The 12-Inch HYGE system is designed to simulate
the effects of a collision in acceleration rather than a deceleration
mode. The standard 12-inch HYGE has 225,000 pounds (1 M newton)
of thrust. The HYGE’s design provides extremely repeatable
and reproducible acceleration pulses, enabling accurate simulation
and modeling of crash conditions in non-destructive fashion.
A given pulse can be accurately produced on any 12-Inch HYGE
system, enabling component suppliers and OEM manufactures to
share testing programs and data interchangeably. The HYGE system
has proven its repeatability/reliability over time. Systems
over 40 years old routinely demonstrate repeatability of better
than +/- 2%.
Over 50 12-inch HYGETM systems are
in active use worldwide for a variety of automotive, military,
aircraft safety testing applications. Some typical HYGETM
- Proven Accuracy – capable of simulating
actual crash pulses to within +/-2%.
- Repeatability – better than +/-2%,
even after more than 40 years and 30,000 firings.
- Reproducibility – pulses can be accurately
reproduced on different HYGETM systems, enabling sharing of
test programs and results between components suppliers and OEM’s.
- Versatility – The HYGETM
has the structural integrity and thrust capability to perform
side impact tests which are not possible with “light rail”
type systems. Lightweight sled allows testing of light trucks
and sport utility vehicles.
- Universally Accepted --testing standard for
FASS and FAA requirements.
- Mechanically Simple – only 2 moving
- User Friendly –operating software.
- Experienced installation, training and service
The 12-inch HYGETM system consists
of five major components:
The Actuator, which has a stroke length of
approximately five feet (1.5 m).
The Rail System and Carriage.
The Pneumatic System, which provides pressurized
gas for firing the piston.
The Fluid Transfer System, which provides
fluid to vary the volume of the cylinders.
The Control Center, which contains the valve
system, computer control and operator station.
The 12-inch HYGE actuator consists of two 12-foot long (3.6m)
stainless steel cylinders; each with a 12-inch (30.48 cm) bore.
The shock tester is mounted on the face of a reinforced concrete
foundation (reaction) block. All HYGE units use a metering pin
is to throttle the amount of energy transferred to the carriage
at any given time during firing, thereby determining the shape
of the acceleration pulse. A particular component, in a particular
crash situation, will have a waveform determined by modeling
or by actual crash tests. Each metering pin is machined to produce
the desired pulse shape for a given specimen and set of crash
conditions. In addition, aspects of the waveform can be varied
through changes in the set cylinder volume, load cylinder volume
and the gas pressures in each cylinder prior to firing.
HYGE, INC. offers a metering
pin design program, which enables the engineer
to enter the characteristics of the desired waveform and automatically
generate the required metering pin profile.
HYGE, INC offers a module
Rail System and Carriage
The rail units are manufactured in 10-foot (3m) sections. A
100-foot (30.4m) rail assembly is supplied with the 12-inch
HYGE system as standard. The rail sections are installed approximately
3-feet (100cm) apart on concrete piers or flush to floor at
the users discretion. Extra rails are available in 10-foot increments.
The rail sections are precision ground on the top, bottom and
inside edge to provide guidance for the carriage. Each rail
section includes the necessary anchor bolts, bolt positioning
template for locating the bolts in the concrete foundation,
and the necessary nuts and washers. The rails may be mounted
flush with the floor, or raised. An optional maintenance pit,
which is about 15 feet long by 2 feet deep, may be installed
as part of the foundation instillation.
Comb End Barrier - Honeycomb over travel barrier
may be installed at the end of the rail system to protect
the carriage in the event of carriage overrun.
Measuring Accessory - This is a photo eye assembly
with display to measure carriage velocity.
Movement System - Replaces the standard cable
hoist system to allow for easy movement of the carriage interlocked
to prevent firing the system while the carriage is still attached.
The compressed air module consists of two compressors, capable
of producing 34 scfm (962 l/min) @ 4500 PSI (310 bar), storage
tanks, a dryer, pulsation tank, condensate trap and blow down
tank with filter and oil separator are provided, complete with
piping and electrical components all mounted on a steel framework,
ready for installation.
The hydraulic fluid reservoir and transfer system provides the
means of varying the gas volume of the cylinders prior to firing.
By adding or removing fluid, the pulse form may be adjusted.
The automated control system provides complete automation of
the preparation and firing sequence. A graphical user interface
allows the operator to visually determine the status of the
system at a glance, and program firing parameters using a menu
system. The control center also offers a convenient interface
to a variety of supporting equipment.
- Max. Load Pressure: 3000 psig (207
- Set pressure for Max. Load Pressure:
500 psig (34.5 bar)
- Maximum force with Max. Load Pressure:
225,000 lbf. ( 1 MNewton)
- Load Cylinder: 120-inches long (3
m) with a 12-inch (30.48 cm) dia bore
- Set Cylinder: 120-inches long (3
m) with a 12-inch (30.48 cm) dia bore
- Maximum stroke length: 60 inches
- Maximum Acceleration: 50 G (490.3
- Maximum payload: 5000 lb. (2268 kg)
- Velocity: 66 MPH (106 killometer/hour)
- As described above two compressors, capable of producing
34 scfm (962 l/min) @ 4500 PSI
(310 bar), storage tanks, etc.
- Compressed dry nitrogen in regulated bottles that
can hold 2200 psi
(152 Bar) for set cylinder.
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