuracy and application. It works with customers to provide
repeatability of test velocities and impact point. an innovative solution to their energy-absorbing
material needs.
With the addition of a pedestrian impact lab, a Visit booth C112
complete suite of advanced technology crash test
dummies, two servo-controlled sleds capable of Crash sled systems
simulating both positive and negative accelerations,
and a state-of-the-art high-speed video capture HYGE will turn a spotlight on
system (10,000fps), PMG’s crash lab constitutes the its crash simulation systems.
ultimate tool for kinematic analysis of occupants, The company has over 60
child restraints and vehicle components. units in operation worldwide
Visit booth C126 – some have been even been
in service for more than 50
High-speed camera family years. HYGE believes that
these have set the standard
Ideal for crash testing for others to meet. Its systems
applications, Vision are used for Federal Motor
Research supplies Vehicle Safety Standards,
the Phantom family ECE standards, Railway
of high-speed digital Interior Crashworthiness,
cameras. These offer Aircraft JAR, Military ISO/CD,
unparalleled image and other tests.
quality, a variety of
resolutions and frame Some of the more recent installations include a vertical system at Fort
rates, and software with Ruckers in the USA for ejector seat testing, and the Q’Straint horizontal system
built-in measurement in the UK for testing and development of securing devices for wheelchair/
analysis. Phantom handicapped devices in automobiles. Systems range from 6in horizontal/vertical
cameras are well suited for image capture and for component testing and evaluation, to 24in for whole-body truck/airplane
analysis in high-speed applications, as well as for testing. Head to HYGE’s booth to discuss and review requirements for new or
onboard and offboard applications in crash testing. existing systems.
Visit booth C130 Visit booth C116

Complete occupant safety test solution

The SureFire system from exhibitor firing, automated lens control, automated multiple ambient temperature and humidity
Microsys is a complete solution for airbag camera positioning system, support for sensors, profile grouping by test cells,
deployment, as well as for testing of Olympus high-speed cameras, support for profile specific metadata, automatic
inflators and pre-tensioners. SureFire application of CFC filters, as well as
performs squib firing, data acquisition, capabilities for adding banner information
camera control, safety management, about a test.
database integration, analysis and
reporting. The mobile system is designed Coupled with this, the Microsys
to be flexible, easy-to-use and upgradeable. PowerPlay software is a powerful data
analysis and data processing tool. It
New features of the system include: can be used for post-processing and
enhanced automatic AVI generation, automated reporting. SureFire integrates
improved test profile configuration, seamlessly with the PowerPlay analysis
improved organization of countdown timers and reporting software.
and test properties, improved handling
of IDT and Vision Research cameras, It comes with new features such as the
improved handling of DTS TDAS data improved video navigation – including
acquisition system, improved lighting using the mouse wheel to scroll forward
control, new faster PLC hardware, support and backward through frames, and a quick
for Messring LED lights, support for firing sync button, which provides quicker access
AC squibs, capacitive discharge squib to the synchronized play function.
Visit booth C124

050 wCrwaswh.ATuestot mTeocthivneoTleosgtyinIgnTtecrnhantoiolongayl International.com
SEPTEMBER 2014

From sensor to
software – all crash
products from one
single source.

Get Better. With Kistler.

200-738e-09.14

Kistler – Your Partner for More Safety and Comfort in the Vehicle.

Kistler – the leading technology supplier for measurement systems around the vehicle in the field
of automotive R&D – offers also a comprehensive product and service portfolio in the field of
Crash & Safety. In addition to our standard products we have customized solutions to instrument
off-board, on-board and in-dummy applications as well as corresponding DAS software and as-
sociated services.

This is our daily business.

www.kistler.com

DIGITAL HIGH-SPEED CAMERAS

When it’s
too fast to see,
and too important
not to.®

Vision Research has the broadest range of digital high-speed cameras
for the Automotive Industry, with special emphasis on

“on-board” and “off-board” cameras for crash test applications
Watch for something new and exciting from Vision Research.

Visit our web site today www.visionresearch.com

Twitter: @phantomhispeed 100 Dey Road, Wayne, NJ 07470, USA
FaceBook: VisionResearch P: 1.973.696.4500
LinkedIn: vision-research
TF: 1.866.450.PHANTOM
E: [email protected]

140148_VR_8.6_Crash Test Tech 2014_183mm X 115mm.indd 1 8/6/14 5:18 PM

PRODUCTS AND SERVICES Customized motion- Orme
tracking software
To learn more about this
The latest edition of Orme’s TrackImage software facilitates the advertiser, please visit
development of customized analysis routines for crash results
www.ukipme.com/info/ctt

ONLINE READER INQUIRY NUMBER 506 Motion-tracking
software currently
available on the parameters – and used for ABOVE: Software applications be developed with minimum
market allows testers to every analysis. This feature is dedicated to a specific test can effort. A runtime license of
analyze videos and measure already a time-saver. now be created in Orme’s TrackImage the detection kernel will be
the motion of objects under program. The screenshot shows an used, and a specific graphical
test (position, velocity, TrackImage also provides application dedicated to crash analysis interface will be built around
acceleration, deformation, a new way to save even more it to fit exactly the user’s
angles) in 2D and 3D spaces. time. When performing specific needs.
The main differences between numerous repetitive tests,
these software applications a customized application can This powerful new feature
lie in the interface’s user- be developed. The software of TrackImage delivers a
friendliness and in the architecture of the new complete software application
detection accuracy, in 3.0 release of TrackImage fully dedicated to a specific
particular in the case of has been built as various kind of test.
3D measurements. Both independent detection kernels
aspects therefore need included in a user-friendly Many applications can be
to be carefully evaluated interface. Every kernel is shaped to fit the user’s needs.
when purchasing such an dedicated to a specific kind of For instance, the analysis
application and comparing detection, such as 2D motion procedure can be completely
the various solutions available tracking, 3D motion tracking, automated, and run in
on the market. deformation tracking or airbag batch mode. When repetitive
Once the software has been deployment. These detection tests are run under the same
selected, all the measurements kernels can also be used conditions, a set of videos in
become available and the outside of the TrackImage a folder can first be opened, a
software will provide the standard version, and file containing the calibrations
desired results. One major included in a customized and all the analysis parameters
issue remains: users usually application. The new is opened, the detection on
need to perform repetitive application, fully dedicated each video is automatically
tests and achieve many to specific needs, can thus performed, and finally the
identical analyses, which corresponding result reports
requires repetitive tedious
actions, time loss and errors.
As a result, the analysis
procedure therefore needs to
be automated to save time and
avoid such errors. Some of the
currently available motion-
tracking software packages
provide tools to manage
repetitive test analyses. For
instance, in the standard
version of Orme’s TrackImage,
the user can define an analysis
template dedicated to a
specific type of test where the
analysis setup can be stored
– calibrations and all analysis

052 Crash Test Technology International
SEPTEMBER 2014

“Every kernel is dedicated to a specific kind of detection, such as PRODUCTS AND SERVICES
2D motion tracking, 3D motion tracking, deformation tracking or
airbag deployment, for example”

LEFT AND BELOW: These TrackImage
screenshots show automatic airbag
deployment analysis in production lines

are provided. The application virtual limits can be set, and be opened by the dedicated
can be run at night to analyze if reached the application application to be able to
all the tests performed during will automatically raise a flag. run automatically. In case
the day, producing the results This relieves the user from something changes in
for the user to retrieve the having to manually check the setup, the file can be
next morning. every analysis, with a reopened by the full version
corresponding risk of error of TrackImage to check
Another example is a when checking a large number what is happening, modify a
specific application dedicated of analyses. To allow the parameter, and save the xml
to production lines to software application to run file once again.
check possible drifts on the automatically, the analysis
production line. Pre-defined parameters are stored in These are two specific
an xml file used by the examples, but many other
TrackImage detection kernel. case scenarios are possible.
These customized applications
This xml file can be created can currently be developed
by the user himself or – more by Orme to the user’s
easily – it can be created by specifications. A software
the full version of TrackImage. development kit is also
A convenient method is provided, allowing users
then to check all the analysis to develop applications
parameters first with the full themselves.
version, then to save them in
the xml file. This file will then Cost-wise, an advantage
is that the customer has full
ownership of the dedicated
software application and can
therefore install it on as many
computers as he wishes. Only
the kernel run-time licenses
need to be purchased from
Orme for each installation,
thereby drastically reducing
the total cost. ‹

