Optional Extensions

Sled-on-Sled Test

For these applications, a collision device ismounted on the base sled, accommodating ahoneycomb to be provided by the customer,which serves as impactor for the penetration test.Additional masses can be mounted on the sled formaking up the desired total mass. This sled isaccelerated to the desired speed by the actuator of the catapult rig

A second sled carries the structure-undergoing testand is positioned on the guideway with its brakesapplied (with a braking pressure of around 140bar). The test allows penetration depths (specimendeformation) up to 700 mm. For measurementpurposes the test specimen (i.e. the doorstructure) and the dummy, which is mounted on a seat, are equipped with acceleration sensors.

The velocity of the impacting sled can be chosenat random up to a maximum velocity of 60 km/h.

Multi-Sled Operation

The sled changing station enables convenientchangeover from one sled to the next, inapplications where multiple sleds are used for avariety of applications.

Side Impact Simulation

The side impact simulation system developed byIST with servo-hydraulically controlled sled brakeenables the simulation of the acceleration timehistories of side impacts without the sled losingcontact with the catapult piston of the catapultactuator.

Low Speed Rear End

For this application IST is offering a simulationpackage enabling highest signal reproductionaccuracy, even with low accelerations. On thehydraulics side, a servo block with electricallycontrolled changeover module is mounted on thedriver cylinder of the four-stage servo valve. Theservo block carries two-servo valve combinationsthat are activated automatically depending on thetest selected on the test PC (low speed rear,frontal/rear end crash, side impact or pitchingtest). At the same time all system parametersassociated with this test type are loaded.

Pitching

This application simulates the pitchingmovement of the vehicle during a frontal crash.Up until now, the simulation of overlaid pitchingmovements of the vehicle during the crash has onlybeen possible in real, destructive crash tests, giventhat conventional catapult systems, not providingfor active, controlled pitching simulation, do notreproduce the damage on the test person (dummy)with sufficient accuracy.

The HIC (Head Injury Criterion) value, forexample, is up to 40% higher (depending on vehicle type) on a crash simulation system without pitching simulation, compared to a real, destructive crash test. To reduce this discrepancy to a tolerable level, ISThas developed a special system for pitching simulation.

Hydropuls®- Crash-Simulation System

Cata

pult

Instron SStructural Testing SSystems CCorp.28700 Cabot Drive, Suite 100,Novi, MI 48377, USATel: +1 248 553 4630 • Toll free: +1 800 651 0924Fax: +1 248 553 6869

Japan Tel: +81 44 853 8520Fax: +81 44 861 0411

South EEast AAsiaTel: +65 6774 3188Fax: +65 6774 1837

China Tel: +86 21 6215 8568Fax: +86 21 6215 0261

South AAmericaTel: +55 11 4195 8160Fax: +55 11 4195 8133

KoreaTel: +82 2 552 2311Fax: +82 2 553 9180

www.instron.com/istInstron is a registered trademark of Instron Corporation. Other names, logos, icons and marks identifying Instron products and services referenced herein are trademarks of Instron Corporation and may not be used without the prior written permission of Instron. Other product and company names listed are trademarks or trade names of their respective companies. Copyright © 2005 Instron Corporation. All rights reserved. All of the specifications shown in this brochure are subject to change without notice. POD IST0035 AE

Instron SStructural Testing SSystems GGmbHLandwehrstr. 65 64293 DarmstadtTel: +49 6151 / 3917-0Fax: +49 6151/ 3917-500

For information on IST products and services call your local worldwide sales, service and technical support offices:

The protection of life and limb of vehicleoccupants is one of the prime tasks in motorvehicle development. Next to active safetysystems, passive passenger restraint systems arecritical elements when it comes to preventinginjury and ensuring the safety of vehicleoccupants in the case of accidents. In the event ofa crash, occupant restraint systems prevent acollision of the occupants with hard components inthe vehicle interior such as the dash panel orsteering wheel.

