the world standard in crash simulation systems
....cost-effective, flexible solutions for all your dynamic shock testing needs
1155 Myers Lane * Kittanning, PA 16201 * Ph. 724-545-8331 or 888-780-8331* Fx. 724-545-8332

 

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HYGETM 6-Inch
Vertical System

Shock testing is not new; in order to study the effects caused by shock waves to an object many devices have been created. Precise study requires a testing device that will produce a shock which is predictable, reliable and repeatable. The 6-Inch Vertical HYGE system is designed to simulate the effects of a shock in an acceleration rather than deceleration mode.

The 6-Inch Vertical HYGE system develops thrust up to 56,000 lb f (249 KN), it can also produce acceleration values to several hundred times gravity for milliseconds duration and it can produce several different waveforms at various levels.

The 6-Inch HYGE Vertical system consists of a 6” (15.2 cm) ID set cylinder attached to a primary load cylinder this is secured to the mounting base. An optional mounting base can allow for additional load cylinders.

The thrust column is attached to the thrust piston for the stroke. This system design provides extremely repeatable and reproducible acceleration pulses, enabling accurate simulation.

The system has proven its repeatability over time. HYGE systems over 40 years old routinely demonstrate repeatability of better than +/- 2%.

The test specimen is either mounted to a light weight carriage that is attached to a rail system or directly mounted to the thrust column. Pneumatic brakes are mounted on the carriage. Additional rail sections and different carriage sizes are available.

The HYGE system offers precise control of pulse shape, excellent test repeatability and universal acceptance within the automobile manufacturing community.

 

METHODS OF CONTROLLING ACCELERATION

Acceleration of test specimen of the Hyge shock test is governed by the thrust and the specimen mass. The thrust is equal to the difference in pressure between the set chamber and load chamber, times the net piston area exposed. To provide the control necessary to produce a given acceleration waveform or shock patter a specific metering pin attached to the underside of the thrust piston projects through the orifice into the load chamber. The contour of the pin meters the gas flow through the orifice, regulating the acceleration and making the utilized thrust precisely repeatable.

 



DECELERATION EXTERNAL

  • Deceleration can be controlled externally, by means of a rail and carriage system.

  • The rail system includes a carriage on which the test specimen is mounted, this is guided by rails.

  • Prior to firing the carriage is held in contact with the thrust column.

  • Once the unit has been fired and the acceleration phase is over, the carriage and specimen are brought to rest with brakes that are mounted to the carriage.

 

 



DECELERATION INTERNAL

  • With internal deceleration the set chamber is subdivided into two chambers with a deceleration orifice.

  • Part of the set chamber is filled with hydraulic fluid and there is a deceleration metering pin attached to the thrust column.

  • The small test object is mounted to the end of the thrust column.

  • Once fired and a distance is traveled the fluid is forced through the deceleration orifice bringing the thrust column and test object to rest.

 

 

MAJOR COMPONENTS

Rails: the rails guide the carriage and specimen during deceleration in order to maintain as low a deceleration level as is desired. Rails can vary from 8 to 20 feet. Ideally the rail system should be as long as the overhead clearance permits. Actuator can be located in pit to increase usable rail length and lower specimen carriage to floor level.

Carriage: supports specimen mounting onto a fixture bolted to the carriage. The carriage assembly includes pneumatic brakes. There are optional emergency brakes for firing the carriage with decreased primary brake pressure. There is an included carriage return mechanism.

Foundation: the recommended foundation is six-foot cube.

Actuator: the internal working parts of the Hyge unit including the thrust piston, thrust column, seal rings and orifice plate (or plates if deceleration is ordered). There is also an optional safety interlocking device or lock yokes.

Control System: the touch screen control center contains a graphical representation of the system. The control system features an intuitive user interface that provides controls for every automatic function of the system, from the automatic filling of the system pressure to the storing of successful test parameters data. Click here for more information on the Control System

Distribution Center: the distribution center contains all of the valves, regulators, power supplies, etc.

Compressed Air: The 6” Hyge system can be operated from compressed nitrogen bottles. The optional air compressor decreases nitrogen usage by using compressed air on the load side of the system, allowing for pressures up to 3,000 psi to be used (extending the range of operation from 40,000 pounds (178 K Newtons) thrust to 56,000 pounds (249 K Newtons) thrust).

 

The video below shows a 6 vertical HYGe system with actuator cylinders
mounted below floor level, with Sled and 50 foot rail system.

APPLICATIONS

Systems are in use worldwide for a variety of automotive and aircraft safety testing applications. Some typical applications include:

  • Aircraft ejection seat testing
  • Hand held equipment and small appliances
  • Hemets and protective head gear
  • Components and subassemblies

 

FEATURES AND BENEFITS

  • Proven Accuracy - capable of simulating actual crash pulses to within +/-2%.
  • Reproducibility - pulses can be accurately reproduced on various systems, enabling sharing of test programs and results between components suppliers and OEMs.
  • Versatility - can perform velocity and acceleration tests.
  • Mechanically Simple - Very few moving parts.
  • Low Cost Energy - 2200 psi nitrogen

 

SYSTEM PERFORMANCE

The system is capable of producing a wide variety of shock pulses. There is a standard half sine wave meting pin supplied with the system. The pulse may be modified by adjusting the Hyge system firing parameters.

 

Technical Specifications
Actuator:
  • Max. Load Pressure: 3,000 psig (207 bar)
  • Set pressure for Max. Load Pressure: 500 psig (23 bar)
  • Maximum force with Max. Load Pressure: 56,000 lbf. (249 K newtons)
Space Requirements
  • See Layout Below
Maximum Volumes:
  • Load Cylinder: 6 inches (152 mm) diameter bore, max length of 72” (183 cm) varies depending on test needed
  • Set Cylinder: 6 inches (152 mm) diameter bore, length varies depending on test needed
  • Maximum stroke length: up to 36 inches (91 cm) length varies depending on test needed
Performance:
  • Maximum Acceleration: 64G (627.6 m/s2)
  • Maximum payload: 1000 lb. (455 kg) Specimen
Power:
  • 115/230 VAC, 50/60 Hz for control system
Air
  • Compressed dry nitrogen in regulated bottles that can hold 2200 psi (137 Bar) (optional air compressor for load pressure allows for operation up to 3,000 psi (207 bar)