Streamlining Crash Testing: New Test Device Manages Over 800 High-Speed Data Channels

Crash testing plays a crucial role in advancing occupant and pedestrian safety worldwide. As part of that pursuit, modern crash tests now collect vast amounts of high-speed data, a trend on the rise for decades. Originally, most of the crash data collected directly supported U.S. and Global NCAP test requirements. Today, a significant amount of additional data is being collected to advance finite element modeling or crash simulations.

Collecting vast amounts of data requires more complex data acquisition solutions. DTS, a leader in data acquisition systems for dynamic testing, has developed the SLICE PRO DISTRIBUTOR to simplify this complex landscape. The new test device is a centralized hub that manages signal integration, communication, and power distribution for multiple crash test dummies and up to a remarkable 820 data channels in a single vehicle.

Managing hundreds of data channels during a crash test is a significant challenge. The SLICE PRO DISTRIBUTOR acts as a central nervous system for the test setup. Event and status signals from each connected system are isolated internally and then integrated to provide a single event and status signal for the entire system.

“With the increasing complexity of vehicle safety testing, DTS’s goal is to simplify testing. Whether it’s 8 channels or 800, it’s all about reliability and repeatability from the test setup to the final data download,” says Chad Ivan, automotive applications manager for DTS. “The SLICE PRO DISTRIBUTOR is a game-changer for automotive testing.”

Instead of managing multiple connections to a control PC, external switch, or wireless unit, all communication functions, diagnostics, system status monitoring, and data downloads are managed through a single connection. The SLICE PRO DISTRIBUTOR is compatible with a range of DTS products and can be easily integrated into existing test environments.

Key features of the SLICE PRO Distributor include:
• Compact, crashworthy enclosure
• Gigabit Ethernet communications protocol that enables all 8 ports to simultaneously download data without throttling
• Supports a mix of up to 820 channels of in-dummy and SLICE PRO DAS
• Higher primary input power range of 36-56 VDC
• The ability to support up to two POWER PRO battery units for redundant power backup

There are ongoing discussions that debate whether physical crash testing is needed with today’s sophisticated finite element models (FEMs). As long as it’s law and physical testing is required to validate and improve modeling, crash testing will continue. The vast amount of test data collected is also advancing new vehicle designs and improving future testing. The bottom line is that more data is a global win for safety.

DTS is a leading provider of data acquisition systems and sensors for automotive safety testing, aerospace, injury biomechanics, and other demanding applications. DTS is committed to providing innovative solutions that help its customers improve product safety and performance.

10 Top Reasons to Choose DTS Data Acquisition Systems & Sensors

 1. Miniature. DTS data acquisition systems and sensors are ultra-small and designed to be embedded on or in test articles, without altering test dynamics.

2. Rugged. Highest shock rating available. Engineered to be reliable in even the most extreme test environments, from crash and blast testing to aerospace applications.

3. High-Speed. DTS DAS features full signal conditioning plus user-configurable sampling rates from 10 – 1M samples per second per channel.

4. SWaP-C Optimized. Size, weight, power, and cost optimized. DTS systems are COTS (commercial off-the-shelf) which makes them cost-effective and readily available with short lead times.

5. Onboard Recording & Streaming. Remote reliability, data writes directly to non-volatile flash memory, plus real-time streaming options available.

6. Standalone or Networked. DTS DAS can work standalone, networked, and as part of a centralized solution — including FTI systems.

7. Versatility & Flexibility. Modular systems are designed to be customized to support required features, functions and channel count.

8. Reduced Cabling & Connectors. Small and rugged enough to be positioned near the sensors, DTS DAS reduces set-up times, cost, and potential issues caused by complicated long cable runs.

9. Eliminates Slip Rings. Ideal for collecting vibration, strain and stress data on rotating applications without the need for slip rings.

10. Worldwide Technical Support. DTS global Technical Centers and online Help Center support customers technical needs 24/7/365.

