Advanced Non- Methods for Automotive Components Ensure faster and more accurate safety assessments already during the development cycle

White paper

Abstract

The rapid integration of advanced technologies in automobiles and automotive components has dramatically increased pressure on vehicle and original equipment manufacturers (OEMs) to speed the development process for new vehicles. In this environment, the demand for efficient, accurate and cost- effective testing of prototype vehicles and components is resulting in a greater emphasis on virtual simulations based on finite element analysis (FEA) principles and non-destructive component testing. It is also leading to the development of state-of-the-art non-destructive component testing solutions that can more accurately simulate the effect of full-scale crash testing, thereby reducing development time as well as the expense associated with such testing.

TÜV SÜD Contents

VEHICULAR SAFETY: A CONTINUING JOURNEY 3

REQUIRED SAFETY TESTING DURING THE VEHICLE DEVELOPMENT CYCLE 4

THE USE OF NON-DESTRUCTIVE TESTING (NDT) TECHNIQUES IN SAFETY VALIDATION TESTING OF AUTOMOTIVE COMPONENTS 5

RECENT ADVANCES IN NON-DESTRUCTIVE COMPONENT TESTING 6

YOUR BENEFITS OF CONDUCTING NON-DESTRUCTIVE AUTOMOTIVE COMPONENT TESTING WITH TÜV SÜD 8

CONCLUSION 8

APPENDIX 9

About the TÜV SÜD experts

Martin Škopek Business Unit Manager, Human and Mobility TÜV SÜD Czech Martin Škopek has been with TÜV SÜD Czech since 2013 and has worked on multiple aspects of vehicle testing and certification, including passive safety, dynamic component testing and crash testing. Martin received his engineering education at the Department of Automotive, Combustion Engine and Railway Engineering at the Czech Technical University in Prague, and also has extensive experience in teambuilding and coaching.

Michal Kalinský Project Manager for side impact crashes (ALIS) TÜV SÜD Czech With TÜV SÜD since 2004, Michal has worked for the past three years managing physical simulation testing of side impact crashes in TÜV SÜD’s dynamic component testing laboratory. During this time, he was involved in the development of the side crash test rig and various other testing procedures. Michal also received his engineering education at the Czech Technical University in Prague, where he is currently pursuing his Ph.D.

2 Advanced Non-Destructive Testing Methods for Automotive Components | TÜV SÜD Vehicular safety: a continuing journey

Over the past 60 years, significant new set of safety challenges to the advancements in safety technologies automotive industry, as well as new have contributed to steady declines opportunities to improve vehicular New safety in fatality rates connected with safety. Indeed, the potential for challenges but also motor vehicles. The introduction truly autonomous vehicular travel of structural innovations like greatly expands traditional safety the opportunity to deformable zones in the vehicle parameters. In addition to evaluating improve safety arise structure and the addition of critical vehicle structural designs and safety safety components like seat belts components for use under previously with the development and air bags have made important unenvisioned operating conditions, of autonomous contributions to overall vehicle safety manufacturers are now investigating and have saved countless lives. As the safety and effectiveness of new vehicles. a result, even as our dependence on systems and components required vehicular travel has grown and the to detect and react in real-time to total miles travelled has dramatically road conditions and hazards, as well of testing data collected from increased, automobiles are safer as establishing defences against simulated crashes, gives than ever before. malicious cyber attacks against manufacturers concrete evidence onboard vehicular systems. regarding the effectiveness of Nonetheless, the automotive current safety technologies and industry continues to actively Finally, ongoing testing and clues about modifications that could address vehicular safety in the 21st research is providing automotive lead to improved safety results. century. For example, in recent manufacturers with greater Testing also provides an effective years, regulators around the world insight into how new and existing tool to evaluate prototype safety are seeing increases in the number safety systems and components systems and components under of motor vehicle accidents and actually perform in vehicular crash simulated conditions, thereby fatalities. In many instances, the conditions. This research, often helping to ensure their effectiveness causes for these increases can be supplemented by assessments in the real world. attributed to poor driver behaviours, such as texting while driving, driving while under the influence of alcohol or other substances, and the failure to properly utilize essential equipment like seatbelts. Although it is impossible to completely protect drivers and passengers from their own negligent behaviours, automotive manufacturers are continuously exploring new ways to integrate systems and features that help reduce the likelihood that such behaviours will lead to catastrophic consequences.