The interaction between the airbag and othervehicle components has a critical influence on thelevel of protection afforded by the airbag. To thisend, the properties of the seat belt including beltretractors, steering wheel, headrest, seat cushionsand kneepads must be optimally adapted to theairbag system.

The development of new vehicle conceptsnecessitates the design of a complete new occupant restraint system. All phases of component development andevaluation of their interaction with other vehiclecomponents are supported by numericalsimulation.

2

Hydropuls® - Crash - Simulation System

3

System Overview

Numerical simulation includes the following aspects:K Crash behavior of mechanical structures

K Simulation of occupant behavior

K Component simulation for optimization of,e.g., gas generator, airbag etc.

K Strength analysis

K Simulation and coordination ofelectromechanical and electronic sensorsystems for crash detection

Numerical simulation significantly reduces the time and cost spent on manufacture andtesting of prototypes. The basis for decisionmaking on the necessary measures forcoordinating the various system components is broadened and the development process is streamlined.

Following implementation of the simulationresults in the development of the prototype,optimum interaction between all components ofthe restraint system is then tested with the help ofvehicle crash tests, tests on a catapult rig andother testing procedures. The Hydropuls® CrashSimulation Rig therefore constitutes animportant element in the development ofrestraint systems and their components.

Areas of Application of theCrash Simulation System:

K Dynamic seat testing to ECE R 17

K Dynamic seat testing to AS 8049(Aerospace Standard)

K Crash Simulation Tests with dummies in thevehicle body or on a rigid fixture

K Dynamic testing of restraint systems to ECE R 16

K Crash Simulation tests with pyrotechnicalrestraint systems (belt retractors, airbags)

K Testing of cargo restraint systems to DIN 75410/2

K Child seat testing to ECE R 44

K "Low Speed Rear End Impact" - seat testing

K Test pulses to US and Euro NCAP (New Car Assessment Program)

Catapult Performance Data Modular Concept

The Hydropuls® Crash Simulation Rig isdesigned so that all applications currentlyavailable as options (see under Options) can beretrofitted quickly and easily at a later stage. Tomake sure that this will work without problems, thebase plate for the external braking system for sideimpact testing is already included in thefoundation, and pits and anchor bolts forinstallation of the pitching drive are alreadyprovided for in the basic system, to mention only afew examples.

RS CrashSim Software

The RS CrashSim simulation software isconceived for drive signal generation,visualization of the test sequence, andpresentation of test results and display of thesystem status. It also serves as interface to theperipheral equipment.

Main featuresRS CrashSim is a software module based on theRS LabSite® software suite enabling drive signalsfor the catapult rig to be calculated and iteratedfrom pre-set acceleration time histories.

Main features of the software module are:K Direct calculation of drive signals from

specified acceleration signals, based ona non-linear, inverse model of the catapult rig.

Acceleration force max. 2,500 kN

Working stroke max. 1,700 mm

Payload max. 2,000 kg Including test specimen, dummies, fastening elements, data acquisition equipment, cameras, camera stand

Velocity max. 90 km/h

Acceleration gradient (typical value) >10 g/msec

Frequency range max. 150 Hz

Tolerance on maximum speed max. +/- 0,5 km/h

Repeatability (rms value on total signal)Acceleration ± 1 gVelocity ± 0,5 km/h

K Enhanced signal reproduction accuracythrough iteration on the basis of measuredacceleration signals; display of errorconvergence

K Monitoring with respect to drive signalsexceeding system limits prior to triggering ofthe shot

K Parameterization of the model and input of specimen properties through a userfriendly operating interface

K Visualization of system status through aprocess master display

Labtronic® 8800 StructuralTest Controller

The Labtronic 8800 structural test controller is acontrol system adapted specifically to therequirements of Hydropulstesting systems.It provides a maximum of six control channels forup to four test groups. Sensor signals andcommand signals are digitally processed. In conjunction with the programmable logiccontroller, the Labtronic 8800 structural testcontroller constitutes the central element of thetesting system.