Extreme test environments? Not a problem with DTS rugged and waterproof enclosures. Tight size and mass constraints? DTS sensors and DAQ are ultra-small and lightweight. For critical testing, you can trust DTS test and measurement solutions to deliver the data you need.

DTS Test & Measurement Solutions In Action

Imagine the test possibilities – learn more about how customers are using DTS data acquisition systems and sensors:

• Automotive Safety – Crash testing, occupant safety testing, vulnerable road user safety testing, off road (field testing), sled testing

• Aerospace Testing – Modification testing, in-flight testing, space capsules, parachutes, seat testing, UAV/Drones, ejection seats, crash survivability, wind tunnel R&D, in flight and rotor testing

• Military/Defense – Military vehicle testing, helmet recorders (combat helmet smart-sensor track traumatic brain injuries in soldiers), blast testing, missile/ordnance, ballistics, underbody blast manikin (WIAMan)

• Sports and Recreation – Sports helmets, bicycles, skis, roller cosaters

• Other vehicles – boats/marine, heavy equipment, trains/rails, motorsports, motorcycles

• Injury Biomechanics – helmet testing, PMHS testing, Research, race horse injury prevention

• Industrial – Mining, wind turbines, product development, robots, package transit, oil & gas

10 Top Reasons to Choose DTS Data Acquisition Systems & Sensors

 1. Miniature. DTS data acquisition systems and sensors are ultra-small and designed to be embedded on or in test articles, without altering test dynamics.

2. Rugged. Highest shock rating available. Engineered to be reliable in even the most extreme test environments, from crash and blast testing to aerospace applications.

3. High-Speed. DTS DAS features full signal conditioning plus user-configurable sampling rates from 10 – 1M samples per second per channel.

4. SWaP-C Optimized. Size, weight, power, and cost optimized. DTS systems are COTS (commercial off-the-shelf) which makes them cost-effective and readily available with short lead times.

5. Onboard Recording & Streaming. Remote reliability, data writes directly to non-volatile flash memory, plus real-time streaming options available.

6. Standalone or Networked. DTS DAS can work standalone, networked, and as part of a centralized solution — including FTI systems.

7. Versatility & Flexibility. Modular systems are designed to be customized to support required features, functions and channel count.

8. Reduced Cabling & Connectors. Small and rugged enough to be positioned near the sensors, DTS DAS reduces set-up times, cost, and potential issues caused by complicated long cable runs.

9. Eliminates Slip Rings. Ideal for collecting vibration, strain and stress data on rotating applications without the need for slip rings.

10. Worldwide Technical Support. DTS global Technical Centers and online Help Center support customers technical needs 24/7/365.

Extreme test environments? Not a problem with DTS rugged and waterproof enclosures. Tight size and mass constraints? DTS sensors and DAQ are ultra-small and lightweight. For critical testing, you can trust DTS test and measurement solutions to deliver the data you need.

DTS Test & Measurement Solutions In Action

Imagine the test possibilities – learn more about how customers are using DTS data acquisition systems and sensors:

• Automotive Safety – Crash testing, occupant safety testing, vulnerable road user safety testing, off road (field testing), sled testing

• Aerospace Testing – Modification testing, in-flight testing, space capsules, parachutes, seat testing, UAV/Drones, ejection seats, crash survivability, wind tunnel R&D, in flight and rotor testing

• Military/Defense – Military vehicle testing, helmet recorders (combat helmet smart-sensor track traumatic brain injuries in soldiers), blast testing, missile/ordnance, ballistics, underbody blast manikin (WIAMan)

• Sports and Recreation – Sports helmets, bicycles, skis, roller cosaters

• Other vehicles – boats/marine, heavy equipment, trains/rails, motorsports, motorcycles

• Injury Biomechanics – helmet testing, PMHS testing, Research, race horse injury prevention

• Industrial – Mining, wind turbines, product development, robots, package transit, oil & gas