Motor-Actuated Pendulum Braking for Dummy Neck Certification
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Solution Overview
Problem
Conventional test pendulum arrangements for certifying crash test dummies are ergonomically unfavorable, require significant space, are time-consuming, and costly due to the need for multiple tests and the use of replaceable aluminum honeycomb structures, necessitating high operational expertise and inefficient use of resources.
Innovation Solution
A braking device system for a test pendulum arrangement that includes a plunger actuated by a motor, allowing precise deceleration of the pendulum and head-neck assembly, replicating the behavior of a honeycomb structure, which can be retrofitted to existing setups, reducing setup time and costs, and enabling more frequent use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional test pendulum arrangement with aluminum honeycomb structure is used, then the certification can be performed according to standard requirements, but the setup time and costs are high, and the equipment requires significant space and operational expertise
Solution Approach 1:
The patent creates a virtual model of the aluminum honeycomb structure's deceleration characteristics and implements it through computer-controlled braking. Instead of physically replacing honeycomb structures for each test, the system copies the essential deceleration profile through software control of the brake caliper, eliminating setup time while maintaining certification accuracy.
Solution Approach 2:
The patent replaces the mechanical aluminum honeycomb deceleration structure with an electronically controlled braking system. The brake caliper with programmable force application substitutes the physical honeycomb compression mechanism, allowing rapid reconfiguration between different test scenarios without physical setup changes.
2Force
If aluminum honeycomb structures are used for pendulum deceleration, then the required deceleration pulse can be achieved, but the structures must be replaced for each certification test, increasing costs and waste
Solution Approach 1:
The patent replaces the consumable mechanical honeycomb structure with a reusable electromagnetic/actuated braking system. The brake caliper can be reset and reused indefinitely, eliminating the need to discard honeycomb structures after single-use compression, thereby reducing material waste while maintaining the required deceleration force.
Solution Approach 2:
The patent allows dynamic adjustment of braking force parameters through software control. Different deceleration profiles can be programmed by changing control parameters rather than physically changing the deceleration medium, enabling multiple test configurations with a single reusable brake assembly.
3Speed
If the pendulum is deflected upwards by 125° to achieve sufficient acceleration, then the head-neck assembly can be properly tested, but the structural requirements become difficult to meet in conventional buildings
Solution Approach 1:
The patent replaces the gravity-dependent large-angle swing mechanism with a horizontally mounted pendulum system using active braking control. Instead of relying on gravitational acceleration from a 125° deflection, the system uses a brake caliper to control the pendulum's deceleration phase, achieving the same test objectives with minimal deflection angle and reduced structural requirements.
Solution Approach 2:
The patent transitions from a vertical pendulum arrangement requiring high ceiling clearance to a horizontal arrangement. By mounting the pendulum horizontally and using a laterally positioned brake caliper, the system eliminates the vertical space requirement while maintaining the essential impact and deceleration mechanics needed for head-neck assembly testing.
4Reliability
If multiple tests are conducted on the test pendulum for each crash test dummy certification, then thorough certification can be achieved, but the process becomes time-consuming and only a small number of certifications can be completed per day
Solution Approach 1:
The patent creates virtual copies of different honeycomb structure characteristics through software programming of the brake caliper. Multiple test scenarios can be executed by loading different deceleration profiles without physical reconfiguration, enabling rapid sequential testing while maintaining thorough certification validation.
Solution Approach 2:
The patent implements a dynamically reconfigurable braking system where the brake caliper's force application can be programmatically adjusted between tests. This dynamic control allows the same physical apparatus to adapt to different certification requirements instantly, eliminating the time needed for physical reconfiguration between multiple tests.
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 braking device system allows for efficient and precise certification of crash test dummies with reduced setup effort and time, increasing the number of tests per unit time, minimizing waste, and improving operational efficiency.
Implementation Method 1
The braking device has a plunger which can be axially actuated by means of a motor arrangement
Implementation Method 2
the plunger is designed to come into contact with the pendulum in the defined lower braking region and to brake the pendulum by means of a braking force exerted by means of the plunger
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
A description is given of a braking apparatus system (14, 18, 22) for a test pendulum arrangement (2) for carrying out crash test dummy certifications, having a braking apparatus (14, 18, 22) for braking a moving pendulum (4), on which a head/neck assembly (10) of a crash test dummy can be arranged, in a lower braking range (B), wherein the braking apparatus (14) has a plunger (30) which can be axially actuated by means of a motor arrangement (32) and is designed to come to rest with the pendulum (4) in a defined braking range (B) and to brake the pendulum (4) by means of a braking force (FB) exerted using the plunger (30). A description is also given of a test pendulum arrangement (2) and a method for operating a test pendulum arrangement (2).