Dynamic Component Testing & ECE Test Procedures

What is a non-destructive physical crash test simulator?

In the automotive industry, dynamic component testing (DYCOT) involves the use of virtual and physical non-destructive simulation when carrying out a vehicle crash test. These new non-destructive test methods offer a more efficient approach to crash testing by providing comprehensive physical simulations of the impact that would be experienced by vehicles and their systems during traffic accidents.

Watch the video to see how a non-destructive physical crash test simulation is conducted.

WHY IS IT VALUABLE TO USE A CRASH TEST SIMULATOR?

Non-destructive dynamic component testing delivers multiple benefits to original equipment manufacturers (OEMs) in the auto-industry:

Quickly generate robust data under realistic crash conditions

Achieve high quality test reproducibility and repeatability at low service costs
Test results support your product development, type approval and conformity of production testing (CoP)
Make significant savings compared to traditional physical crash testing
Generate reports that demonstrate that you have completed extensive crash test simulations to ensure product safety
Access global markets by ensuring compliance with relevant international regulations

TÜV SÜD PROVIDES COMPREHENSIVE VIRTUAL CRASH TEST SOLUTIONS

Our state-of-the-art crash simulator facilities, combined with our global network of technical experts, provide you with a single-source solution for achieving compliance with all applicable regulatory requirements, standards and voluntary industry schemes.

Our laboratory is equipped with the latest technologies such as the Active Lateral Intrusion Simulator, which is an advanced pneumatic catapult that simulates side impacts. Using these technologies, TÜV SÜD can support you with a variety of physical dynamic load tests, on both components and structures. The entire TÜV SÜD system has been customised to test restraint systems and structures in accordance with new legislation, as well as the requirements of consumer organisations and manufacturers. Components and structures of up to five tonnes can be tested in combination with virtual simulation and environmental tests.

Our laboratory is ISO/IEC 17 025:2005 accredited and has passed a TISAX information security audit for handling development prototypes. It also has several independent preparation rooms to ensure maximum privacy in case of parallel testing for different customers.

OUR DYCOT LABORATORY IS EQUIPPED WITH THE LATEST CRASH TEST TECHNOLOGIES

IST CSA Advanced Acceleration System (catapult):

Force 2.5 MN acceleration
90g @ 1,000kg / 35g @ 5,000kg, -35g @ 800kg
Maximum speed 100km/h
Maximum gradient 14G/MS
Repeatability 0.5km/h or 1G
Working stroke 1.7m
Low G simulation 5-12GIIHS/IIWPG whiplash test
EuroNCAP Whiplash Standard
FMVSS 202a (dynamic sled procedure)

ENCOPIM Active Lateral Intrusion Simulation System:

Multiactuator simulator of side crashes
Structural testing
Structure deformation before sled movement
Driver and passenger loaded simultaneously

HS Vision LED lighting and camera system

Kistler DAS and sensor system

In-house dummy family HIII 5%, 50%, 95% (DTI), WS (DTI), Qs

3D static and 3D dynamic photogrammetry

TÜV SÜD’S NON-DESTRUCTIVE VIRTUAL CRASH TEST AND DYCOT SERVICES

Our accredited DYCOT laboratory can perform tests against the following standards:

UN ECE R11, R16, R17, R21, R44, R67, R80, R110, R129

Other standards e.g. FMVSS, VSTD, ADR, FIA, NCAP, ISO, AMS, EASA CS, ZMK

Our overall DYCOT Services:

Physical crash simulations of frontal, rear and side impacts
EuroNCAP tests – including knee mapping and whiplash
Component tests – including airbags, Instrument panels, central consoles, seats, fuel tanks, roof racks, trims and accessories

Dynamic Component Testing