053Crash Test Technology International
SEPTEMBER 2014

PRODUCTS AND SERVICES Crash test High Speed Vision
recording center
To learn more about this
Visart control software from HSVision enables the precise and advertiser, please visit
synchronous control of filming and recording equipment in crash tests
www.ukipme.com/info/ctt

ONLINE READER INQUIRY NUMBER 507

The integration (such as preparatory/setup ABOVE: The matchbox provides a size With its standard interfaces,
capabilities of operation or trigger test comparison for HSVision’s NANO LED Visart guarantees maximum
High Speed Vision’s mode) can be called up flexibility and compatibility
(HSVision) Visart control or reproduced at any time, – both today and in the future.
software open new horizons simply at the press of a
for complete system control button. In addition to exact A practical example is the
when making high-speed reproduction of high-speed synchronous control of 34
recordings. recording settings and low high-speed cameras and 42
Visart enables the precise susceptibility to errors, its lamp modules in a real-life
and synchronous control of makers say that the Visart test environment.
all recording components used system control also saves a
in a network for crash tests. considerable amount of time With an example
These include high-speed when setting up and carrying recording rate of 1,000fps
cameras from HSVision (and out crash tests. Depending and synchronous LED
other manufacturers), precisely upon configuration, the time lighting of 200µs, high-quality
timed LED lighting systems, necessary for a system setup recordings are guaranteed.
and the automated relocation can be reduced from several The synchronicity of high-
of transverse LED lighting hours to well under one hour. speed cameras and LED ‘flash’
units to programmed lighting with reduced lighting times
positions using crane control. As well as comprehensive plays a decisive role. Only
Despite its high functional control and control functions, when all components are
complexity, the software HSVision Visart software perfectly coordinated with
is outstanding in terms of provides templates and each other is practical work
intuitive user guidance and wizards for aiding system possible and can optimal
user friendliness. Once set up, setup and various possibilities results be achieved. Two
different recording scenarios for image processing and positive side-effects are
analysis following recording. that this high-frequency
‘stroboscope technology’

054 Crash Test Technology International
SEPTEMBER 2014

“A separately available universal lens PRODUCTS AND SERVICES
adaptor enables simple mounting of
conventional camera lenses”

provides maximum lighting TOP: SyncLamp LED light panels with minimal wiring pixels) at 2,128fps and HD+
for the cameras running in reduce energy requirements for testing requirements. Connection resolution (1920x1440 pixels)
synchronous operation during to the camera is courtesy of at 1,603fps. The impressive
the light flashes, whereas ABOVE: The Linkbox offers centralized the plug-and-play principle shock and vibration values
the human eye sees the light support for up to eight cameras and is effected with just one (30g and 25g in all axes)
as being only dim. This low cable. Key features are very underline its high level of
strain level of light on humans compact dimensions, a weight mechanical workmanship,
is an important health aspect. of just 2kg, a central power thus making the Megavis
supply (battery), a central cameras perfectly suited for
The second positive trigger and sync input, a sync operations under the harshest
side-effect is the low power generator, Gigabit Ethernet and conditions. Gigabit Ethernet
consumption of HSVision’s two free Ethernet interfaces. makes incorporation of the
ultra-modern LED exterior camera into existing computer
lighting panels. Each panel When high-level lighting systems remarkably simple
provides almost the same light performance and widespread and an optional HDSDI
intensity as a 4,000W HMI illumination are required for interface is available for
floodlight, but requires a onboard recordings in areas downloading live image
maximum of only 240W. where space is limited, the and monitor viewing
high-performance NANO data. A separately available
The individual system LED is an ideal solution. universal lens adaptor
components from HSVision It is probably the smallest enables simple mounting of
are divided into crash-proof and most powerful LED head conventional camera lenses
(onboard) and non-crash- available, and has an aperture from renowned manufacturers
proof (offboard) components. angle of 110° and a color such as Canon and Nikon.
temperature close to daylight
The HSVision SpeedCam of 6,500K. It is available The high-performance LED
mini-1 and SpeedCam mini-2 with 7,000 lm or 14,000 lm SyncLamp 4432 for exterior
cameras are used for onboard intensity per head. areas (already mentioned
recordings. Both models in the real-life example
are extremely compact, light The components of the above) achieves a lighting
and robust, and provide the SpeedCam mini-1, mini-2, performance equaling
highest levels of image quality Linkbox and NANO LED that of a 4kW HMI floodlight
and light sensitivity, as well including battery pack are but with a very low power
as high dynamic range with acceleration proof up to 100g consumption of just 240W.
extreme contrasts. At a typical in all three axes (mechanical The LEDs always operate
recording rate of 1,000fps, the shock), thus making them within their limits, thus
SpeedCam mini-2 provides a suitable for highly demanding ensuring a long working life.
resolution of 1472x1036 pixels. onboard crash tests. During operation, each LED
floodlight is fed with an
The Linkbox from For general exterior external synchronization
HSVision is tailored precisely recordings (offboard), the signal from a sync generator
to SpeedCam cameras, HSVision SpeedCam Megavis that supplies the entire LED
enabling a centralized supply family provides compromise- lighting system. An internal
for up to eight onboard free image quality. This peak power buffer limits
cameras and (among other high-speed camera fulfills power consumption during
features) an identical sync demands for the highest lighting phases, thus enabling
frequency for all cameras quality prescribed for several SyncLamps to be
connected. HSVision says professional digital cameras operated from a standard
the Linkbox is an extremely used in film and television 16A power supply. ‹
robust central component productions. It enables
for all onboard recordings, HD resolution (1920x1080
combining simple handling

055Crash Test Technology International
SEPTEMBER 2014

PRODUCTS AND SERVICES Small overlap EXHIBITOR
test barrier
Kistler
Kistler has developed an instrumented crash barrier
segment for the IIHS small-overlap vehicle test To learn more about this
advertiser, please visit

www.ukipme.com/info/ctt

ONLINE READER INQUIRY NUMBER 508 Kistler Instrumente This test was designed to
supplies sensors for replicate a large number of
measuring pressure, vehicle-to-vehicle collisions FROM LEFT: Forty piezoelectric piezoelectric technology for
force, torque and acceleration, where the front corners of load cells are installed in the barrier this type of measurement
as well as the related the vehicles hit each other segment; the customizable modular application has many
electronics and software. with a relatively small overlap small overlap barrier system developed advantages. Due to its
Kistler’s sensing technology is ratio. Other scenarios that are by Kistler; and the segment block inherent mechanical stiffness,
used in many applications to covered by this test procedure integrated in the original IIHS barrier high force measurement
measure and analyze physical are collisions of vehicles with ranges can be reached.
events, and to optimize and stationary objects, such as Likewise, the natural
control industrial processes. trees or utility poles. frequency of these sensors
The automotive research is at a much higher level
and test division within In the test procedure, the compared with similar type
Kistler covers all measurement vehicle hits a rigid barrier face load cells based on strain
applications in the automobile at an impact speed of 40mph gauge technology. Naturally,
industry, as well as related (64km/h). Only 25% of the the linearity behavior of
industry sectors such as large total vehicle width, on the these piezoelectric sensors
(marine) diesel engines, power driver side, impacts the barrier is excellent.
stations, etc. The division face. Results from crash tests,
consists of four major strategic executed by IIHS, showed Thirty-two load cells, used
business fields: engine R&D, that the crash behavior differs in the barrier segment, are
engine marine and stationary, considerably from vehicle to three-channel sensors with
vehicle dynamics and vehicle in this type of collision. a capacity of 500kN in the
durability, and vehicle safety. impact direction. Sensors that
In recent decades, In order to collect more are used as corner elements
improvements in vehicle safety detailed information about
have dramatically reduced the the vehicle structure in
number of fatalities caused the collision area, Kistler
by road accidents. Increasingly developed a modular,
stringent crash test instrumented crash barrier
requirements and procedures segment with a built-in data
impose more complex acquisition system. Customers
development cycles, with can choose between two
increasing costs, on vehicle options: buying a completely
manufacturers and their integrated barrier, or
suppliers. By providing a modifying the existing barrier
one-stop shop for all required to fit an instrumented outer
sensors, data acquisition segment. With a width
systems and software, of 650mm and height of
Kistler is making a major 1,000mm, the size of the
contribution to the future instrumented barrier segment
success and manageability covers all passenger car
of vehicle safety crash tests. dimensions with respect to
Back in 2012, the the impact area. Furthermore,
Insurance Institute for it can be used for left-hand
Highway Safety (IIHS) side as well as right-hand
introduced a small overlap side impacts.
frontal crash test procedure.
A total of 40 piezoelectric
load cells are installed in
the barrier segment. Using

