HYGE Crash System Design Overview

HYGETM was originally developed for shock and impact testing of military control hardware. The design was, and still is, subject to rigid US military specifications for capacity, performance, quality, and safety. The reaction block, cylinders, and rail pillars have been modeled using the finite element method to ensure the necessary rigidity and strength under all conditions with generous safety margins. The resulting over design of the HYGETM enables it to operate with heavier payloads and to provide a wider range of tests than other sled acceleration systems.

The standard 12-inch HYGETM, with its 225,000 pounds of thrust (1.1 M Newtons), is capable of testing light trucks and sport utility vehicles, as well as passenger car bucks. The HYGETM system can be used for off-axis force tests for side-impact simulation. It may also be fitted with a sled that provides pitching motion as well as linear acceleration.

Accuracy and Repeatability

The most important features of the HYGETM is the accuracy and repeatability of the reaction. The form of the metering pin and the gas volume in each cylinder can be precisely controlled, producing exactly the desired pulse to within 2% each time the system is fired. The simple mechanical design of the HYGETM provides this repeatability over many years of active service.

Because of the HYGETM long operation capabilities systems with over 25,000 tests have been relocated to new locations to continue use. Many of the installed 12-inch HYGETM systems in operation today have performed over 30,000 tests. The workload has been increasing in resent years with systems being scheduled for over 1,000 shots per year. With this heavy workload the HYGETM still performs the accurate and reliable testing required.

Click here for a graphic representation of the accuracy and repeatability of HYGETM systems.

Reproducibility Provides Efficiency and Convenience

The HYGETM pulse is also extremely reproducible. Pulses produced on one HYGETM system can be precisely duplicated on another HYGETM system using the same metering pin, or one of the same design. This enables component suppliers and auto manufacturers to share testing programs and metering pins between different HYGETM installations. This is extremely advantageous to component suppliers, since virtually every automobile manufacturer in the world has one or more 12-inch HYGETM systems.

Pulse Shaping

With the HYGETM Design Program the pin shape can be calculated and operating parameters adjusted by simulation to optimize design. Providing data to machine the metering or segment size and location to assemble from the Segmented Pin Kit. Fine tuning pulse shape is accomplished in minutes buy changing segments of different diameter at location on pulse you desire to adjust.

Optional Lightweight Sled for Greater Versatility

The Optional Lightweight Sled reduces sled weight by 600 pounds, extending the HYGETM to cover a wider range of tests by increasing both acceleration and payload capabilities.

The changeover from the standard sled to the lightweight sled is simple and takes only a few hours, with no engineering and minimal mechanical work required. We also offer a rotating turret sled, allowing complete 360 degree rotation of test specimens.

The rails the sled travels on may be installed either on piers raised from floor or flush to floor surface at user discretion. The raised rail system is the most preferred by users, because it places the specimen at a more comfortable working height, resulting in fewer potential back stress/injuries to personnel. Either installation plan allows the HYGETM to be relocated to a new facility in the future.

Comments are closed.