The protection of life and limb of vehicleoccupants is one of the prime tasks in motorvehicle development. Next to active safetysystems, passive passenger restraint systems arecritical elements when it comes to preventinginjury and ensuring the safety of vehicleoccupants in the case of accidents. In the event ofa crash, occupant restraint systems prevent acollision of the occupants with hard components inthe vehicle interior such as the dash panel orsteering wheel.

The interaction between the airbag and othervehicle components has a critical influence on thelevel of protection afforded by the airbag. To thisend, the properties of the seat belt including beltretractors, steering wheel, headrest, seat cushionsand kneepads must be optimally adapted to theairbag system.

The development of new vehicle conceptsnecessitates the design of a complete new occupant restraint system. All phases of component development andevaluation of their interaction with other vehiclecomponents are supported by numericalsimulation.

2

Hydropuls® - Crash - Simulation System

3

System Overview

Numerical simulation includes the following aspects:K Crash behavior of mechanical structures

K Simulation of occupant behavior

K Component simulation for optimization of,e.g., gas generator, airbag etc.

K Strength analysis

K Simulation and coordination ofelectromechanical and electronic sensorsystems for crash detection

Numerical simulation significantly reduces the time and cost spent on manufacture andtesting of prototypes. The basis for decisionmaking on the necessary measures forcoordinating the various system components is broadened and the development process is streamlined.

Following implementation of the simulationresults in the development of the prototype,optimum interaction between all components ofthe restraint system is then tested with the help ofvehicle crash tests, tests on a catapult rig andother testing procedures. The Hydropuls® CrashSimulation Rig therefore constitutes animportant element in the development ofrestraint systems and their components.

Areas of Application of theCrash Simulation System:

K Dynamic seat testing to ECE R 17

K Dynamic seat testing to AS 8049(Aerospace Standard)

K Crash Simulation Tests with dummies in thevehicle body or on a rigid fixture

K Dynamic testing of restraint systems to ECE R 16

K Crash Simulation tests with pyrotechnicalrestraint systems (belt retractors, airbags)

K Testing of cargo restraint systems to DIN 75410/2

K Child seat testing to ECE R 44

K "Low Speed Rear End Impact" - seat testing

K Test pulses to US and Euro NCAP (New Car Assessment Program)

Catapult Performance Data Modular Concept

The Hydropuls® Crash Simulation Rig isdesigned so that all applications currentlyavailable as options (see under Options) can beretrofitted quickly and easily at a later stage. Tomake sure that this will work without problems, thebase plate for the external braking system for sideimpact testing is already included in thefoundation, and pits and anchor bolts forinstallation of the pitching drive are alreadyprovided for in the basic system, to mention only afew examples.

RS CrashSim Software

The RS CrashSim simulation software isconceived for drive signal generation,visualization of the test sequence, andpresentation of test results and display of thesystem status. It also serves as interface to theperipheral equipment.

Main featuresRS CrashSim is a software module based on theRS LabSite® software suite enabling drive signalsfor the catapult rig to be calculated and iteratedfrom pre-set acceleration time histories.

Main features of the software module are:K Direct calculation of drive signals from

specified acceleration signals, based ona non-linear, inverse model of the catapult rig.

Acceleration force max. 2,500 kN

Working stroke max. 1,700 mm

Payload max. 2,000 kg Including test specimen, dummies, fastening elements, data acquisition equipment, cameras, camera stand

Velocity max. 90 km/h

Acceleration gradient (typical value) >10 g/msec

Frequency range max. 150 Hz

Tolerance on maximum speed max. +/- 0,5 km/h

Repeatability (rms value on total signal)Acceleration ± 1 gVelocity ± 0,5 km/h

K Enhanced signal reproduction accuracythrough iteration on the basis of measuredacceleration signals; display of errorconvergence

K Monitoring with respect to drive signalsexceeding system limits prior to triggering ofthe shot

K Parameterization of the model and input of specimen properties through a userfriendly operating interface

K Visualization of system status through aprocess master display

Labtronic® 8800 StructuralTest Controller

The Labtronic 8800 structural test controller is acontrol system adapted specifically to therequirements of Hydropulstesting systems.It provides a maximum of six control channels forup to four test groups. Sensor signals andcommand signals are digitally processed. In conjunction with the programmable logiccontroller, the Labtronic 8800 structural testcontroller constitutes the central element of thetesting system.