056 Crash Test Technology International
SEPTEMBER 2014

“To collect more detailed information about the vehicle structure PRODUCTS AND SERVICES
in the collision area, Kistler developed a modular, instrumented
crash barrier segment with a built-in data acquisition system”

have greatly reduced data acquisition system sending a mobile 3DOF solutions with respect to
dimensions, but still have that contains a transducer calibration system to the ease of use, assembly and
a capacity of 250kN. One electronic data sheet (TEDS), customer’s crash laboratory. operation, Kistler continues
of the key points during the operators can also use the Naturally, all disassembly and to be at the leading technology
development phase was the instrumented crash barrier reassembly activities on-site edge within the vehicle safety
user-friendliness for assembly segment without requiring are carried out by Kistler staff testing field.
and disassembly of the load a sensor or device database during the calibration process.
cells, as well as the complete in the background. As the Upon completion of the Vehicle crash tests will
instrumented segment. This sensors in the barrier segment calibration, the updated continue to grow in quantity
resulted in a modular design are self-descriptive, all sensor information is loaded and increase in complexity.
with an optimized base required information for into the sensor TEDS and Test throughput can only be
plate structure with built-in the test/system setup can be usage can continue without boosted further if all of the
electronics. The load cells, uploaded directly from the a major loss of time. components involved warrant
which have an integrated sensor itself. Additional test for seamless interaction. As
data acquisitions system, can and sensor information can be With the development Kistler focuses on the overall
be mounted individually onto combined using international of the instrumented Small application from the initial
the base plate. exchange interfaces, such as Overlap Barrier segment, sensor design to the final
e2x (data exchange format) or Kistler has proven once more control software development,
Operation of the barrier xml files, allowing for a quick its leading role in vehicle crash the solution provided is
segment is carried out via the setup of the complete test. test applications. Leveraging repeatedly tested to ensure
Kistler proprietary control proven Kistler technologies the highest level of reliability
software. Due to the fact that Kistler offers complete and combining these with on a component and on a
the sensors have an integrated on-site calibration service by innovative engineering complete system level. ‹

057Crash Test Technology International
SEPTEMBER 2014

PRODUCTS AND SERVICES Optical 3D metrology GOM

Non-contact measuring systems from GOM provide advanced To learn more about this
analysis of how components react during crash and impact testing advertiser, please visit

www.ukipme.com/info/ctt

ONLINE READER INQUIRY NUMBER 509 To speed up design,
simulation and
development cycles, Therefore a precise analysis Sled testing, for example, 3D displacement vectors,
the automotive industry of the dynamic behavior typically uses point-based while additionally measuring
now increasingly uses optical of individual parts and measurement processes as a real speed and acceleration in
measurement systems instead components is necessary. fast method for testing seats, any test setup.
of conventional strain gauges, For better visualization and body restraint systems, and
accelerometers, transducers understanding, the systems interior trim components. The collected measurement
and extensometers. provide point-based as well These test setups do not data is used, for example, to
Companies implement these as full-field measurement involve the destruction of determine the movement of
non-contact systems not only techniques. Optical measuring costly prototypes or entire seats and crash test dummies.
in crash and impact tests, but systems are applied not vehicles, as they are simply The evaluation enables full
also in climate chamber, wind only in crash and impact, accelerated to predefined 6DOF analysis of movements,
tunnel and fatigue testing. but also in wind tunnel speeds. This makes it possible including the rotation and
Particularly important for tests, chassis and engine to demonstrate the impact of translation motions of a
car manufacturers such as test stands, in vibration frontal, side and rear crashes dummy’s head. Additionally,
Audi, BMW, Daimler, Porsche analysis, as well as in door at low cost. Point-based body movements and rotation
and Volkswagen, as well as and closure testing. systems like PONTOS show are measured, as well as
suppliers such as Autoliv, the speed at which the head
Bosch, Continental, TRW
and ZF, is the fact that the
optical measuring systems
can be fully and effortlessly
integrated into existing test
facilities and test stands.
Optical sensors provide
data on part and component
geometries, as well as on three-
dimensional displacements
and deformations. Static and
dynamic deformations are
determined on the basis of
individual points as well as
entire surfaces. With this data,
manufacturers can evaluate
part safety and functioning,
while also optimizing
their simulation and design
processes at the same time. As
a result, product development
can be noticeably accelerated.
The most interesting
aspect for test engineers is
how parts and components
react during crash and impact
tests – this is the only way
to guarantee the safety of
passengers and pedestrians.

058 Crash Test Technology International
SEPTEMBER 2014

PRODUCTS AND SERVICES

hits the headrest, and leg OPPOSITE: Point-based systems component behavior, but also Tighter regulations
movements. During this like PONTOS show 3D displacement static deformations in a before/ and varying international
process, displacements in the vectors and a full 6DOF analysis of the after comparison. Portable standards make it necessary to
measured points are displayed dummy’s head movements. Trajectories optical systems such as have a metrology system that
in 3D. Test engineers use the can also be evaluated and visualized TRITOP determine the is flexible and easy to adapt.
data to analyze precisely how coordinates of three- Today’s optical measuring
the dummy’s head and body ABOVE LEFT: Evaluation video with dimensional objects by means systems perform static,
will move within a given diagram of a side impact crash test to of photogrammetry. Systems dynamic, point-based
space. This, in turn, makes it measure the intrusion of B-pillar and of this type are used in climate and full-field analyses
possible to draw conclusions door into the passenger room chamber tests to analyze in a non-contact way.
about the safety of seat and point-based deformations Measurement areas, frame
belt systems, but also shows ABOVE RIGHT: Based on the and changes in gap and rates and resolution can
whether there is a risk of head measurement data, test engineers can flush dimensions under be adjusted to the different
impact inside the vehicle. analyze precisely how the dummy’s various temperature and test setups. This replaces
head and body will move inside the car environmental conditions. conventional strain gauges,
Point-based measurement Measurements enable accelerometers, transducers
systems are very easy to measurement systems (e.g. conclusions to be drawn on and extensometers. The
integrate in various test ARAMIS) are frequently used material stiffness as well as recorded 3D measurement
stands. Inspection points are in crash and impact tests, as on design quality. data is permanently available
identified via measurement well as in component testing, and can be evaluated after
markers. In addition, test for instance on airbags and on Photogrammetry systems testing and in different
setup is accelerated due tire test rigs. are also used to document the contexts. The measurement
to an integrated positioning state of a vehicle before and results can be displayed
function: an optically Airbag housing and airbag after a frontal crash test. On in charts, diagrams, videos
tracked touch probe quickly inflation characteristics are the basis of the 3D coordinates and images.
determines and marks the analyzed with high-speed from the two measurement
positions specified by testing cameras. The full-field stages, point deformation The 3D measurement data
regulations for, for example, measurement data is then vectors on the x-, y- and z-axes is used to draw conclusions
dummies and seats. The used to calculate surface strain can be determined, making on safety risks, parts
measurements themselves and planar displacements it possible to understand durability, creep and aging
are easily performed even in for all axes. Crash tests deformations at the A, B processes, and on changes to
rough environments, because are another area in which and C pillars, for example. outer appearance during part
of the integrated strong full-field measurement lifetime and usage.
illumination and a flexible systems are deployed, Where point-based
image recording trigger. for components such as measurement is inadequate, This results in improved
Image recording rates of up windshields. Since modern optical 3D scanners such as safety and comfort as well
to 1,000,000Hz are achieved car windows consist of several ATOS are available to acquire as longer durability and more
for setups ranging from material layers, numerical a full-field description of the attractive product design.
long-term tests to high-speed simulations are often part geometry and to make The measurements are also
applications. Furthermore, inaccurate for determining static deformations visible. used in simulation verification
analog channels (force, their behavior under load. The These 3D scanners collect to review and improve
distance, angle, temperature, full-field measurement data full-field data on complete simulation parameters, as well
etc) can be recorded recorded by the high-speed chassis, individual parts and as to optimize current and
simultaneously. cameras of the ARAMIS components, as well as on future design processes. As
system can then be used to barriers before and after a result, users can reduce the
For other test setups draw reliable conclusions testing. Scanning data of overall number of test runs
full-field information relating on crack propagation in a barriers displays a complete and consequently speed
to dynamic deformations windshield that otherwise impression of the test up product development.
is vital for components that stays invisible. automobile, making it easier This means a competitive
are of relevance to safety. to assess energy absorption advantage for manufacturers
As a consequence, full-field Quality assurance covers during a frontal crash. and suppliers. ‹
not only dynamic part and

