The Future of Crash Testing: The new Mercedes-Benz Technology Center for Vehicle Safety Prof. Norbert Schaub

The Future of Crash Testing: The new Mercedes-Benz Technology Center for Vehicle Safety Prof. Norbert Schaub, Mercedes-Benz Cars Development Sindelfingen July, 03, 2018

MTC Sindelfingen Center for High-Tech 2016: drive integration center 2013: aeroacoustics wind tunnel 2010: driving simulator 2011: climatic wind tunnels Technology Center for Vehicle Safety The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Seite 2

Overview History of Crash Testing Specifications for the Test Center derived from the Integral Safety Concept of Mercedes-Benz Current and future Requirements Building: Design, Development and Setup Startup, Operation and Results Outlook The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 3

History of Crash Testing starting 1959 Inauguration of the facility and first crash in 1973 The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 4

Crash Test Facility yesterday and today Comparison of the test sites T TFS Former crash test facilitiy S New Technology Center for Vehicle Safety F The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 5

Vision, Strategy, Aims Vision A C C I D E N T F R E E D R I V I N G Safe Driving Preventive Action Adaptive Protection Post-Crash Safety Strategy I N T E G R A L S A F E T Y Laws/Ratings Real Life Safety Innovations Aims The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 7

The Integral Safety Strategy of Mercedes-Benz Integral Safety Approach Safe driving: Provide safe driving environment with Intelligent Drive Active Safety Intelligent Drive In detected critical driving situations: Assist with Intelligent Drive and prepare for a possible crash with PRE-SAFE Real Life Safety During a crash: Protect with sophisticated vehicle structures and adaptive restraint systems Passive Safety Intelligent Protect After a crash: Warn other road users and call for professional assistance if needed The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 8

New Requirements from Intelligent Drive Car-to-X-Communication Active Emergency Stop Assist PRE-SAFE PLUS Active Lane Keeping Assist ATTENTION ASSIST Active Steering Assist Active Lane Changing Assist Active Distance Assist DISTRONIC in Driver Assistance Package including Route Based Speed Adaption Active Speed Limit Assist Active Braking Assist standard with Pedestrian Detection, in Driver Assistance Package additionally with Cross-Traffic Function and Congestion Emergency Braking Function MULTIBEAM LED Headlights with Adaptive High Beam Assist Evasive Steering Assist Remote Park-Assist PRE-SAFE PRE-SAFE Sound Active Blind Spot Assist The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 9

Requirements from Examples of New Test Modes PRE-SAFE Impulse Side: Actuator: pyrotechnically filled bladder integrated in the back rest of outboard front seats Sensor: Radar sensors located in the front bumper Algorithm: Detect and trigger/deploy shortly before of a detected lateral impact of another vehicle Use case (example) Non use case (example) PRE-SAFE Scenarios: Crash tests with realistic pre-crash scenarios investigating the benefit of advanced driver assistance systems and PRE-SAFE The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 10

Obligation Safety Requirements Legal Requirements and Commitments Country-Specific Product Liability Requirments - State of the art - Reference manual Producer-Specific Requirements - Brand-specific - Model-specific Rating Requirements - Consumer protection institutes - Insurances - Press and Media The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 11

The Future for Vehicles with Alternative Drive Technologies at the TFS The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Seite 12

Requirements from Examples of New Test Modes Crossroads accident scenarios Compatibility-Crash Test; Car to Car (USA and EU) vehicles colliding under variable angles (e.g. NHTSA oblique) The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 13

Requirements from Examples of New Test Modes Post-crash: Carry out crash configurations with large vehicle runout area. Vehicle is hit and automatically brakes down to a stop with partial deceleration. ERA-Glonass, ecall Russia: law governing automatic emergency calls to the Russian telephone network after a crash The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 14

Test Facility for all Daimler Models The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 15

Project Profile: Vehicle Safety Technology Center (TFS) Building size: 170 m x 279 m (557 ft. x 918 ft.) Building height: 23.10 m (75ft.) Usable area: 35,100 m 2 (114,000 ft. 2 ) Gross floor area: 58,260 m 2 9 (190,288ft. 2 ) Column-free crash hall: 90 m x 90 m (295ft. x 295ft.) Length of crash tracks: 245 m (80ft.), 110 m (360ft.), 105 m (330ft.) Communication forum: In-house event and public relations Completion/commissioning: September 2016 The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 17

