Scientists of the research field Lightweight and Hybrid Design Methods are developing a method for an efficient sled test setup for vehicle components meeting the requirement to stress and embed components in a reproducible way. Further, the crash behaviour of these components is required to closely emulate real use in vehicles.
Key element of this method is a construction kit based modular system with a focus on movement-restricting connecting elements which is constantly being extended. These energy-absorbing elements are first designed in a FEM system and validated in generic tests. An optimisation tool is used for the time-efficient design of the test parameters for the sled tests and the design of the properties of the connecting element.