059Crash Test Technology International
SEPTEMBER 2014

PRODUCTS AND SERVICES Crash data AMS GmbH
management
To learn more about this
MaDaM-C software from AMS offers powerful search advertiser, please visit
technology and an excellent post-processing tool
www.ukipme.com/info/ctt

ONLINE READER INQUIRY NUMBER 510 Crash test data is a
valuable asset. Hence,
it must be looked The modern HTML5-based TOP: The crash composer in AMS’s data and with potentially
after. This includes efficient web front-end provides easy MaDaM-C software heterogeneous metadata.
storage for easy retrieval, but and simple access to imported
also getting the most out of data. The engineer can ABOVE: Synchronized video analysis As defined in ISO 13499,
every crash. search for measurements with MaDaM-C crash test measurement files
MaDaM is a measurement with free text queries and can contain information about the
data management system furthermore filter them based lab and the engineer involved
(MDM) and the most recent on defined qualities, such as in the test. Every photo and
addition to the AMS toolchain test date or laboratory. video has descriptions as well.
for the crash engineer. It
was developed with the The system minimizes
aforementioned requirements the effort that engineers
in mind and supports the have to spend on their tasks
complete analysis process and, due to the purely HTML5
up to the full NCAP report. interface, offers access from
The system was created any device that is equipped
with three base concepts in with a modern browser.
mind: specialized import,
high-performance search Test engineers can use
and powerful analysis. The MaDaM from every major
measured data is incorporated operating system – be it
into the main system through desktop or mobile.
an importing module full
of business logic. It can A measurement data
subsequently be searched management system regularly
with a powerful and fast deals with large amounts of
search engine. Finally, after
retrieving a specific crash
test, an interactive analysis
can be executed to create
standardized reports or to
compare measurements.
Reliable searches depend
on the consistency of the
data. The specialized MaDaM
importer ensures consistency
during the initial importing
process. Changes made to
the metadata of imported
measurements are validated
against information provided
by the server.
MaDaM is the only
completely web-based
measurement data
management system.

060 Crash Test Technology International
SEPTEMBER 2014

“The system minimizes the effort that engineers have to spend on PRODUCTS AND SERVICES
their tasks and, due to the purely HTML5 interface, offers access
from any device that is equipped with a modern browser”

Beyond that, there is the ABOVE: Overview of the system channel with a maximum the creation of PDF files is
implicit data, which includes exceeding 600m/sec² takes entirely handled by the server.
statistic information regarding BELOW: Test engineers can access about 10ms in a database of
the measured channels. The the system on an iPad in Safari 1,000 measurements. Alternatively, engineers
entirety of this metadata has can interactively analyze the
to be searchable in order to This level of performance data when a static report is
efficiently retrieve specific is the reason for the utilization insufficient.
crash tests from a database of an index instead of a
housing thousands of tests. database – especially for Using Java WebStart
diverse information such technology, the AMS flagship
Choosing to forego a as test data. product jBEAM is started
relational database in favor on the client machine and
of an index-based solution Beyond a powerful and offers vast post-processing
leads to a system that does fast search, MaDaM offers capabilities. It can analyze
not force data into a static vast capabilities once a videos, perform calculations
model. MaDaM examines measurement file is retrieved for crash metrics or design
the test data and employs from the system. There are report templates that can
technologies similar to those two different courses of easily be stored and applied
used by Google to achieve action that may be taken: to different measurements.
high-performance searches. creation of standardized
reports or interactive analysis The data traffic is reduced
Relevant aspects of with jBEAM. dramatically by using
the measurement file are the EnCom protocol. Be it
extracted during the import Test engineers can utilize channel, video or photo – only
and indexed once uploaded. customized templates to the data that is actually used
Searching through this index create PDF reports of varying by the client is transferred.
is a matter of milliseconds. degrees of complexity in
order to gain an overview of A noteworthy quality of
Finding every the data. A report can consist the MaDaM system is that
measurement that contains of anything from a small set it automatically converts
a lateral head acceleration of graphs to completely rated videos in the former ISO
NCAP reports. 13499 standard video codec
Indeo to the currently utilized
As MaDaM uses the jBEAM H264 codec. Thus users
web server as an engine for can analyze older crash
both calculation and graphics, tests conveniently without
the effort of making older
codecs work.

AMS believes that MaDaM
is a solution for efficient crash
data management and analysis
that employs powerful search
technology and utilizes
an exceptionally powerful
post-processing tool – jBEAM.

The company is looking
forward to November 2014
when SAIC Motor, Shanghai,
celebrates the grand opening
of its new crash testing facility.
MaDaM will be one of the core
components of this facility. ‹

061Crash Test Technology International
SEPTEMBER 2014

PRODUCTS AND SERVICES Minimal downtime AOS Technologies
in sled testing
To learn more about this
AOS Technologies has cameras and related equipment that meet the advertiser, please visit
demand for smooth workflow and reduced downtime in sled testing
www.ukipme.com/info/ctt

ONLINE READER INQUIRY NUMBER 511 The installation
of crash test sled
facilities is a big parts such as cables, high- ABOVE: The AOS Q-MIZE HD, with adding features to the control
capital investment. Once speed cameras, camera its high-quality algorithm, provides software. This work can
construction, installation and synchronization boxes sequences in formats of up to be highly time-consuming
fine-tuning are complete and (high-g hubs) and today’s LED 1920 x 1080 pixels. The camera can and a possible source
the facility is ready to operate, illumination, which works be pre-programmed with different of errors for setting non-
a new challenge arises: how synchronized to cameras, sets of recording parameters, making corresponding parameters
can the owner ensure flawless can be done quickly and is it easy to make replacements in test for the test.
operation, with all deadlines not technically challenging. setups, and speeds up preparation
for test and data analysis Proper planning and ready time for the next shot From a hardware point of
being met? Luckily, modern access to spare parts keeps view, it is easy to have proper
hardware and software delays in the test schedule functionality checked. Several
infrastructures enable to a minimum. Once new display signals are available
quick replacement of test equipment is in place, if using modern equipment.
measurement devices. the operators have – in simple The high-g camera hub, for
Nothing is more cases – to test new equipment example, provides an ‘all
inconvenient than downtime (cables). For equipment armed out’ signal that can
in crash test sled operations such as high-speed cameras, be used for visual inspection
caused by malfunctioning test test engineers often have only, or fed back to the sled
equipment or due to defective to feed in new parameters control systems indicating
cabling. Important pieces manually or by returning that all connected high-speed
of equipment in crash tests to the control room and cameras are okay and ready to
are high-speed cameras receive a trigger.
and accessories such as
distribution boxes for
synchronization signals,
cabling, or LED onboard
illumination. These ‘electronic
eyes’ provide high-speed
insight into what happens
during the test, and are a
key source for obtaining
test results of prototypes or
confirmations – for example,
for seat restraint systems
already in production.
Occasionally something
doesn’t work or a last-minute
change in settings or recording
parameters is requested.
This is usually where it
gets hectic, and a well-
prepared set of replacement
parts comes in handy.
Acting fast in such a
situation minimizes delays in
the test schedule. Replacing