At the same time, the advent of the autonomous vehicle presents a

TÜV SÜD | Advanced Non-Destructive Testing Methods for Automotive Components 3 Required safety testing during the vehicle development cycle

Testing of critical safety-related including the testing of some or At present, there are more than parameters during the product all of the following systems or 100 separate regulations under the development cycle of new vehicles components: scope of the UNECE applicable to has been a requirement for passenger cars, covering vehicle automotive manufacturers since Frontal crash protection safety, energy efficiency, theft the late 1970s. At that time, the U.S. Side barrier crash protection resistance and environmental issues. National Highway Traffic Safety Side pole crash protection Some of the UNECE regulations Administration (NHTSA) established Rear view video system directly applicable to vehicle passive the world’s first new car assessment Blind spot detection safety include: program (NCAP) in response to Lane departure warning system legislation intended to encourage Lane keep assistance system R11 – door latches and door automotive manufacturers to build Forward collision warning system retention components safer vehicles. Under the NHTSA’s Automatic emergency braking R14 – safety belt anchorages NCAP, new car models receive a system R16 – safety belts and restraint safety rating based on the results of Crash avoidance systems systems pre-market testing of critical safety R17 – seats, seat anchorages, parameters. The vehicle’s NCAP In addition to safety testing generally head restraints safety rating is then posted on the required under NCAPs, most R21 – interior fitments vehicle’s sales sticker to provide jurisdictions around the world are R44 – child restraint systems consumers with information on the participants in the United Nation’s R80 – strength of seats and vehicle’s overall safety profile. World Forum for Harmonisation anchorages of Vehicle Regulations, which R94 – frontal collision protection Since then, NCAPs have been operates under the auspices of the R95 – lateral collision protection adopted by many other automotive Sustainable Transport Division of R129 – enhanced child restraint industry programmes around the the UN’s Economic Commission for systems world. These include the European Europe (UNECE). Working Party R135 – pole side impact New Car Assessment Programme (WP) 29 of the Forum, formally R137 – frontal impact with focus (Euro NCAP), Japan’s New Car known as the Working Party of on restraint systems Assessment Programme (JNCAP) experts on technical requirements and the China New Car Assessment of vehicles, is charged with creating In addition to NCAP and UNECE Programme (C-NCAP), as well as unified automotive standards and requirements and regulations, comparable programmes in Korea, regulations to facilitate international vehicle and vehicle component India, Latin America and Australia/ trade. manufacturers may be subject to New Zealand. The Euro NCAP is additional, pre-market safety testing modelled after NHTSA’s NCAP, while in some jurisdictions. This further other programs are complementary complicates the challenge for global in structure, but not necessarily OEMs and suppliers manufacturers seeking to simplify identical in terms of specific testing face the challenge to the process of ensuring compliance requirements. with applicable safety requirements, simplify the process especially when many manufacturers In general, NCAPs require of ensuring safety are also simultaneously attempting manufacturers to conduct a pre- to introduce new and innovative market evaluation of the safety- compliance. automotive safety systems and critical aspects of new vehicles, components.

4 Advanced Non-Destructive Testing Methods for Automotive Components | TÜV SÜD The use of non-destructive testing (NDT) techniques in safety validation testing of automotive components

can facilitate the use of virtual simulations based on finite element modelling principles. This approach to non-destructive testing allows manufacturers to evaluate multiple real-world scenarios to improve the accuracy and predictability of automotive safety systems and component performance. While not completely eliminating the need for real vehicle crash simulations, the use of non-destructive testing techniques can reduce the dependence on whole-vehicle crash testing to generate critical safety data, thereby helping to curb the overall cost Aside from demonstrating shorten the time required to bring of testing. Non-destructive testing can compliance with safety requirements new and innovative vehicle safety also significantly reduce the total time and regulations, safety testing during technologies to market. Today, pre- required for testing, making safety the product development cycle market testing utilising advanced, testing more efficient and less time- can be an effective way to actually non-destructive testing techniques consuming.

NON-DESTRUCTIVE TESTING (NDT) TECHNIQUES SUPPORT CUSTOMERS ON EVERY STAGE OF THE PRODUCT LIFE-CYCLE

V-Model R&D R&D Type Conformity of Testing & Component Vehicle Approval Production Type Testing Testing (CoP) Approval

OE Vehicle development cycle Aftermarket cycle

Concept Certification Production

Vehicle Decomposition validation AfM development & type approval Component Design validation

