Crash test simulation with sled tests

When carrying out vehicle crash tests, dynamic component testing (DYCOT) uses virtual and physical non-destructive simulation. These non-destructive test methods offer a more efficient approach to traditional crash testing. They provide comprehensive physical simulations of the impact a vehicle and its systems would experience during traffic accidents.

Watch the video to see how TÜV SÜD conducts non-destructive physical crash test simulation, using our state-of-the-art sled testing technology:

Non-destructive dynamic testing of components enables original equipment manufacturers to quickly generate robust data under realistic crash conditions. This delivers high quality test reproducibility and repeatability at low service costs, achieving significant savings compared to traditional physical crash testing. The test results support your product development, type approval, and conformity of production testing (CoP). 

The resulting reports demonstrate that you have completed extensive crash test simulations to ensure product safety. Those sled tests help you to access global markets by ensuring compliance with relevant international regulations and standards.

Our state-of-the-art sled test facilities, combined with our global network of technical experts, provide you with a single-source solution for compliance with regulations, standards, and voluntary industry requirements.

Our laboratory uses the latest sled test technology, like the High G catapult and the active lateral intrusion simulator (ALIS). This is an advanced pneumatic catapult that simulates side impact intrusions. Using these technologies,  TÜV SÜD supports you with a variety of physical dynamic load tests, for 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 parallel sled tests for different customers are conducted.

Our accredited crash test and dynamic component testing laboratory performs tests against the following standards: 

• ECE tests: 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 dynamic component testing services include:

• 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 

Our DYCOT laboratory is equipped with the latest sled test technology:

• IST CSA Advanced Acceleration System (catapult)
• Force 2.5 MN acceleration
• 90g @ 1,000kg / 35g @ 5,000kg, -35g @ 800kg
• Maximum speed 90km/h
• Maximum gradient 14G/MS
• Repeatability 0.5km/h or 1G
• Working stroke 1.7ms
• Low G simulation 5-12G
• Personalised crash pulse iterations
• Reliable EuroNCAP whiplash high standard
• Second seating row whiplash capability
  
  
• ENCOPIM Active Lateral Intrusion Simulation System
• Multiactuator simulator of side crashes
• Structural testing structure deformation and sled movement
• Driver and passenger loaded simultaneously
• Side and central airbag development
  
  
• HS Vision LED lighting and camera system
• Kistler DAS and sensor system
• In-house dummy family HIII 5% (DTI), 50%(DTI), 95% (DTI), WS (DTI), Biorid-II, Qs
• 2D, 3D static and dynamic photogrammetry,
• 3D Scanning