Layout TFS Ground floor Dummylab Sledtest Area Crash Pre- and Postprocessing Angle Track Track 1 North Track 1 South The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 18

Layout TFS Ground floor Dummylab Sledtest Area Crash Pre- and Postprocessing Angle Track Track 1 North Track 1 South The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 19

Layout TFS Crash Block Masses Crash block on track 2 (west): Mass: 240,000 kg (529,000lbs) Crash block on track 3: Mass: 180,000 kg (396,000lbs) Angled tracks Track 1 (north) Track 1 (south) Revolving crash block on track 1 (north): Mass: 100,000 kg (220,000lbs) Drivable crash block: Mass: 100,000 kg (220,000lbs) Crash block on track 1 (south): Mass: 540,000 kg (1190,000lbs) The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 20

Layout TFS Parallel Use of Crash Tracks Control room 2 Control room 3 Control room 1 Angled tracks Track 1 (north) Track 1 (south) The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 21

An Impressive Construction Is Born April 2014 Start of construction Pre-planning November 28, 2012 Draft planning April 26, 2013 Approval planning June 26, 2013 Earth-moving July 17, 2013 Start of construction April 7, 2014 The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 22

An Impressive Construction Is Born September 2014 - Construction progress The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 23

An Impressive Construction Is Born November 2014 - Construction progress V632c The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 24

An Impressive Construction Is Born December 2014 - Construction progress The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 25

An Impressive Construction Is Born December 2015 - Construction progress The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 26

An Impressive Construction Is Born Februay 2016 - Construction progress The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 27

An Impressive Construction Is Born April 2016 - Construction progress The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 28

An Impressive Construction Is Born April 2016 - Construction progress The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 29

An Impressive Construction Is Born May 2016 - Construction progress The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 30

An Impressive Construction Is Born July 2016 - Construction progress The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 31

An Impressive Construction Is Born November 2016 - Construction progress The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 32

TFS Live Crash Audience Walkways for Events November 2016 Completion The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 33

TFS Crash Hall and Crash Tracks November 2016 Completion The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 34

TFS Opening Ceremony on November 30, 2016 The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 35

Technological Highlights All crash tracks lead into a column-free crash hall 90 m x 90 m (295x295 ft.) column-free crash hall Angled tracks Track 1 (north) Track 1 (south) The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 36

Technological Highlights Extremely flat crash hall surface with core heating/cooling of concrete floor Requirement regarding the floor levelness of the crash tracks: In one strip of ± 4 m around the crash track center: ± 2 mm/m Across the entire length of the track: ± 5 mm/100 m Core temperature of concrete floor: 20 C On the longest run-up track (s = 245 m from crash block to crash block and r Earth = 6,378,137 m), the curvature of the earth is already 1.18 mm. Calculation of h: = ( ) = 1.18 mm r s h The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 37

Highly Flexible and Efficient Crash Track Drive Concept Two switchable drives for crash tracks 1 (north), 1 (south), crash track 2 and the angled track with overground rails, thus with 4 power outputs A third drive for the combined crash/hydrobrake track 3 Drives each with a rated output of 650 kw, 1,300 kw of power for 15 seconds in boost mode The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 38

Technological Highlights Crash track drive system and overground rails on the angle surface DC electric motor (rated output of 650 kw, 1,300 kw of power for 15 seconds in boost mode) Innovative deflection systems for separable run-up track Overground rail elements can be variably installed at any angle (fixed 15 increments already in place) Rapid installation of the overground rail elements (> 1 day) The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 39

Technological Highlights Challenges LED crash lighting and crash measurement technology with trigger sync system Accurate triggering and synchronization of measuring, video and LED lighting systems, stationary and on-board Flexible distribution of 5 trigger/sync circuits at all 7 impact sites depending on the crash configuration Programming, activation and operation by 3 control rooms Maximum flexibility depending on the crash configurations/crash scenarios Measuring, video and LED lighting systems, stationary and on-board Test preparation and test execution simultaneously at several crash sites > 100 x > 500 x 7 crash points 5 trigger/ sync-circles 3 control rooms longest distance within the building > 200 m The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 40