062 Crash Test Technology International
SEPTEMBER 2014

This isBOOSTING INNOVATIONhop ad

not a ower s

WE DO* TEST RIGS

*design & manufacture of custom built passive safety test rigs

Universal Impact Test System for

-Active bonnet misuse
-Pedestrian protection
-Interior tests
-Ejection mitigation

ABOVE: The AOS High G Ethernet
Hub provides control signals for both
visual feedback as well as feedback
signals for the sled control system.
It also feeds camera signals to
LED illumination, in order to run
synchronized with recording
parameters of individual cameras

For recording, the cameras connection. A live video-out High Dynamics Actuator for
require exact parameters on the camera allows setting
such as resolution, point of f-stop and focus. -Components test
of trigger, etc. To change a -Advanced Lateral Impact Simulation
set of parameters, one must Running sled systems -Simulation of complex crash pulses (sled)
often connect the camera to with low breakdown times is
the control PC and feed in important for justifying the 063Crash Test Technology International
parameters by way of software. large investment. Suppliers of SEPTEMBER 2014
Modern cameras can store a state-of-the-art measurement
set of predefined settings in devices are part of the
the camera. These camera optimization by designing
templates are pre-programmed equipment that meets
in the camera. Once the the demand for a smooth
camera is operating, it workflow. In the end, both
automatically loads recording the manufacturer of test
settings, starts gathering equipment and operators of
images, and waits for sled systems face the same
triggering. This releases the challenge: staying competitive
operator from time-consuming with high-quality services and
setup by reconnecting the reliable equipment. This is a
camera to the control PC for first step toward a profitable
relationship with customers. ‹

PRODUCTS AND SERVICES Pedestrian airbag L&T Technology Services
development
To learn more about this
L&T Technology Services has used finite element modeling to advertiser, please visit
closely analyze pedestrian airbag technology
www.ukipme.com/info/ctt

ONLINE READER INQUIRY NUMBER 512 L&T Technology
Services has been at
the forefront of the mechanisms to save ABOVE: Human finite element Pedestrian airbags are one
crash test industry for years. pedestrians’ lives. There pedestrian dummy models and a of the passive safety products
It uses its expertise and is also continual development finite element vehicle model were that reduce injury to the
experience to meet mobility of active safety systems to used to evaluate the performance of pedestrian during frontal
test demands with precision, avoid accidents involving a various pedestrian airbag components impacts. From a technical
professionalism and speed. pedestrian. Until now, it has point of view, knowledge
The company has more than not been possible to achieve can be taken from interior
15 years of experience in zero impacts/accidents using airbag technology and applied
new product development only active safety systems. to an airbag that is located
processes such as ideation, Pedestrians in conflict with outside the passenger cabin.
optimization, testing, passenger cars represent
research and development, an important portion of The pedestrian airbag,
preproduction prototyping, all road user fatalities. the first of its kind in a
production control, and Almost 1.1 million people production vehicle, consists
post-production lifecycle per year die in road accidents of a number of components
management and support. worldwide, many due all working together to enable
The company engineers to pedestrian impacts. the overall performance.
solutions in crash test During the development
simulations for full vehicle
crashes, occupant safety
and pedestrian safety
through the system and
component-level simulation
of body-in-white (BIW)
structures, seatbelts, airbags,
instrument panels, etc.
In parallel, its electronics
team supports the
development of safety
products such as antilock
braking systems (ABS),
lane departure warning
systems and crash avoidance
systems, with the use of
model-in-the-loop (MIL)
to real-time tests with
software-in-the-loop (SIL)
in a simulated environment.
In the automotive
market, many different
studies are continually being
conducted in the domain
of passive safety systems –
and not just for the occupants;
car manufacturers have
also started developing

064 Crash Test Technology International
SEPTEMBER 2014

“The basic pedestrian safety system includes pedestrian airbag PRODUCTS AND SERVICES
control unit, pedestrian airbag module, hood lift limiter, hood
hinge release mechanism, hood hinges and sensors”

process, numerous challenges ACCELERATION (g) WITHOUT PEDESTRIAN AIRBAG simultaneously sent to the two
were mastered – both on WITH PEDESTRIAN AIRBAG pyrotechnical mechanisms
a component and complete (hood popper and the
system level. The technology TIME (ms) pedestrian airbag inflator).
presented is a first unique
step in using airbag PEDESTRIAN MECHANISM TO milliseconds. In comparison Computer-aided
technology to address IMPACT SIGNALS OPEN THE HOOD with a conventional interior engineering simulations
collisions with pedestrians. FROM SENSORS (HOOD POPPER) passenger airbag, which were created based on human
Passenger cars are reported primarily opens a lid and finite element pedestrian
as the most frequent (74%) DEPLOYMENT OF positions itself, this process (dummy) models and a
collision opponent in fatal PEDESTRIAN is much more complex finite element vehicle model
pedestrian accidents. AIRBAG and puts high demands on using explicit solvers such
the design and folding of as LS-Dyna, PAM-CRASH,
In 75% of recent car- TOP: Comparison of accelerations of the airbag. Abaqus and RADIOSS. The
pedestrian crashes, the the head during pedestrian impact with purpose was to evaluate the
car is moving forward and and without airbag The basic pedestrian safety performance of the complete
in more than 85% of these, system includes pedestrian airbag performance, airbag
the collision takes place ABOVE: Diagram depicting how a basic airbag control unit, pedestrian coverage and overall occupant
at speeds up to 40km/h. pedestrian airbag system works airbag module, hood lift kinematics. The human
Furthermore, the most limiter, hood hinge release FE pedestrian model of the
frequently injured body parts mechanism, hood hinges 50th percentile male was
are the lower extremities and sensors. The system’s considered.
followed by the head, upper activation range is between
extremities, chest, pelvis, 20km/h and 50km/h. Finite element simulations
spine, face and abdomen. Sensors embedded in the using a generic car and the
front of the car’s bumper pedestrian dummy (citation:
Further adaptations transmit signals to the LSTC) were considered for
were needed to surrounding pedestrian airbag control the pedestrian impact case.
components and several new unit. When the car comes in The Head Injury Criterion
developments were required contact with an object, the (HIC) is a major injury
to achieve the essential overall signal changes. The control criterion that measures the
performance of the system. unit evaluates the signals likelihood of a head injury
For example, the lift limiter and if it registers what it arising from an impact.
and tailor-made hood hinges, interprets as a human leg,
which may be perceived the pedestrian airbag The study has been
as minor parts, actually technology will be activated. performed as part of the
contribute a lot to the When a decision to trigger the development of pedestrian
overall performance of pedestrian airbag technology airbags. It was observed
the technology. During the is made, trigger signals are that the HIC15 in a pedestrian
inflation phase, the pedestrian impact drastically decreased
airbag has to push the hood thanks to the pedestrian
upward and deploy itself airbag. A value of 700
over an uneven surface and is the maximum allowed
position on the windshield HIC15 under the provisions
and the A-pillars (vertical of the US advanced
or near vertical supports of airbag regulation.
windshield).
Pedestrian airbag
Opening of the hood technology thus lowers
and deployment of the airbag the risk of a severe injury
needs to be done in a few and helps in improving
pedestrian safety. ‹

065Crash Test Technology International
SEPTEMBER 2014

PRODUCTS AND SERVICES Heavy-duty sled EXHIBITOR
testing system
HYGE
The HYGE 24in sled is a bigger acceleration testing system designed
for the heavy test specimens that are becoming more common To learn more about this
advertiser, please visit

www.ukipme.com/info/ctt

ONLINE READER INQUIRY NUMBER 513 Recent changes in 120
testing requirements
and the use 100
of specialized sled and
test fixtures have added Acceleration ( g) 80
considerable weight to
test specimens, exceeding 60
the capabilities of many
acceleration test systems. The 40
HYGE 12in System’s ability
to handle major testing loads 20
with accuracy and precision
has made it an industry 0 4,800 lb 1,200 lb
standard for decades, but its 10,000 lb (2,177kg) (544kg)
makers say that the proven (4,536kg)
capabilities of the HYGE 24in
System make it the perfect Payload (lb & kg)
choice for the biggest and most
demanding testing payloads. ABOVE: 24in typical performance
The HYGE 24in System range – acceleration versus payload
can produce 1,000,000 lb
(4,500,000N) of force (over provides fluid to vary the TOP: Several rows of seating in a added by specialized test
four times the force of the volume of the cylinders; Boeing 737. Testing was also done fixtures, while the standard
12in System) and handle and the control center, with this rig to determine the restraints sled allows for testing of
10,000 lb (4,500kg) of payload which contains the valve required to hold items in the cargo bay light trucks and sport utility
with ease. With smaller system, computer control vehicles. In addition, the 24in
payloads, the 24in System is and operator station. System has the structural
capable of producing pulses integrity and thrust capability
at 100g and a velocity of Pulse shaping is done to perform side-impact tests,
110mph (177km/h). with metering pin technology. which are not possible with
The 24in System uses HYGE’s special pin design/ ‘light rail’ systems.
HYGE’s proven technology, development software enables
with its mechanical simplicity, the engineer to enter the It is also designed to be
for increasing efficiency and characteristics of the desired user-friendly. A graphical user
reducing downtime. The waveform and automatically interface enables the operator
system has just two moving generate the required metering to visually determine the
parts, simplifying and pin profile. Pins can either be status of the system at a
reducing maintenance labor machined or assembled from glance, and program firing
and cost. The entire HYGE HYGE’s modular pin option. parameters using a menu
24in System consists of just The 24in System’s design system. The control center
five major components: the provides extremely repeatable also offers a convenient
actuator, which has a stroke and reproducible acceleration interface to a variety of
length of 6ft (183cm); the pulses, enabling accurate supporting equipment. ‹
rail system and carriage; the simulation and modeling of
pneumatic system, which crash conditions. The system
provides pressurized gas for has proven its repeatability
firing the piston; the fluid and reliability over time,
transfer system, which with systems over 40 years
old routinely demonstrating
repeatability of better than
±2% today.

HYGE says that the 24in
System is extremely versatile.
It has been used for years
to test school buses, trucks,
airplanes and other large
specimens, and can easily
handle the increased payload

066 Crash Test Technology International
SEPTEMBER 2014

Crash analysis MeasX GmbH & Co KG PRODUCTS AND SERVICES
software
To learn more about this
The X-Crash software package from MeasX is Euro NCAP’s advertiser, please visit
choice for efficient and accurate crash analysis
www.ukipme.com/info/ctt

Crash tests and active ONLINE READER INQUIRY NUMBER 514
safety tests play a
central role in the PHOTO: EURO NCAP
development of vehicles
and their components. They thoroughly focused on ABOVE: Euro NCAP crash analysis (Canada), Occupant Crash
provide verification that the the needs of its users. of an Alfa Romeo Giulietta using the Protection for Hybrid II
required safety standards and Individual tests and complete X-Crash software package and Hybrid III, FMVSS 214
protection criteria are met test series can be quickly and (USA), Side Impact Protection,
or even exceeded, and they reproducibly analyzed and able to explore and preview ECE R94 (Europe), Frontal
also encompass vehicle compared according to current data. Users can store and Collision Protection, ECE R95
and component tests for laws and standards. For norm manage their test data either (Europe), Lateral Collision
optimizing safety systems and regulation compliant in file oriented systems, Protection, ECE R80 (Europe),
within defined target analysis and report purposes, databases or also in an Regulation for Motor Vehicle
areas and for reinforcing a great variety of algorithms ASAM conformal database. Equipments and Parts, Hybrid
development strategies. is available. Analysis macros II, ADR 69/00 (Australia),
Challenges in the area of carry out all necessary Automatic analysis Full Frontal Impact Occupant
vehicle safety are constantly calculations automatically procedures and reports are Protection, Hybrid II and
increasing in complexity and and present the results in available for the following Hybrid III.
demand testing and analysis tables and diagrams. These permit regulations: FMVSS
systems of the highest quality. results can be stored in 208 (USA), MVSS 208 X-Crash also impresses
The analysis software different formats and generate with its extensive customizing
X-Crash from MeasX complete reports. The analysis options: the user interface
reliably supports automobile part contains the proven dialogs, analysis algorithms
manufacturers, suppliers and macros of the Crash Base and report layouts can
crash laboratories in analyzing System. Using the DIAdem be adapted to changing
and documenting all types programming and VBS- conditions and individual
of safety tests. In constant Libraries, users can easily requirements via either pure
development since the extend the functionality parameterization or scripting
mid-1990s, the software of X-Crash. QuickLook, with Visual Basic Script.
is today one of the world’s QuickCalc and QuickEdit
leading standard systems for contain a variety of functions The latest version of
analyzing vehicle safety tests. X-Crash, release 5.0, includes
Even the European New Car full ISO MME 2.0 support. ‹
Assessment Programme (Euro
NCAP) relies on X-Crash: all
accredited crash laboratories
in Europe use MeasX’s
software for analysis
and reporting. Vehicle
manufacturers with their own
dummy labs and certification
labs also appreciate the
functionality of X-Crash
ATD, which was specially
developed for the certification
of dummies. From the first
examination of the data to
the final report, X-Crash is

067Crash Test Technology International
SEPTEMBER 2014

PRODUCTS AND SERVICES High-speed imaging EXHIBITOR

Research at the University of Freiberg shows that crash testing is not Vision Research
the only area of automotive research employing high-speed cameras
To learn more about this
advertiser, please visit

www.ukipme.com/info/ctt

ONLINE READER INQUIRY NUMBER 515 Automotive crash airbags are deployed,
testing is one of the researchers use high-speed
first applications cameras to capture the ABOVE: The Phantom moving the laser sheet, the
people think of for high-speed inflation process at Miro R120 features team scanned multiple planes
cameras, enabling researchers anywhere from 2,500 image-based auto-trigger to of view, essentially resulting
to study an event that to 5,000fps. Because capture unpredictable events and in a three-dimensional
ordinarily happens too fast an airbag inflates at has a minimum exposure of 1µs visualization of the particles.
for the human eye to see. On approximately 200mph
board a vehicle, researchers once triggered, By comparing successive
use Phantom Miro cameras verifying exactly how images of the particles,
that are small, lightweight and long this process takes engineers could accurately
rugged, making them ideal would be impossible determine their velocity,
for detecting potential dangers with just the naked eye. meaning that they now knew
for passengers, without both the speed and direction
obstructing or interfering with In seeking to improve that the fuel was flowing.
the rest of the space. Outside fuel efficiency, engineers at This knowledge helped them
the vehicle, high-resolution the University of Freiberg are to deduce if any of it was
cameras record the impact the leveraging Vision Research being wasted or could be
crash has on a vehicle’s overall Phantom cameras to study put to more efficient use if
structural integrity. However, the fluid mechanics inside adjustments were made to the
crash testing is not the only combustion engines. The engine itself. The team hopes
application that uses high- amount of power generated that the data they’ve collected
speed cameras. by a combustion engine is will eventually lead to the
The research and dependent upon a proper development of replacement
development of key car balance of fuel and air, engine parts optimized for
components such as airbags, making efficient particle better engine flow.
antilock braking systems, flow crucial to the engine’s
tires, car seats, vehicle functionality. The work being done
aerodynamics, and even fuel in Germany is just one of
efficiency, use digital high- In order to be able to the many ways that Vision
speed cameras. capture the processes within Research cameras have
Much like how slow-motion the combustion chamber, enabled researchers to observe
footage helps researchers to the University’s head of Fluid previously unnoticed details,
analyze exactly how a car’s Mechanics and Machines resulting in safer, cleaner and
frame behaves at any given Department, Christopher more efficient automobiles. ‹
instant of a high-speed crash, Brücker, and his team, created
it can also be used to observe a series of combustion engines
airflow or fluid particle with viewing windows that
patterns inside various engine could be peered into using
workings, determine what the Vision Research cameras.
conditions components such Using a process known as
as tires can withstand before particle image velocimetry,
morphing or losing shape, or PIV, the researchers were
or even to discover how long able to track and measure the
it takes certain reactions to velocity of each individual
occur in various car parts. liquid/gas molecule in the
For example, in order to combustion chamber. Tracer
determine the rate at which particles were injected into the
chamber and then illuminated
using a laser sheet. By rapidly

