HYGE Crash System Design Overview

HYGE^TM was originally developed for shock and impact testing of military control hardware. The design was, and still is, subject to rigid US military specifications for capacity, performance, quality, and safety. The reaction block, cylinders, and rail pillars have been modeled using the finite element method to ensure the necessary rigidity and strength under all conditions with generous safety margins. The resulting over design of the HYGE^TM enables it to operate with heavier payloads and to provide a wider range of tests than other sled acceleration systems.

The standard 12-inch HYGE^TM, with its 225,000 pounds of thrust (1.1 M Newtons), is capable of testing light trucks and sport utility vehicles, as well as passenger car bucks. The HYGE^TM system can be used for off-axis force tests for side-impact simulation. It may also be fitted with a sled that provides pitching motion as well as linear acceleration.

Accuracy and Repeatability
The most important features of the HYGE^TM is the accuracy and repeatability of the reaction. The form of the metering pin and the gas volume in each cylinder can be precisely controlled, producing exactly the desired pulse to within 2% each time the system is fired. The simple mechanical design of the HYGE^TM provides this repeatability over many years of active service.

Because of the HYGE^TM long operation capabilities systems with over 25,000 tests have been relocated to new locations to continue use. Many of the installed 12-inch HYGE^TM systems in operation today have performed over 29,000 tests. The workload has been increasing in resent years with systems being scheduled for over 1,000 shots per year. With this heavy workload the HYGE^TM still performs the accurate and reliable testing required.

Reproducibility Provides Efficiency and Convenience
The HYGE^TM pulse is also extremely reproducible. Pulses produced on one HYGE^TM system can be precisely duplicated on another HYGE^TM system using the same metering pin, or one of the same design. This enables component suppliers and auto manufacturers to share testing programs and metering pins between different HYGE^TM installations. This is extremely advantageous to component suppliers, since virtually every automobile manufacturer in the world has one or more 12-inch HYGE^TM systems.

Pulse Shaping
With the sectional metering pin and the metering pin development software, pulse shapes can be developed, reproduced or modified in little time.

Optional Lightweight Sled for Greater Versatility
This option reduces sled weight by 600 pounds, extending the HYGE^TM to cover a wider range of tests by increasing both acceleration and payload capabilities.

The changeover from the standard sled to the lightweight sled is simple and takes only a few hours, with no engineering and minimal mechanical work required. We also offer a rotating turret sled, allowing complete 360 degree rotation of test specimens.

The rails the sled travels on may be installed either on piers raised from floor or flush to floor surface at user discretion. The raised rail system is the most preferred by users, because it places the specimen at a more comfortable working height, resulting in fewer potential back stress/injuries to personnel. Either installation plan allows the HYGE^TM to be relocated to a new facility in the future.