Test systems and Instrumentation

Crash Simulation Sleds

Aries´s crash simulation systems are made up of a sled upon which the components to be tested are placed. It is then accelerated by a set of elastic bands, which make it capable to reach specific end speeds with extremely high accuracy though the use of adaptable computerized control of the energy.

Our crash simulation installations come with one of the following energy absorption devices in order to achieve the required deceleration profile:

This deceleration method is normally used in component tests, such as seat belts. It is recommended by ECE regulations for head-on impact simulation tests (R16) and for child car restraints (R44).

The adaptive velocity control system places the sled in the appropriate “fire” position using an auxiliary sled along the guided rails that are connected to the sled. This carries it to the right position of the track while straining the bungee cords in order to produce the final pre-set velocity.

The required deceleration pulse is achieved by means of re-usable polyurethane tube devices placed in parallel inside steel pipes. Deceleration occurs when a set of steel bars with olive-shaped ends which are fitted to the sled are placed inside the polyurethane tubes. This absorbs the impact energy.

ARIES includes simple, easy-to-use software to control all necessary parameters of these tests. This allows for controlled supervising of the firing sequence, safety procedures, speed meter management, and other auxiliary systems from the control PC.

The different deceleration pulses are obtained by combining the length of the tubes, hardness, speed impact, and the shape and diameter of the olives knobs at the end of the set of shafts.

Aries Ingeniería y Sistemas crash simulation systems can come fitted with a bending steel bar system. The bending bar system is a deceleration barrier for the car in which the components to be tested are placed.

The adaptive velocity control system places the sled in the appropriate “fire” position in accordance with the impact velocity selected. The system includes an auxiliary sled with motorized movement. The auxiliary sled displaces along the guided rails connected to the sled. They carry it to the correct position of the track, while straining the cords to produce the final pre-set velocity.

The required deceleration pulse is reached by means of a steel bar device that must be selected appropriately and situated in its support structure in accordance with a specific configuration. The bars are secured and guided in such a way that when the front nose of the sled crashes into them, they become deformed, dissipating the sled energy with the desired deceleration profile.

ARIES includes simple, easy-to-use software to control all necessary parameters of these tests. This allows for the supervision of the firing sequence, safety procedures, speed meter management and other auxiliary systems to be done from the control PC.

The hydraulic programmable deceleration system (HY-PRO) was developed for crash simulation laboratories (sleds or crash tracks).

The HY-PRO system enables the deceleration pulse generation capacity unlike other deceleration method (steel bars, polyurethane tubes, etc). This furnishes test engineers with a powerful and flexible complex deceleration pulse programming tool to check regulation parameters (ECE, FIA, FMVSS) for R&D purposes, as well as production conformity.

Once the sled has been accelerated by a propulsion system, whatever its type, it crashes against a set of steel cables (perpendicular to its path) and tightens them. These cables, guided by pulleys, transmit their tension to the hydraulic cylinder rods to which they are connected. This force then pushes oil through a valve. A hydraulic valve found in each cylinder is the key system element. It can be operated either mechanically or electrically, according to the version. This regulates the passage of the oil through a valve that can be varied in area, therefore modifying the pressure and force in the cylinders that are connected to the deceleration system.

In the mechanical version, an interchangeable element (pin) regulates the size of the area at the valve outlet hole. This provides different pressure ratios – a flow that is translated into the corresponding deceleration pulses with respect to the time.

The prevention of whiplash injuries has become a basic element in the EuroNCAP vehicle evaluation program. The acceleration specified in whiplash testing procedure is distinct from classic crash test simulations with conventional deceleration and even from what is expected from the systems of inverse acceleration that are on the market.

In the whiplash simulation, the maximum velocities and payloads should be reduced compared to the rest of the crash tests, and as such the large classic acceleration catapults are overpowered and are unable to accurately carry out whiplash simulations. The need for a low grade acceleration in the in the diminishing phase of the test means that traditional deceleration systems, such as the “bending bar” or hydraulics, are not adequate.

Aries Ingeniería y Sistemas offers a turn-key catapult specially designed for low speeds with the correct weight and acceleration for whiplash testing.

 

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