068 Crash Test Technology International
SEPTEMBER 2014

Active hood Encopim PRODUCTS AND SERVICES
misuse testing
To learn more about this
Encopim’s Universal Impact Test System has been adapted advertiser, please visit
to test pedestrian impacts under climatic conditions
www.ukipme.com/info/ctt

After many years ONLINE READER INQUIRY NUMBER 516
supplying turnkey,
custom-built solutions closed-loop control is based MAIN: UITS modular structure
for the passive safety field, on physical model simulation for active hood misuse tests
Encopim has upgraded its (considering adiabatic
Universal Impact Test System expansion, friction and ECE R16) or any velocity/
(UITS) to fulfill the increasing pressure behavior) with acceleration pulse-regulated
needs of car makers and compensation for acceleration application.
accredited test laboratories. deviations. Thus, the level of
One of these new accuracy in the impact speed Besides active hood misuse
necessities is to check whether is maintained, no matter how tests, the UITS is intended
the active hood has deployed cold or hot it is. for testing procedures such
or not after an object (such as as Pedestrian Protection
a basketball or a small animal) The HDA can also be used EC631/2009 and Euro NCAP
has hit the vehicle’s bumper. for applications other than (lower legform to bumper test,
Moreover, since the car pedestrian safety, such as crash upper legform to hood leading
is placed inside a climatic simulations for the testing of edge test, headform to hood
chamber that has been cooled seats and seatbelts (for example and windscreen test, Flex-PLI,
down to -40°C or heated up etc); R12 (body block test,
to +85°C, the launch cannot guided headform test, etc);
take longer than a few seconds JNCAP; knee impact; FMVSS
after the chamber doors have 201U (free flight headform
been opened. inside vehicles); FMVSS 226
In order to be able to fulfill (ejection mitigation); and the
all of the above-mentioned pendulum tests (R17, R25,
conditions, Encopim has R21 and R80).
incorporated its High Dynamics
Actuator (HDA) into the UITS’s Some notable updates to
arm. The HDA is based on a the UITS are the reduced size
pneumatic propulsion system of the Free Motion Headform
whose velocity is closed- Compact module (only
loop controlled by a highly 302mm long) and the new
responsive hydraulic brake. guiding system of the Ejection
The HDA’s predictive and Mitigation module (the system
is contained within the
TOP: Free Motion Headform Compact headform’s projection). ‹
module

ABOVE: Ejection Mitigation module

LEFT: High Dynamics Actuator
assembled on PPBB module to
perform tests with Flex-PLI impactor

069Crash Test Technology International
SEPTEMBER 2014

PRODUCTS AND SERVICES Faster FEA GNS
post-processing
To learn more about this
Version 2.1 of GNS’s Animator4 post-processor for FEA analysis now advertiser, please visit
takes advantage of recent advances in graphics processing units
www.ukipme.com/info/ctt

ONLINE READER INQUIRY NUMBER 517 GeForce GTX 770 on Linux

Since the first days of no noticeable advantage. For 30 GeForce GTX 770 on Linux
GNS’s Animator3, the example, when displaying a GeForce GTX 770 on Linux
computing power of cross-section on a Quadro 30 2.0 2.1
graphics cards has steadily 2000 (see center graph, right). 2.0 2.1
increased. Their extreme 25 2.0 2.1
specialization means that As one can see from the 30
modern-day graphics example of the GeForce GTX
processing units (GPU) yield 770 (see top graph, right), a 25
much more computing power high-end graphics card yields
than the versatile CPUs of noticeable performance boosts, 20
main workstation computers. even on complex tasks such as 25
With this in mind, GNS displaying cross-sections.
decided that it was time to 20
move some calculation tasks Earlier versions of
to the graphics card. Until Animator barely used the 1250
now, its Animator4 product graphics card. That’s why
made only limited use of this it was irrelevant whether 15
optimization. But with Version there was a high-end or
2.1, the graphics card’s entry-level graphics card used 10
memory and processor are in the workstation. Only a 15
used extensively. This brings reliable OpenGL driver was
some changes for the user. mandatory. 10
The first is speed. Its maker
says that Animator4 now With Version 2.1, this is 5
moves, rotates, zooms and about to change. High-end 10
animates 3D models much graphics cards now offer a
more smoothly. If the model much better performance 5
reacts without hesitation to advantage. Since high-end
user input, it’s much easier graphics cards are already 0
to work with than when widely used in high-end 5
the user is fighting with an workstations, the changes 0 A nimation Rotation Fringed Fringed Cross Fringed
asynchronous, jerking model. made in Animator4 2.1 should Rotation
GNS’s benchmarks showed immediately yield an important Rotation A nimation Rotation Section Cross
a speed increase of up to performance boost – for free. Cross SFreincgtieodn
700%. In everyday scenarios, 0 Animation Fringed Fringed Cross
there should still be an In the same way, Section FSreincgtieodn
advantage of 50-200%. Animator4 profits from the A nimation A nimation Rotation Cross Cross
A Quadro 2000 is a larger memory on the graphics Fringed Fringed
three-year-old, mid-range- cards. As more model data Section Section
graphics card. It can be can be stored directly on A nimation Rotation
seen as a reference for many the graphics card, less of it
workstations currently in has to be re-transferred. Quadro 2000 on Windows 7
use. The performance boost
is impressive even for such a Nevertheless, the 8 Quadro 2000 on Windows 7
simple graphics card. advantages are clear, even on 2.0 2.1
The magnitude of the boost entry-level graphic cards, so
depends on the task. There are performance regression will 78 Quadro 2000 on Windows 7
still some areas where there is not be an issue in Version 2.1. 2.0 2.1

Intel Graphics cards (e.g. 768
HD 4600) fare much better 2.0 2.1
with the new OpenGL standard
and get a major performance 657
boost. This improves the
654

534

243

132

021 Rotation Fringed Fringed Cross Fringed
01 Animation Section
0 Animation A nimation Rotation Cross Cross
Section FSreincgtioend
A nimation Rotation Fringed Fringed Cross Cross
Section SFreincgtioend
A nimation Rotation Cross

Rotation Fringed Fringed Section

A nimation Rotation

Intel HD4600 on Windows 7

7 Intel HD4600 on Windows 7 2.0 2.1
2.0 2.1
67 Intel HD4600 on Windows 7

576 2.0 2.1

465

354

234

123

012

01 Animation Rotation Fringed Fringed Cross Fringed
0 Animation Rotation FArninimgeadtion
Rotation AFrninimgeadtion RFrointagteiodn SCerocstison FSCFCCSrreerrriiooonnccsssggttiissseeooddnn
Animation Animation RFrointagteiodn SCerocstison
Rotation Section
The developmSeecntiotn team
ABOVE: Performance comparisons of

Animator4 Version 2.0 versus 2.1 using of Animator4 will continue

three different graphics cards to strive for possibilities to

make the best use of modern

workstations. As usual, this

new version is a milestone,

situation on laptops with but not the ultimate.

