Development of a Door Test Facility for Implementing the Door Component Test Methodology

This paper describes the development of an automated Door Test Facility for implementing the Door Component Test Methodology for side impact analysis. The automated targeting and loading of the door inner/trim panels with Side Impact Dummy (SID) ribcage, pelvis, and leg rams will greatly improve its test-to-test repeatability and expedite door/trim/armrest development/evaluation for verification with the dynamic side impact test of FMVSS 214 (Occupant Side Impact Protection). This test facility, which is capable of evaluating up to four (4) doors per day, provides a quick evaluation of door systems. The results generated from this test methodology provide accurate input data necessary for a MADYMO Side Impact Simulation Model. The test procedure and simulation results will be discussed. Other features and advantages of the automated Door Test Facility are:

• elimination of “cut and weld” of structural braces of the old process
• accommodation of passenger car and light truck doors through a wide range of SID rams “seating” adjustments
• synchronization of SID rams movement and loading rate
• “freezing” the forward movement of “bottomed-out” SID ram(s) to maintain constant force to prevent trim panel spring back
• automated retraction of SID rams upon test completion.