Optional Extensions

Sled-on-Sled Test

For these applications, a collision device ismounted on the base sled, accommodating ahoneycomb to be provided by the customer,which serves as impactor for the penetration test.Additional masses can be mounted on the sled formaking up the desired total mass. This sled isaccelerated to the desired speed by the actuator of the catapult rig

A second sled carries the structure-undergoing testand is positioned on the guideway with its brakesapplied (with a braking pressure of around 140bar). The test allows penetration depths (specimendeformation) up to 700 mm. For measurementpurposes the test specimen (i.e. the doorstructure) and the dummy, which is mounted on a seat, are equipped with acceleration sensors.

The velocity of the impacting sled can be chosenat random up to a maximum velocity of 60 km/h.

Multi-Sled Operation

The sled changing station enables convenientchangeover from one sled to the next, inapplications where multiple sleds are used for avariety of applications.

Side Impact Simulation

The side impact simulation system developed byIST with servo-hydraulically controlled sled brakeenables the simulation of the acceleration timehistories of side impacts without the sled losingcontact with the catapult piston of the catapultactuator.

Low Speed Rear End

For this application IST is offering a simulationpackage enabling highest signal reproductionaccuracy, even with low accelerations. On thehydraulics side, a servo block with electricallycontrolled changeover module is mounted on thedriver cylinder of the four-stage servo valve. Theservo block carries two-servo valve combinationsthat are activated automatically depending on thetest selected on the test PC (low speed rear,frontal/rear end crash, side impact or pitchingtest). At the same time all system parametersassociated with this test type are loaded.

Pitching

This application simulates the pitchingmovement of the vehicle during a frontal crash.Up until now, the simulation of overlaid pitchingmovements of the vehicle during the crash has onlybeen possible in real, destructive crash tests, giventhat conventional catapult systems, not providingfor active, controlled pitching simulation, do notreproduce the damage on the test person (dummy)with sufficient accuracy.

The HIC (Head Injury Criterion) value, forexample, is up to 40% higher (depending on vehicle type) on a crash simulation system without pitching simulation, compared to a real, destructive crash test. To reduce this discrepancy to a tolerable level, ISThas developed a special system for pitching simulation.

Hydropuls®- Crash-Simulation System

Cata

pult

Instron SStructural Testing SSystems CCorp.28700 Cabot Drive, Suite 100,Novi, MI 48377, USATel: +1 248 553 4630 • Toll free: +1 800 651 0924Fax: +1 248 553 6869

Japan Tel: +81 44 853 8520Fax: +81 44 861 0411

South EEast AAsiaTel: +65 6774 3188Fax: +65 6774 1837

China Tel: +86 21 6215 8568Fax: +86 21 6215 0261

South AAmericaTel: +55 11 4195 8160Fax: +55 11 4195 8133

KoreaTel: +82 2 552 2311Fax: +82 2 553 9180

www.instron.com/istInstron is a registered trademark of Instron Corporation. Other names, logos, icons and marks identifying Instron products and services referenced herein are trademarks of Instron Corporation and may not be used without the prior written permission of Instron. Other product and company names listed are trademarks or trade names of their respective companies. Copyright © 2005 Instron Corporation. All rights reserved. All of the specifications shown in this brochure are subject to change without notice. POD IST0035 AE

Instron SStructural Testing SSystems GGmbHLandwehrstr. 65 64293 DarmstadtTel: +49 6151 / 3917-0Fax: +49 6151/ 3917-500

For information on IST products and services call your local worldwide sales, service and technical support offices: