Deformation Sensor Package for Crash Test Dummies
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Solution Overview
Problem
Existing systems for measuring deformation in automotive crash testing, such as those using crash test dummies, are inadequate due to high costs and complexity, particularly when trying to track two-dimensional deformations at high acceleration rates, and often have low linearity and inadequate sensing resolution.
Innovation Solution
A deformation sensor package utilizing two string potentiometers secured within a housing, with sensing cables attached to a common deformation measurement location, allowing for accurate measurement of linear and angular deformation through simple resistance-based electrical conversion, enabling cost-effective and reliable two-dimensional deformation tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex systems with multiple sensors are used to measure two-dimensional deformation, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines two linear potentiometers into a single sensor package that measures both linear and angular deformation. By merging multiple sensing functions into one integrated device, the system achieves two-dimensional deformation measurement capability while reducing the number of separate sensors needed, thus lowering complexity and cost.
Solution Approach 2:
The sensor package is designed to perform multiple functions: measuring linear deformation along one axis, measuring linear deformation along a perpendicular axis, and measuring angular deformation. This multi-functional approach allows a single device to replace what would traditionally require multiple specialized sensors.
2Measurement precision
If multiple sensors are deployed for each rib in crash test dummies, then measurement precision is improved, but cost increases
Solution Approach 1:
By combining multiple sensing functions into a single sensor package, the patent reduces the total number of sensors required for crash test dummies. This consolidation lowers component costs, assembly costs, and calibration costs while maintaining the ability to measure two-dimensional deformation accurately.
Solution Approach 2:
The sensor package uses simple resistance-based potentiometers that are inherently lower cost than complex optical or capacitive sensor systems. This approach prioritizes cost-effectiveness while providing sufficient measurement capability for crash testing applications.
3Adaptability or versatility
If existing sensor systems are used for high acceleration crash testing, then adaptability is maintained, but measurement precision deteriorates
Solution Approach 1:
The patent replaces complex optical or capacitive sensing systems with simple mechanical string potentiometers that use resistance-based measurement. This mechanical approach is inherently more robust for high-acceleration environments while maintaining the ability to measure deformation accurately, and the sensors can be adapted to various crash test dummy configurations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides accurate, reliable, and cost-effective deformation measurements in two dimensions, improving upon existing systems by reducing complexity and enhancing sensing resolution, making it suitable for high-acceleration crash testing applications.
Implementation Method 1
simple resistance-based electrical conversion
Data Source
AI summary
A deformation sensor package includes a housing having a base and a peripheral wall extending from the base. The base and peripheral wall define two cavities each configured to receive a potentiometer, such as a string potentiometer. The peripheral wall defines two apertures formed between a respective cavity and an exterior of the housing. Each aperture is configured to allow for the passage of a moveable sensing end of an associated potentiometer therethrough.