Test Pendulum Braking Plunger for Honeycomb-Free Dummy Certification

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Solution Overview

Problem

Conventional test pendulum arrangements for certifying crash test dummies require extensive setup, are time-consuming, and generate significant waste due to the need for frequent replacement of aluminum honeycomb structures.

Innovation Solution

A braking device system for a test pendulum arrangement that allows for precise reproduction of the braking effect of an aluminum honeycomb structure, enabling the test pendulum to be used more frequently and reducing the need for frequent replacements of the honeycomb structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If aluminum honeycomb structures are used to brake the test pendulum, then the braking effect is achieved, but the honeycomb structure must be frequently replaced causing waste and increased costs

Engineering Contradiction:

Improvebraking effectVSAvoidhoneycomb structure

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent creates a digital model of the aluminum honeycomb structure's braking characteristics and uses a controllable braking device to reproduce the same braking effect. This allows the braking effect to be copied without physically consuming the honeycomb structure, enabling repeated use of the test pendulum without frequent honeycomb replacements.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical aluminum honeycomb structure with a controllable braking device that can be actuated on demand. This substitution eliminates the need for physical honeycomb structures while maintaining the required braking effect, reducing waste and operational costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If aluminum honeycomb structures are used for each test, then certification accuracy is maintained, but setup time and costs increase significantly

Engineering Contradiction:

Improvecertification accuracyVSAvoidsetup time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent pre-calibrates the controllable braking device to match the braking characteristics of the aluminum honeycomb structure. This preliminary setup allows the braking effect to be reproduced consistently without needing to physically install new honeycomb structures for each test, significantly reducing setup time while maintaining certification accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses a controllable braking device that can adjust braking parameters (force, duration, timing) to match the required certification specifications. This allows precise reproduction of the honeycomb braking effect without physical replacement, maintaining measurement precision while reducing setup time.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the test pendulum is used frequently without honeycomb replacement, then productivity increases, but braking accuracy deteriorates

Engineering Contradiction:

Improvecertification throughputVSAvoidbraking accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent employs a controllable braking device that can dynamically adjust its braking characteristics based on real-time feedback and pre-stored calibration data. This dynamic control ensures that braking accuracy is maintained consistently across multiple uses of the test pendulum, enabling high productivity without sacrificing precision.

Inventive Principle:

Principle #15Dynamics

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 significantly reduces setup time and costs, allows for more efficient use of the test pendulum, and minimizes waste by enabling multiple uses of the pendulum without replacing the aluminum honeycomb structure.

Implementation Method 1

The braking device has a plunger (30) which can be actuated axially by a motor arrangement (46.1-46.6) which is designed to come into contact with the pendulum

Methodology Applied

Scientific EffectLinear motor: Linear Motor

Implementation Method 2

the braking device has a plunger (30) which can be actuated axially by a motor arrangement (46.1-46.6) which is designed to come into contact with the pendulum (4) in a defined braking region and to brake the pendulum by a braking force exerted by the plunger

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12339198B2Test pendulum arrangement for performing neck certifications and method for operating a test pendulum arrangement

Publication Date: 2025.06.24 ATD LABTECH GMBH

AI summary

A braking device system for a test pendulum arrangement to perform crash test dummy certifications, the braking device system including a braking device configured to brake a moving pendulum, on which a head and neck assembly of a crash test dummy is capable of being arranged, in a lower braking region, wherein the braking device includes a plunger configured to be actuated axially by a motor arrangement which is designed to come into contact with the pendulum in a defined braking region and to brake the pendulum by a braking force exerted by the plunger.