Acceleration sensors are used in the automotive industry for accident analysis and safety assessment during and after an impact test. They measure the forces acting on vehicle occupants in the event of a collision and provide valuable data for the assessment and optimization of safety systems such as airbags, seat belts and vehicle structures. In crash tests, dummies are fitted with these sensors in order to obtain precise information about the loads on individual areas of the body.
In frontal and side impact tests in particular, the sensors provide detailed data on the shear and impact forces transmitted to the dummy by the vehicle or the restraint systems. This analysis helps engineers to optimize the timing and effectiveness of restraint systems such as seat belts and airbags. These systems must deploy at exactly the right moment to maximize occupant protection. Acceleration sensors provide the crucial information needed to test and improve the performance of the systems under realistic conditions.
The data collected is used to determine the injury potential for various body parts such as the head and spine. The precise recording of acceleration forces makes it possible to draw conclusions about the risk of serious injuries and thus also make the vehicle development process safer and more efficient.
Figure 1 Optimization of the passenger cell with innovative materials
The role of such tests in optimizing the passenger cell, the central safety area of a vehicle, is particularly important. The passenger cell must be designed in such a way that it protects the occupants in the event of an accident by deforming as little as possible and dissipating the impact forces. The data obtained can be used to design the structures and materials of the passenger cell in such a way that they are stiff enough to protect the occupants and at the same time give way in other areas to absorb the impact energy. In this way, areas such as the crumple zone can be specifically reinforced and optimized to achieve better energy distribution and minimize injuries.
The interaction between vehicle structures and restraint systems is thus perfected. For example, the time at which an airbag is triggered can be precisely matched to the deformation of the vehicle body. If it is triggered too early or too late, the protective effect can be reduced.
The KAS4000 – The ideal sensor for crash test dummies
With a measuring range of up to 6G, the KAS4000 is ideal for tests involving extreme forces, such as high-speed accidents or intensive impact tests. Its high load capacity ensures that it delivers reliable data even under extreme conditions, which is essential for improving vehicle safety. This is made possible by the robust, three-layer design of the measuring element using “Micro Machined Technology” in a small, solid housing with an M8 connector and vertical gas damping between the pendulums.
An outstanding feature of the KAS4000 is the ability to adjust the measuring range. The smaller the set measuring range, the higher the accuracy of the recorded data. This flexibility is particularly advantageous in crash tests where a finer resolution of the data is required, for example to precisely analyze the first milliseconds after an impact. This makes it possible to gain specific insights into the effects on critical areas of the body.
This adjustment can also be made retrospectively via the externally accessible infrared interface. This also makes it possible to compensate for changes in the measuring behavior that may occur after the sensor system has been cast.
Such sensor systems offer exceptional accuracy due to the adjustable measuring range, especially when analyzing critical time windows during an impact. This ensures that even the smallest changes in the dynamics of the impact can be recorded.
This makes them ideal for crash tests with high impact energy, but also for applications in motorsport or aerospace, where extraordinary acceleration forces have to be measured.
Figure 2 Acceleration sensors can optimize crash behavior
The data obtained in tests supports the continuous improvement of vehicle designs. New materials and design approaches can be evaluated and further developed on the basis of the test results in order to make vehicles more resistant to different types of collision. In this way, crash tests not only contribute to the optimization of individual safety systems, but also to increasing the overall safety of the vehicle – especially the stability and protection of the passenger cell.
This makes it possible to reduce the risk of injury to occupants in real accident situations. Acceleration sensors therefore make an important contribution to improving vehicle safety and protecting people on the roads.
