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Automotive e-ssentials

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Photo story: Get a first glimpse of our new DYCOT laboratory

At the end of November 2016 our company opened a new test laboratory for the automotive industry. The investment, which also offers physical simulation of dynamic stress on the components and structure of vehicles beyond virtual simulations, recently won 3rd place in the 2015 Investor and Commercial Real Estate of the Year competition sponsored by the Czech Agency for Support of Investment, CzechInvest, in the category of Research and Development.

For an idea of what a test looks like, we’ve compiled a photo story from the preparations and performance of sled testing for the simulation of real traffic accidents.

 The new DYCOT test laboratory at TÜV SÜD Czech  

Our new DYCOT test laboratory at TÜV SÜD Czech for non-destructive testing.

The test sample is fixed by an outside frame for proper clasping in various directions of the simulated impact and for the possibility of repeated testing. The movement of the sample throughout the hall is supported by a crane that covers the entire area of the laboratory including the individual staging areas.

The fixed side frame ensures a safe clasping of the high-speed camera. With the help of this camera motion analyses of the interior parts are compiled.

 Fixation of the test sample
 Two-part test sled  Fastening of the sample

Testing and measurement technician Lukáš Fiřt controls the movement of the sample by remote control. 

 

The proper positioning and above all the safe fastening of the sample is the basis for the successful performance of a test.

 Two-part test sled

The test sled is composed of two parts, where the left part(the “pusher sled”) is permanently attached to the tracks and serves for the installation of measuring equipment, and the right part (the “pallet sled”) serves for mounting the test sample. The pallet sled can be quickly removed and replaced with a different one – with another prepared test sample, in order to increase the efficiency of the tests conducted. The pusher sled is also equipped with a system of brakes, power, and its own measuring system for regulating the desired progress of acceleration.

 Two-part test sled  Installation of a test dummy

 Head of Testing Lukáš Rákosník installs the test dummy, which with its dozens of sensors is the most important part of the entire test chain for assessing vehicle safety. In this case, it is a female Hybrid III 5th test dummy representing the class of smallest adult passengers. The exact placement of the test dummy is not only a condition according to legislation, but generally any test with regard to repeatability and comparability.

           

Positioning of high-speed cameras High-speed cameras are also placed in the interior (top right), particularly for assessing the behavior of various components and for detailed shots of any interaction of the passengers with the interior.

 Put the safety belt on  Connection check

In both sections of the safety belt force meters are installed in the belt.

 
 

Test technician and cameraman Martin Dědič checks the proper connection of power and data communications of the camera system.

 Camera setting

One of the many effective tools in the laboratory is setting the camera system with a view of the ensuing effect in real time.

 Illumination of the test sample is provided through the most modern LED light Panels.  Illumination of the test sample is provided through the most modern LED light Panels.
 

Illumination of the test sample is provided through the most modern LED light Panels.

 Checking the interior cameras and Illumination.  Photo documentation before the test

Checking  the interior cameras and llumination.

The head of testing completes the photo documentation following the test.

 Preparation of the test dummy

Testing and measurement technician Alan Šumelda carries out the final color designation of test dummies for clear identification of the positions of contact with the airbags of the Vehicle.

 Check after the test  Visualisation of contact points

The cameraman checks and processes the shots by the  high-speed camera after the test.

  Visualisation of contact by the head of the dummy with the airbag.

 The brain center of the entire laboratory is the central control board, where the test technicians check the status of all systems and the head of testing sets and controls the catapult itself.

 The DYCOT catapult

View of the catapult for accelerating the test sample. 

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