Safety testing

We conduct tests for our customers to prevent pedestrian injuries as well as to protect occupants.

Airbag
Pedestrian protection
Occupant protection
Bumper pendulum
Serial monitoring
Special tests

Testing    Safety tests - Airbag

Safety tests - Airbag

Our responsibilities also include conducting airbag inflation tests, for example, for head, side, driver, and passenger airbags according to the AK-LV guidelines of the automobile manufacturers. We condition the test objects through environmental simulation and test in the temperature range of -40 to +100 °C with video recording using up to six high-speed cameras.

Test objects
  • Front airbag
  • Head airbag
  • Side and center airbags
  • Pedestrian protection airbag
Test specifications
  • AKLV 01, AKLV 04, AKLV 07, AKLV 13 and AKLV 35
Test conditions
  • Active front hoods
  • Digital high-speed video recording with up to 6 cameras inside the climate chamber
  • Individual camera position possible
  • Testing in a closed climate chamber
Conditioning
  • Test rooms (LxWxH) 2.9 x 2.0 x 1.9m and 7.9 x 4.8 x 3.2m
  • Temperature range -40 to +100°C
  • Shaker, shock, sunlight simulation, humidity possible

Testing    Safety tests - Pedestrians

PEDESTRIAN PROTECTION

How can we reduce head, leg, and thigh injuries to pedestrians? We conduct tests for this as part of the development of the vehicle's front end, including the bumper, hood, and windshield. We simulate a collision between a pedestrian and a car. Our in-house FEM simulation, design departments, and prototype construction round out the development process. The tests are conducted using a hydraulic high-energy catapult from B.i.A.

  • Travels L 3900 mm, W 2200 mm, H 2500 mm
  • Tower can be rotated 360°
Impactors
  • Child's head
  • Adult head
  • TRL leg
  • FlexPLI
  • Upper Leg
Test specifications
  • UN ECE-R127, EuroNCAP, GTR 9
Test conditions
  • Recording of accelerations and forces
  • Digital high-speed video recording up to 6 cameras
  • Dynamic distance measurement
  • Investigation of crack behavior of windshields
  • Vehicle measurement

Testing    Safety tests - occupants

PASSENGER PROTECTION R21

To develop a safe vehicle interior and body structure, we conduct tests on instrument panels, center consoles, headrests, and headliners. The goal is to protect occupants in the event of a crash. The tests are conducted using a hydraulic high-energy catapult from B.i.A.

  • Travels L 3900 mm, W 2200 mm, H 2500 mm
  • Tower can be rotated 360°
Impactors
  • Head pendulum reduced mass m=6.8 kg
Test specifications
  • UN ECE-R21, FMVSS201
Test conditions
  • Digital high-speed video recording up to 3 cameras
  • Production of test frames
  • Prototype construction for test parts

Free Motion Headform

We conduct tests as part of the development of vehicle interiors. This involves simulating a head impact within the interior. The head impact tests are conducted using a launch device from Microsys.

  • Nitrogen-powered launcher
  • Electronic readjustment (Advanced Speed Control)
Impactors
  • Free Motion Headform Hybrid III 50% Man Skull
Test specifications
  • FMVSS201
Test conditions
  • Digitale High-Speed-Video-Aufzeichnung bis zu 3 Kameras
  • Prototypenbau für Versuchsteile
  • Oberflächenscan von Bauteilen

Testing    Safety tests - Bumpers

BUMPER PENDULUM

We conduct tests to examine the stability of the materials used in bumpers, spoilers, and plastic mounting supports. This involves simulating a collision while parking, and determining damage at speeds of up to 4 km/h.

  • Testing is carried out on the trolley or on the vehicle (can be loaded with a load of up to 3,500 kg)
  • Test racks can be manufactured or supplied by the customer.
Test specifications
  • UN ECE-R42
  • US Part 581
  • CMVSS215
  • SSA 273/1982
Impactors
  • Test weight 1.0 to 2.6 t according to UN ECE-R42
  • Wood test specimens for component testing

Testing    Safety tests - Serial monitoring

Serial monitoring

We conduct CoP tests to ensure consistent quality of your vehicles. We perform the following tests on-site:

Windshield defrosting and demisting systems
  • VO (EU) 672/2010
  • FMVSS 103
  • CMVSS 103
  • GOST R 52031-2003
Windshield wiper and washer systems
  • VO (EU) 1008/2010
  • FMVSS 104 and CMVSS 104
  • FMVSS 104
  • GB 15085-2013
  • GOST R 52032-2003
    Indirect view
    • UN ECE-R 46
    • FMVSS 111
    • ADR 14/02 – without Annex 6
    • GB 15084-2013 – withoutAnnex A
    Direct view
    • UN ECE-R 125
    • GB 11562-2014
    • EAEU 877/2011 – On the adoption of the technical regulation of the customs union "On the safety of wheeled vehicles" (Annex 3 Subpart 5)
    External security
    • UN ECE-R 42 – Bumpers
    • 49 CFR Part 581 – Bumpers
    • CMVSS 2015 – Bumpers
    • FMVSS 101 – Controls and Displays
    • ADR 43/04 – Vehicle configuration and dimensions
    Passive safety
    • UN ECE-R 21 – Interior fittings (Annex 6/8 excluded)
    • UN ECE-R 35 – foot-operated devices
    • UN ECE-R 127 – Pedestrian protection
    • EuroNCAP – Pedestrian Protection
    • FMVSS 118 – power operated windows
    • FMVSS 201 – Occupant Protection in Interior Impact
      • FMVSS 208 – Out-of-Position Tests
      • AK LV 01 – Airbag inflation test (steering wheel, instrument panel)
      • AK LV 04 – Side airbag inflation test (doors)
      • AK LV 07 – Side airbag inflation test (seats)
      • AK LV 13 – Inflation test of head impact protection airbag (roof frame)
      • AK LV 35 – Front windscreen airbag inflation test

      Testing    Safety tests - Special tests

      SPECIAL TESTS

      We conduct CoP tests to ensure consistent quality of your vehicles. We perform the following tests on-site.

      • Abrasion test for airbag seat backs
      • Surveying with tactile and optical measuring systems; Leica Tracker, PONTOS
      • Packaging test (sprinkle, stack pressure, drop test, puncture test)