Dynamic Component Testing

Non-destructive physical crash simulation tests

The automotive manufacturing supply chain is under growing pressure to reduce both development times and costs, while meeting the increasingly stringent requirements of safety legislation and customer expectation. New non-destructive test methods offer an alternative, more efficient approach to physical crash tests by providing comprehensive physical simulations of the impact experienced by vehicles and their systems during traffic accidents.

What is Dynamic Component Testing (DYCOT)?

While crash tests using entire vehicles continue to be conducted by original equipment manufacturers (OEMs), this approach is resource, time and cost intensive. Virtual and physical non-destructive simulation is increasingly replacing these traditional destructive methods, significantly reducing overheads. A nondestructive DYnamic COmponent Testing system (DYCOT) delivers robust data quickly, as well as high quality test reproducibility and repeatability (pulse iteration within three shots), at low service costs. DYCOT can therefore support product development, type approval and conformity of production testing (CoP).

How can we help you?

Our TÜV SÜD laboratory is equipped with the latest sled technology, the Advanced Lateral Impact Simulator, which is an advanced hydraulic catapult combined with a programmable system that simulates side impacts. Using these technologies, TÜV SÜD can support you with a variety of physical dynamic load tests, on both components and structures. The entire TÜV SÜD system has been customised to test restraint systems and structures in accordance with new legislation, as well as the requirements of consumer organisations and manufacturers. Components and structures of up to five tonnes can be tested in combination with virtual simulation and environmental tests.

Our laboratory is ISO/IEC 17 025:2005 accredited and has passed a TISAX information security audit for handling development prototypes. It also has several independent preparation rooms to ensure maximum privacy in case of parallel testing for different customers.

Our DYCOT laboratory can perform tests against the following standards:

• UN ECE R11, R16, R17, R21, R44, R67, R80, R110, R129
• Other standards e.g. FMVSS, VSTD, ADR, FIA, NCAP, ISO, AMS, EASA CS, ZMK

Our DYCOT laboratory Equipment

IST CSA Advanced Acceleration System (catapult)

• Force 2.5 MN acceleration
• 90g @ 1,000kg / 35g @ 5,000kg, -35g @ 800kg
• Maximum speed 100km/h
• Maximum gradient 14G/MS
• Repeatability 0.5km/h or 1G
• Working stroke 1.7m
• Low G simulation 5-12GIIHS/IIWPG whiplash test
• EuroNCAP Whiplash Standard
• FMVSS 202a (dynamic sled procedure)

ENCOPIM Advanced Lateral Impact Simulation System (available from January 2018)

• Multiactuator simulator of side crashes
• Structural testing
• Structure deformation before sled movement
• Driver and passenger loaded simultaneously

HS Vision LED lighting and camera system

Kistler DAS and sensor system

In-house dummy family HIII 5%, 50%, 95% (DTI), WS (DTI), Qs

3D static and 3D dynamic photogrammetry

Our DYCOT services

• Physical crash simulations of frontal, rear and side impacts
• EuroNCAP tests – including knee mapping and whiplash
• Component tests – including airbags, Instrument panels, central consoles, seats, fuel tanks, roof racks, trims and accessories

Why choose TÜV SÜD?

TÜV SÜD has more than a century of vehicle safety, testing and certification experience. Our extensive knowledge and international reputation enables us to work as a partner with our global customers, including top OEMs and automotive suppliers. Our state-of-theart testing facilities, combined with our global network of technical experts, can provide your company with a single-source solution for achieving compliance with all applicable regulatory requirements, standards and voluntary industry schemes. As an innovative Solutions provider, we are directly involved in the development of safety regulations, standards and efficient automotive testing solutions to drive the future of mobility. Our test approach for the simulation of dynamic events can also be extended to support other industries, including aviation, military and rail.