Crash Test Rig

Our client (TRL Ltd) operates a range of transport research and test facilities. A new facility has been built for testing components such as child seats, wheel chair securing attachments, F1 racing car nose cones, etc. JK Controls Ltd. have designed, built and commissioned the controls for operating the test and recording results.

A trolley carries the sample under test, which is projected along a track by strong rubber cords using a patented design. The trolley is then brought to rest by means of a rapid deceleration apparatus or by impact with a solid steel wall, dependent upon the type of test being carried out.

JK Controls supplied a PLC and SCADA based control system to handle the test set-up, test sequencing, safety interlocking, data gathering and post-test recording of results. The system uses Microsoft Access for data set-up and results history, Citect SCADA for operator interaction, and Mitsubishi Q series PLC for data I/O and control. The screen appearances of the software systems are customised to give a consistent ‘house’ look.

The operator is able to type in a desired impact speed, the number of cords and the diameter of the cords, as well as many other menu based test set-up characteristics. The trolley is weighed and the point of initial impact registered. The trolley is winched back and the system then carries out a calibration sequence using force and position measurements with calculations to determine the desired release point for the trolley that will enable the final speed at impact to be within 1% of the desired value. At the onset of impact a high speed measuring phase is started which gathers depth of impact data, checks its validity, stores the data and records the greatest depth of impact prior to rebound. Position measurement was a challenge due to the rapid movement, deceleration and non-contact requirement of the application. We researched several methods of measurement and carried out extensive tests, finally settling upon a Sick-Stegmann laser system with rapid update. This enables measurement of impact depth to within 2mm and location of the trolley over the full track length of 22 meters.

On completion of the test further data is recorded regarding maximum acceleration prior to impact and measured impact speed. The stored energy at release and the energy actually imparted at impact are calculated to determine the efficiency and hence refine the calibration of subsequent tests.

JK Controls built the control panels and custom designed electronic systems for speed measurement and calibration.

Crash Test Rig Control Cabinet SCADA Screen

Contact Information: e-mail to info@jkcontrols.co.uk, or telephone +44 2380 892021

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