integrated graphics. All of the above means that

The new OpenGL technique users should be able to get a

enables some beautification for lot more performance for the

no performance cost: impact same money, but investment is

points are now really round still required. The GPUs need

instead of octagonal. SPH to support OpenGL 3.3, which

elements are now real spheres has been the standard in CAE

instead of tetrahedral. departments for some years

The smooth visualization now. Note that a GPU is

of 3D models is a crucial required – recent Animator

characteristic of Animator4, versions are not capable of

which is why, the makers say, running on an HPC cluster

Animator is a favorite choice without a graphics chipset,

for professional users. as was possible in the past. ‹

070 Crash Test Technology International
SEPTEMBER 2014

The future of crash Dummies4You PRODUCTS AND SERVICES
test dummies
To learn more about this
Professor Hermann Steffan of the Vehicle Safety Institute at the Graz advertiser, please visit
University of Technology, Austria, assesses hardware versus software
www.ukipme.com/info/ctt

Since the early 1950s, biomechanics is the ONLINE READER INQUIRY NUMBER 518
different kinds of application of so-called human
so-called ‘dummies’ body models. Some of them ABOVE: Dummies4You can supply Thus the availability
have been used to evaluate even include muscle models the required spare parts for a range of sophisticated crash test
and develop the safety and their control algorithms of ATDs including Hybrid IIIs, SID-IIs dummies remains an inevitable
of aircraft and cars. They to simulate human behavior in and pedestrian dummies component in the development
were originally developed the crash and pre-crash phase. and evaluation of vehicle
in the USA; nowadays these These models are currently safety. To guarantee the
human-like test devices mainly applied in automotive further development and high
are used as a standardized research to further enhance quality of these test devices,
development tool for new cars vehicle safety in different, real multiple providers such as
and aircraft all around the crash scenarios. Humanetics, Dummies4You
world. They are continuously and Jasti will need to work
improved to guarantee the Although numerical in parallel for many years. ‹
best possible human-like models are being improved
behavior (biofidelity), as well all the time, at least the
as good repeatability. Also, final evaluation of a vehicle’s
their robustness during the safety is still performed using
crash tests must be physical tests. They still offer
guaranteed. several advantages compared
In recent years, numerical with numerical models. For
models of the dummy have every numerical model, its
been developed to use for validation is a big concern,
the virtual simulation and which demands a lot of
optimization of the vehicle testing at least at component
and its restraint systems. level. Nevertheless a major
They are mainly applied in uncertainty remains regarding
the development phase of a the completeness of the
new car. The latest step in model and the predictability
of all physical phenomena.

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Humanetics .......................................................................................35

071Crash Test Technology International
SEPTEMBER 2014

OPINION

Vehicle crash dynamics is a complex LGUEKNIAE NOV object where transfer of momentum is not a
science involving crash momentum, factor, these equations imply that adequate
energy absorption, occupant Big, heavy vehicles are no crush space is the key to acceptable
dynamics, biomechanics, force- and match for physics when deceleration.
time-based analysis, and a host of other it comes to crash safety
considerations. It can be useful, however, Given that mass is not included in
to take a look at the basics that we studied A big light vehicle these equations, do we have a conflict
in university and just do some bench racing would not be as energy with the popular viewpoint that big, heavy
regarding the subject. efficient as a small light cars are the safest on the road? Big cars
Back in university we learned the vehicle, but we would imply larger crush spaces, hence are safer,
equations of linear motion. One of the be moving in the right, but these conventional vehicles also have
less popular equations seems to have responsible direction. greater mass and more kinetic energy
a lot of relevance to crash dynamics: Either way, we would be requiring absorption in a crash with a
vf2 = vi2 + 2as. designing vehicles for a static object, and greater fuel consumption.
This equation is not as familiar to us Weight begets weight.
engineers as the linear equations containing brighter future
acceleration (a) and time (t) such as So why not look to bigger but lighter
vf = vi + at vehicles? These vehicles could have
or adequate crush space, but could minimize
s = vit + ½ at2 mass for reduced energy absorption as
but it contains elements useful for well as for improved fuel economy. A big
consideration in crash dynamics: (vf2 - vi2) light vehicle would not be as energy efficient
is an expression of impact velocity squared as a small light vehicle, but we would be
while (a) and (s) are expressions of moving in the right, responsible direction.
deceleration and the distance over which Either way, we would be designing vehicles
this occurs. In other words, crush distance. for a brighter future.
This distance could be the space around
the engine, inside the door, or the thickness We could also consider the vehicle length
of padding in the A-pillar. separately from the width; vehicle length
Granted, this is a linear equation, can provide front and rear crush space, and
but it illustrates the point that in order to length does not affect frontal area, which
minimize decelerations we need to maximize impacts fuel economy. Greater vehicle
crush distance. We also need to absorb width, on the other hand, affects lateral crush
the crash energy efficiently over the entire space and rollover propensity positively, but
space available. does impact fuel economy negatively. As an
Let’s look at some examples. At 30mph aside, height also impacts fuel economy and
(48.28km/h) and an average deceleration safety negatively (increased frontal area and
of 20g we would need 0.46m crush space rollover probability). It seems like Ford has
to not exceed 20g deceleration. At 15mph moved in this direction with the Focus and
(24.14km/h) we would need 0.11m to not Flex; both are relatively long and low.
exceed the same 20g deceleration threshold.
This assumes a constant deceleration. And while we are bench racing, why not
Inefficient deceleration, where the g-level consider moving the engine out of the way
drops below the 20g threshold, implies of frontal crush space? The powertrain acts
that more crush space would be needed as a rigid block subtracting away from frontal
to counter the less effective deceleration crush space anyway. Let’s put it in the back
and to avoid spikes of deceleration later in and use that front space for luggage and
the crash pulse. crush space. Suitcases and clothes surely
This equation, once rearranged, is the are not as rigid as the engine and transaxle.
solution of the crash-related energy density We would have to absorb the kinetic
integral: energy of the powertrain throughout the full
e = (vf2 - vi2)/2 frontal crash, but is there a net gain? Maybe
which also equals as in the linear equation Tesla, Porsche and the old Beetle can teach
of motion. The two are connected.
Vehicle mass is not included in these us something! ‹
equations. Given an impact with a static
Gene Lukianov spent 20 years at Chrysler
working in vehicle dynamics and analytical
dynamics. Now a consulting engineer
with a thirst for knowledge, he runs
VRAD Engineering, providing vehicle
and suspension design services to the OEM
and aftermarket industries

SEPTEMBER 2014

Read exclusive news and features PICK UP YOUR FREE COPY www.AutomotiveTestingTechnologyInternational.com June 2014 JUNE 2014
online NOW! Plus: download your fully AT AUTOMOTIVE TESTING EXPO 2014
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Autonomous cars
Transmissions
What to test, and where and how
to test it: the challenges facing the Quieter vehicles are proving to
developers of driverless vehicles be an NVH challenge, and the
race is on to define more realistic
Digital EVs durability test cycles

The role of virtual prototyping It’s all about the electronics:
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in shortening EV programs new flagship won’t stop when
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Fiat safety centerAcnomexpcleluxsaivnedtoinusrigohf tthinetoOirtbsafsustuarneoplans Heat soakedTire testing UKIP Media & Events Ltd Inside Balocco Neusser speaks End-of-line
Calspan rebornNbHTCeaThhwRTeeiSasAnltiAdSatinitHnearggesTErtsveExceinSpsraaaioTrtsiocsNZhrhsOostaraeNttnosnhEctdAAetuemntcaoeehtmwrntihoocetilasoiqvguehyiiwpstmworewicn.tAfaisucHVotriooIlfeRitwvamyTocUtolthuiAvtetieiLvolaehnDtTuieUzemseMstacgtMnirenamInEgseohSTrdeateetclissohtnicnnooguloldgyInternational.com Calspan invests in electric
motors to bring the original We tour Fiat Group’s Volkswagen’s head of development on High-voltage components
flat-track right up-to-date historic proving ground the learning curve involved in moving for LaFerrari required a
in northern Italy from powertrain to full vehicle bespoke test rig

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UKIP Media & Events Ltd proving ground in the Mojave desert

Weathering Brake testing Cadillac Wind tunnels

Following a 10-year study, new An innovative facility at Developing We tour Fiat’s upgraded
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