Prototype

TÜV SÜD | Advanced Non-Destructive Testing Methods for Automotive Components 5 testing technique specifically components in combination with a applicable to automotive systems wide range of alternative systems Non-destructive and components. Instead of requiring and components. This enables OEMs testing provides whole-vehicle testing, DYCOT allows and component manufacturers for the testing of individual systems to proactively refine and modify multiple benefits and components. This approach component designs well in advance for automotive enables manufacturers to evaluate of whole vehicle testing. DYCOT safety and performance aspects of also provides substantive data in manufacturers and key interior parts, including seats, support of component validation safety belts and head restraints efforts and, ultimately, type approval, suppliers. during the earliest stages of new certification and other forms of product development. recognition as required by vehicle Testing data collected through manufacturers and regulatory Dynamic component testing (DYCOT) DYCOT can be used to assess authorities. is a specialized non-destructive the performance of individual

Recent advances in non-destructive component testing

As previously noted, data from some studies using finite element now include lateral impact safety ongoing research into vehicle crashes modelling have determined that requirements applicable to vehicle often identifies safety aspects of brain stress due to lateral impact is safety systems and components. vehicle design that may benefit significantly greater than the same from more rigorous oversight and pressure applied through frontal To keep pace with these and other regulation. Examples of this include impact. Responding to these and changes, innovative non-destructive potential safety issues associated similar findings, the UNECE and a DYCOT technologies are now being with side impact collisions, in which number of NCAPs and regulators introduced to facilitate required

SET-UP OF THE ACTIVE LATERAL INTRUSION SIMULATION (ALIS) TEST BENCH

Door structure Pneumatic actuators deforms and Linear biomechanical ALIS guide incl. Door loads are read impact On-board system trim and Dummy, structure and structure seat with ensures restraint kinematics system Pneumatic actuators Restraint ALIS sample palette systems tuning

Acceleration pulse

6 Advanced Non-Destructive Testing Methods for Automotive Components | TÜV SÜD assessments of automotive safety systems and components. In the area of safety related to side impact collisions, active lateral intrusion simulation (ALIS) testing systems are available to assess the performance of critical vehicle safety components in physical simulations of side impact crashes. These advanced, non- and rear passengers. Initial testing destructive DYCOT systems can be results can be used to refi ne ALIS particularly useful in evaluating the simulation testing parameters in real- performance of passenger restraint Multiple displacement actuators time to optimise the accuracy of the systems including frontal and side can be applied in a wide range of overall testing process. airbags. confi gurations along the side of the facsimile vehicle under test, allowing By subjecting interior safety ALIS testing systems utilize a sled technicians to simultaneously components to side impact testing catapult device as well as separate evaluate the results of simulated using ALIS systems during the pneumatic/hydraulic actuators that side and pole impact for both front earliest stages of the product simulate the crucial aspects of the development process, component impacts, such as an manufacturers can more eff ectively intrusion of the side vehicle structure capture and measure the unique Door structure into the occupant space. Entire Active Lateral variables that characterize the safety deforms and systems are designed and carefully performance of their components biomechanical Intrusion Simulation controlled by computer-generated under real-world conditions. Further, loads are read simulation software based on fi nite (ALIS) system is a they can assess how their products element mathematical models. perform when integrated with other The Finite Element Analysis (FEA) unique, state-of- safety components and features, support is an integral part of vehicle the-art technology providing a more comprehensive and development projects with the ALIS realistic assessment of passenger system. A virtual image of sled tests for non-destructive safety. Data collected through provides a comprehensive insight physical simulation of ALIS testing can then be used to into the problems of the system modify safety component designs set-up and helps to achieve maximum side crashes. to optimize their performance in the effi ciency of the tests. context of side impact collisions.

TÜV SÜD | Advanced Non-Destructive Testing Methods for Automotive Components 7 Your benefits of conducting non-destructive automotive component testing with TÜV SÜD

TÜV SÜD’s DYCOT testing laboratory automotive manufacturers with a TÜV SÜD has more than a in the Czech Republic is equipped with single source for virtual and physical century of vehicle safety testing the most advanced equipment for the testing of vehicle systems and and certification experience. non-destructive testing of automotive components. In addition, TÜV SÜD’s Our extensive knowledge and structures and components. Most DYCOT testing laboratory is ISO/IEC international reputation enables us recently, the laboratory has made 17025 accredited, while also meeting to work as a partner with our global significant investments in advanced customers, including the leading DYCOT technologies from industry- OEMs and automotive suppliers. Our leading developers of testing systems TÜV SÜD’s DYCOT state-of-the-art testing facilities, and equipment, including Imaging combined with our extended network Systems Technology (IST) for the laboratory offers full of technical experts, can provide catapult and ENCOPIM for ALIS. Our your company with a single-source newest programmable ALIS testing support throughout solution for achieving compliance system was expressly developed for the whole vehicle with all applicable regulatory TÜV SÜD to effectively simulate the requirements and standards impact on vehicle safety components development process. and voluntary industry schemes from lateral impact, in accordance for automotive structures and with NCAP and UNECE requirements components. Furthermore, we are and purchasing specifications of the requirements of the Trusted directly involved in the development vehicle manufacturers. Information Security Assessment of safety regulations, standards and These enhanced testing capabilities Exchange (TISAX) for the secure efficient automotive testing solutions enable TÜV SÜD to provide handling of automotive prototypes. to drive the future of mobility.

