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How Car Stuff Works

How Car Crash Testing Works

Have you ever wondered how car crash tests are conducted? Today, cars are much safer than they were some years back as now there is a well-established testing program. Also the federal law requires all cars to pass a 30-mile-per-hour frontal crash test.

Crash test dummies are the key as they are used as replica for man in a crash test. Dummies are made of materials that imitate human physiology. Though dummies of different sizes are used, dummy weighing 172 lbs (78 kg) and standing at 69 inches (5 ft. 9 inches or 1.75 m) tall is the most frequently used in testing. Since 1997, GM's Hybrid III dummies became the industry standard that complied with government regulations.

Dummies are equipped with instruments like accelerometers, load sensors and motion sensors for collecting data of impact on different parts of body like head, chest, pelvis, legs, feet etc. Accelerometer calculates acceleration in all three directions—fore-aft, up-down, left-right and helps to determine the likelihood of injury. Load sensors placed in parts like femur help to determine the amount of force on bones and the likelihood of them breaking while motion sensors are used to determine the deflections in body parts during crash. Before test, different parts of dummy are painted with different color so that after the crash, researchers will know what body part hit what part of the vehicle inside the cabin by the color of the paint that is smeared on the airbag, steering wheel, etc.
According to the New Car Assessment Program (NCAP) of National Highway Traffic Safety Administration (NHTSA) cars made for model year 1997 and after must pass both the tests frontal crash testing and side impact crash testing.

Frontal crash testing:

In this test the car is driven into a wall at 35 miles per hour (56 kph). This is equivalent to a head-on collision between two identical cars each traveling at 35 miles per hour, or at a closing speed of 70 miles per hour. About 15 high-speed cameras will document the action, shooting about 1,000 frames per second.

Side impact crash testing:

In this test a sled of 3,015-lb (1,368-kg) with a collapsible bumper hits the side of the test car. This is the equivalent of a car being sideswiped by another car.

How safety system works in crash test:

Though avoiding crash is the ideal situation it is not possible always. So the best case scenario is the smoothest crash which results in the survival of the person in the car. Absorbing the kinetic energy that drops from a high speed to zero after the crash is the key in this case. Safety systems must absorb this kinetic energy as slowly and as evenly as possible to prevent injuries. Seatbelt forms the first line of defense and removes some of the impact. Then milliseconds later, to stop the force of the seatbelt from becoming too high and thus hurtful, force limiters in the seatbelt kick in. Then the airbag releases, and it absorbs some more of the forward motion and prevents occupants from slamming into a hard part of car. In this way all the systems act together to minimize the kinetic energy.

The growth of technology and continuous researches on crash testing are helping to make the accidents less fatal and save thousands of lives.







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