Vehicle Impact Testing Fixture with Deformation Simulation
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Solution Overview
Problem
Current vehicle impact simulation methods, such as rollover and frontal impact tests, do not accurately simulate exterior deformation of the vehicle, which is crucial for testing seat belt operations like the movement of the D-ring during a rollover, as they protect the vehicle's exterior and do not allow for repeated use without damage.
Innovation Solution
A testing device with a cage and a testing fixture that includes a piston and ratchet mechanism to simulate the deformation of vehicle pillars during rollover and a sled buck system for frontal impacts, allowing for accurate simulation of seat belt operations and repeated testing without damaging the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cage is used to protect the vehicle exterior during rollover simulation, then the vehicle exterior is prevented from damage, but the simulation does not accurately portray exterior deformation and seat belt operation
Solution Approach 1:
The testing system is divided into two independent parts: the cage that protects the vehicle exterior, and the testing fixture that independently simulates pillar deformation. This segmentation allows each component to fulfill its specific function without compromising the other.
Solution Approach 2:
The testing fixture acts as an intermediary device between the cage and the seat belt system. It mechanically replicates the deformation effects that would normally occur to the vehicle pillar, allowing accurate seat belt operation testing while the cage remains intact.
2Productivity
If the vehicle exterior is protected during simulation, then the vehicle can be reused for repeated testing, but the simulation fails to capture real-world deformation effects
Solution Approach 1:
Instead of deforming the actual vehicle pillar, the testing fixture creates a mechanical copy of the deformation effect. The fixture's movable support structure replicates the pillar's movement and deformation characteristics, allowing repeated testing without damaging the vehicle while maintaining simulation realism.
Solution Approach 2:
The testing fixture dynamically changes its support parameters (position, movement trajectory, deformation magnitude) to match the expected pillar behavior during rollover. This allows the system to maintain realistic simulation conditions across multiple tests without physical degradation.
3Measurement precision
If the B-pillar deformation is simulated through fixture movement, then seat belt operation is accurately tested, but the device complexity increases
Solution Approach 1:
The testing fixture is designed to perform multiple functions: it supports the D-ring, simulates pillar deformation through controlled movement, and can be adjusted for different test scenarios. This multi-functionality reduces the need for multiple specialized devices while maintaining testing accuracy.
Solution Approach 2:
The fixture employs dynamic movement of the support structure to simulate pillar deformation rather than using complex static mechanisms. The movable support can be actuated to follow the expected deformation trajectory, achieving accurate simulation with relatively simple mechanical components.
Data Source
AI summary
A fixture includes a vehicle body and a tube connected to the vehicle body. The tube has an axis, and the fixture includes a piston slideably disposed in the tube along the axis. A seat belt D-ring is mounted to the piston. The tube and the piston each define holes positioned to be aligned with each other when the piston is in multiple positions along the axis in the tube. A pin is engageable with the holes when the holes are aligned.