Conclusion

For the automotive industry, working that requires continuous focus and components is an important tool in the to ensure the safety of drivers and innovation. Non-destructive testing effort to introduce advanced safety passengers is a never-ending pursuit of critical vehicle safety systems and functions and features to the market in a timely and cost-effective manner. The deployment of new and advanced non-destructive testing systems, such as ALIS testing systems, is essential to keep pace with the today’s automotive safety innovations, and to help vehicle systems and component manufacturers meet the demands of industry, regulators and the general public in their quest for increased vehicle safety and quicker market access.

8 Advanced Non-Destructive Testing Methods for Automotive Components | TÜV SÜD Appendix 1

Technical Parameters of the DYCOT test catapult at the TÜV SÜD laboratory in Czech Republic

INSTRON CSA ADVANCED CATAPULT PERIPHERALS

Max force 2.5 MN Hybrid III 5%, 50% and 95% with Kistler in-dummy DTI

Max acceleration 90 G at 1000 kg / 35G at 5000 kg World SID 50% with Kistler in-dummy DTI

Max decceleration -35 G at 800 kg Q1.5 / Q3 / Q6 and Q10 dummies

Max Speed 100 kph AICON dummy positioning system

Max gradient 14 G/ms Kistler KiDAU & Kistler sensor equipment

Low G simulation 5-12 G High speed cameras HS Vision (PCO) 1600 x 1200 pix. @ > 2000 fps Repeatability 0.5 kph or 1 G

Working stroke 1.7 m LED technology HS Vision, synchronised with cameras

Sled pallet 3.5 x 1.8 m 3D static and 3D dynamic photogrammetry

Pulse iteration within 3 shots

System expandable to Dynamic Pitching Motion

TÜV SÜD | Advanced Non-Destructive Testing Methods for Automotive Components 9 Appendix 2

Technical Parameters of the ALIS test catapult at the TÜV SÜD laboratory in Czech Republic

TECHNICAL FEATURES OF ALIS

ALIS – Active Lateral Intrusion Simulation

ALIS designed by ENCOPIM, Barcelona

Structure deformation before and during sled movement

Independent control of cylinders

Full synchronisation between cylinders and also with sled system

Cylinder mounts allows for front and rear seat simultaneous barrier test

Driver and passenger loaded simultaneously – unique feature

Up to 6 hydraulic cylinders, up to 120 kN

Virtual simulation support

Real close-loop velocity and position control system

Improvement and accerleration deviations at each iteration

Non-predictable contact forces real-time reaction

Linear guide structure avoids inappropriate forces to the cylinder for better control

10 Advanced Non-Destructive Testing Methods for Automotive Components | TÜV SÜD GLOSSARY OF ACRONYMS NCAP – New Car Assessment Program ALIS – Active Lateral Intrusion Simulation NDT – Non-Destructive Testing C-NCAP – China New Car Assessment Program NHTSA – National Highway Traffic Safety Administration DYCOT – Dynamic Component Testing OEM – Original Equipment Manufacturers Euro NCAP – European New Car Assessment Program TISAX – Trusted Information Security Assessment Exchange FEA – Finite Element Analysis UNECE – United Nations Economic Commission for Europe IST – Imaging Systems Technology WP – Working Party JNCAP – Japan’s New Car Assessment Program

FOOTNOTES [1] “USDOT Releases 2016 Fatal Traffic Crash Data,” National Highway Traffic Safety [2] “Comparison of Brain Responses Between Frontal and Lateral Impacts by Finite Administration, U.S. Department of Transportation, October 6, 2017. Available at Element Modeling,” Journal of Neurotrauma, February 2001. Abstract available at https://www.nhtsa.gov/press-releases/usdot-releases-2016-fatal-traffic-crash-data https://www.researchgate.net/publication/12131424_Comparison_of_Brain_Responses_ Between_Frontal_and_Lateral_Impacts_by_Finite_Element_Modeling

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