New Technologies for Alternative Powertrains Two basic concepts for the different drive types The crash vehicle is secured at the crash location This means that localized measures are implemented that either prevent the hazard from occurring at all or attempt to combat the hazard as soon as it occurs. Examples: gasoline-, diesel-, gas- (LPG/CNG) or hydrogen-powered vehicles The crash vehicle is removed following a crash This means that, as soon as the crash has taken place, potential hazard sources are detected and, if necessary, the telescopic loader Manitou immediately removes the crash vehicle from the hall and takes it to the outdoor water basin in the deep yard. Examples: vehicles equipped with high-voltage batteries (Li-ion technology) The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 41

New Technologies for Alternative Powertrains Removing the damaged vehicle Transport and lower the fire-damaged vehicle into the water basin Reverse out of the crash hall, turn around, then drive forwards to the water basin Water basin position as per planning status Lower crash vehicle using telescoping arm that has been extended to the required length 1.0 m 1.2 m The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 42

TFS Sled Test Area Preparation boxes, dummy positioning, buffer areas Sled with hydro brake at track 3 crash block Hydraulic crash simulation sled Combination sled with linear motors The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 43

TFS Sled Test Area: Performance Acceleration tests Deformation tests 90 90 80 80 Speed in [km/h] 70 60 50 40 30 Crash simulation facility Hydrobrake Speed in [km/h] 70 60 50 40 30 Combination sled 20 10 0 Combination sled 0 15 30 45 60 75 90 105 120 20 10 0 0 100 200 300 400 500 600 Acceleration in [g] Mass in [kg] The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 44

TFS Sled Test Area: Hydrobrake Sled Max. braking force: 3,200 kn Max. acceleration: - 70g with a payload of 2,500 kg (5512lbs) - 120g with a payload of 400 kg (881lbs) Max. speed: 80 km/h (50 mph) Track length: 105 m (114 feet) The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Seite 45

TFS Sled Test Area: Hydrobrake Sled Tests Full Scale - Testing Vehicle Restraint System Automatic ecall (70g) Testing charged HV- Battery Testing strenght of seats The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Seite 46

TFS-Dummy-Lab The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Seite 47

TFS Dummy Laboratory with in-dummy Technology Q-Serie ES2 THOR 50% WorldSID SID2s HIII 50% BioRID The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 48

TFS Dummy Laboratory Tasks: Prepare the dummies for use in the tests Dummy maintenance/repair, etc. Dummy certification The highlights: The dummy laboratory covers two floors (laboratory area, storage area) Both levels are air-conditioned to 20.6 C 22.0 C (24,8 F to 42 F) The test benches can be controlled at the PC workstations Programmable test bench control; standardized operating panels Optimized test bench arrangement (currently twin test benches) Ergonomic working heights Efficient, semiautomatic test sequences Dummy positioning by means of grid laser "In-dummy-ready" test benches for digital dummies The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 49

Video Startup, Operation The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 51

Fully Programmable Vehicle Motion Vehicle motion inside the crash hall can be programmed independent of the towing cable system by operating the vehicle systems including steering, braking, and gas with an external controller. A special laser tracking device detects the position inside the facility. Requirements: Tests in the complete crash hangar: 3 tracks + 1 angle track Number of vehicles: max. 2 Measuring equipment crash prove up to 75g High positioning and speed accuracy Speed up to 80 km/h Predicted accuracy of ± 20 mm Max. vehicle acceleration 3 g Bahn 1 Nord Pre-crash driving maneuvers: Longitudinal and lateral acceleration or deceleration High driving dynamics up to unstable driving conditions (sliding) Two cars can move independently prior the impact Bahn 1 Süd The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Page 53

Future Outlook: Autonomous Driving F015! The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Seite 54

Vehicle-Architectures, Safety-Systems, Interior-Concepts - Occupant safety autonomous driving Seating positions variable to some extend e. g. rearward facing seating-position related occupant protection necessary Seat belts Front airbags Side airbags Interaction-airbag PRE-SAFE Conditioning The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Seite 55

Thank you for your attention! The new Mercedes-Benz Technology Center for Vehicle Safety / 2018-07-03 / Seite 56