Sensors and Instrumentation for Automotive Crash & Impact Testing

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Sensors and Instrumentation for Automotive Crash & Impact Testing

The Automotive Crash & Impact Testing market vertical plays a critical role in advancing vehicle safety, regulatory compliance, and innovation in mobility.

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The Automotive Crash & Impact Testing market vertical plays a critical role in advancing vehicle safety, regulatory compliance, and innovation in mobility. As global safety standards become more stringent and vehicle architectures evolve with electrification, autonomy, and lightweighting trends, the demand for precise, reliable crash measurement technologies has grown significantly. Within this vertical, on-vehicle sensors and in-dummy sensors form the backbone of data acquisition systems used during crash simulations and physical impact testing.

On-vehicle sensors are installed directly on vehicle structures and subsystems to measure parameters such as acceleration, strain, force, pressure, and deformation during impact events. These sensors enable engineers to analyze crash pulse characteristics, structural integrity, battery safety (in EVs), and occupant compartment performance. Their deployment spans full-vehicle crash tests, component-level impact tests, and sled testing environments, providing real-time insights that guide design optimization and safety validation.

In contrast, in-dummy sensors are integrated into Anthropomorphic Test Devices (ATDs), commonly known as crash test dummies, to capture biomechanical responses experienced by occupants during collisions. These sensors measure head injury criteria (HIC), chest deflection, neck forces and moments, femur loads, and other injury-related metrics. The data collected supports the evaluation of restraint systems such as airbags and seatbelts, enabling manufacturers to meet regulatory requirements and achieve higher safety ratings from assessment programs.


On Vehicle Sensors

The Automotive Crash & Impact Testing market vertical for on-vehicle sensors focuses on the deployment of high-precision instrumentation directly on vehicle structures and subsystems to capture critical data during crash events. These sensors, including accelerometers, load cells, pressure sensors, and displacement transducers, enable engineers to measure dynamic responses such as deceleration forces, structural deformation, load transfer, and safety system activation timing within milliseconds of impact.

ACCELEROMETERS

H64M Light Weight Crash Accelerometer

  • Ranges ±50g to ±2000g
  • Frequency to 4000 Hz
  • Output varies with range
  • -20 to 85 Deg C

H201 Compact Accelerometer

  • ±100g to ±2000 g dynamic range
  • Frequency response to 5000 Hz
  • Durable, Low Noise Cable
  • Low Cost, High Performance

H40 Critically Oil Damped Accelerometer

  • ±25g to ±2000g dynamic range
  • Frequency response to 5000 Hz
  • Compliant to SAE J2570
  • Temperature Compensated

 

H30 Road Testing Accelerometer

  • +/-500g to +/-20000g dynamic ranges
  • +/- 50mV full scale output
  • Up to 10000 Hz frequency response
  • -20 to 85 Deg C operating
  • temperature

H52M Low Cost Miniature Accelerometer

  • Ranges ±50g to ±2000g
  • Frequency to 7000 Hz
  • Gas Damped MEMS
  • Reliable Performance

H53A Triaxial Crash Test Accelerometer

  • +/-50g to +/-6000g dynamic ranges
  • Up to 5000 Hz frequency response
  • 100mV full scale output
  • -40 to 121 Deg C operating
  • temperature

PRESSURE

PM5 Miniature Thread Pressure Sensor

  • Ranges 1 to 350 bar gauge, sg, abs
  • Output mV or 0.5 to 4.5V
  • Linearity up to ±0.25% FS
  • Titanium construction

 

 

LOAD CELL

F20 Seat Belt Load Cell

  • Ranges 16 kN
  • Output 2 mV/V
  • Accuracy to 1% full scale
  • Low Mass Titanium design

 

 

In-Dummy Sensors

In-dummy sensors are essential for evaluating the effectiveness of restraint systems such as airbags and seatbelts, as well as for supporting compliance with global safety regulations and consumer safety assessment programs. As vehicle designs evolve with electrification, automation, and new interior configurations, the demand for higher-accuracy, multi-axis, and miniaturized sensing solutions within ATDs continues to grow. This makes in-dummy instrumentation a fundamental element of occupant protection development and automotive safety validation processes.

ACCELEROMETERS

H64C In Dummy Accelerometer

  • ±50g to ±6,000g ranges
  • Frequency to 7000 Hz
  • SAE J211/SAE J2570 compliant
  • ISO 17025 calibrated

H68C In Dummy World SID

  • ±100g to ±2000 g ranges
  • Output 2 mV/g
  • 68CM1 cover option
  • SAE J2570 Compliant

STRING POTENTIOMETERS

Precision String Pot Series 150

  • Ranges 0 to 38 mm
  • Voltage Divider output
  • Temperature -65 to 125 Deg C
  • Infinite Resolution

 

 

Data Acquisition

Select from a range of data acquisition chassis tailored for automotive crash and impact testing, with benchtop and mobile options to suit different setups and channel requirements. Nexdaq, TrioNET & DEWE3 systems feature powerful onboard PCs for real-time high-speed data capture, analysis, and up to 1 TB of onboard storage. Their compact, rugged design includes interfaces such as USB, LAN, HDMI, and RS-232 for easy integration. Add TRION and TRION3 input modules to support sensors like accelerometers, strain gauges, and load cells for precise crash measurement.

NEXDAQ

  • 8 analogue channels
  • Counters, CAN-FD & digital IO
  • Up to 1 MS/s sample rate
  • Sealed to IP67

TRIONet

  • Up to 4 power channels
  • Up to 16 analogue inputs
  • Up to 10 MS/s sample rate
  • Requires external PC

DEWE3-A4 Portable

  • Up to 8 power channels
  • Up to 32 analogue inputs
  • Up to 10 MS/s sample rate
  • PC with touchscreen and SSD

 

 

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