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The TÜV SÜD department of computer aided services (CAS), an integral part of the testing laboratory, uses cutting-edge technology and software and is able to support any partner around the globe. All services are provided virtually and therefore no physical specimen is required. Our experts are able to simulate and identify any potential weak points in the structure and suggest improvement. Together with DYCOT (DYnamic COmponent Testing lab) we are able to fine-tune restraint systems such as seatbelts and airbags that are highly sought for both frontal and side crash tests. The department of CAS also provide partners with weight-to-stiffness/strength optimization and whole variety of analyses ranging from single point loading to complex crash simulations.
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DYCOT & ALIS
What is DYCOT (Dynamic Component Testing)
What is ALIS (Advanced Lateral Impact System)
Non-destructive dynamic component testing, i.e. sled tests that bring much more robust information than computer-based models and deliver this information earlier and at much lower price than full crash tests enable this efficiency. The testing can be used
for development, type approval and conformity of production testing (CoP) purposes.
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The TÜV SÜD Active Lateral Intrusion Simulation system is a unique, state-of-the-art technology for physical simulation of side crashes with active and controlled deformation of vehicle side structure. It is not only one of few such systems in Europe but it is the first system that introduces testing of both front and rear seat loading at the same time.
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Watch video from DYCOT lab
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What is virtual simulation?
While physical test uses usually very expensive sample and prototypes, virtual simulation is based on mathematical reproduction of physical world. For virtual simulation it is sufficient to acquire from business partner only 3D CAD and material definition. Once the virtual model is built it is rather quick and simple to change any structure, material, thicknesses or just loading and boundary conditions to get an insight into sensitivity of the complete model behaviour to any input parameters. Nowadays virtual simulations are an integral part of both R&D and certification areas and support the partner along the whole development in various industry sectors.
An overview of a virtual simulation method under ECE Regulation No. R66 – bus rollover [ PDF 832 kB ]
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In the field of computer aided engineering (CAE), we offer a wide range of services for the manufacturers of vehicles and their components, from designing, intelligent computer-based testing, calculations serving for homologation, through to support of experiments and preparation of technical documentation.
As current market demands increase volume of work, while time and costs decrease, new approaches are sought. It is imperative to meet increasing safety requirements and customer expectation in both research & development (R&D) as well as certification testing sensitivity and robustness analyses lead to desired objective of having covered all possible scenarios and variants that comply to safety requirements. This does not have to be necessarily related only to crash simulations, but NVH, durability, strength, stiffness etc.
Using the virtual simulation results in development time reduction and often in weak points identification yet before the prototype is made and hence significantly decrease associated costs. Virtual simulations are very often correlated with physical testing to ensure accuracy and reliability. This leads to overall acceptance of the virtual simulations as a suitable tool by customer and authorities.
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FE analysis of the road barrier crash event
- FEA allows performing a fully detailed model and finally leads to assess the road barrier behavior as well as the vehicle during the crash event
- Simulation could be used as input for assessing the conformity of an approved barrier - in case of modifications A and B (EN 1317-5, Annex A)
- Detailed evaluation and analysis of each of the individual road barrier members – in physical test not possible
- Thanks to the predictive modeling we can significantly decrease the system uncertainties before certification test
- Simulation of the corrosion losses (reduced thickness)
FE model development and verification
FE analysis of the crash event should be divided into following three main areas
- FE model of the road barrier
- Impact characteristics of the vehicles
- FE model of the passenger car
- FE model of the bus and heavy truck
- Global simulation definition
Impact characteristics of the vehicles
- Standard (EN 1317-2 2010) defines the basic parameters of cars to be used in real crash tests, such as dimensions, weight and COG
- Real test results may vary according to the used type of the testing vehicle
– Tyre pressure
– Bumper height
– Global shape of the frontal part – in case of the bus
FEA validation via:
- Comparing the videos including time sequences
- Comparing the characteristic values (W, D, ... ASI)
- Behavior of longitudinal members and anchorage points
- Vehicle deformation after impact
- Possible parts separation during impact
- Requirements for the reliability target level of road barriers in accidental design situations have not yet been sufficiently specified
- It is appropriate to use probability analyses and risk based approach to determine the target reliability levels
- To analyse the consequences of structure failure or barrier overcome in a collision with a heavy vehicle the methods of risk engineering and FEA simulations described in the paper can be successfully applied