Autoliv Testing Buck

Project

The purpose of this project is to build a testing buck to test airbags for out-ofposition passengers.

Autoliv is the world's largest automotive safety supplier. Their vision as a company is to save more lives and reduce serious injuries. This fixture is helpful in achieving their vision and continuing to make advancements in airbags for everyday vehicles.

The fixture replicates various sized cars and passengers. The testing buck will run airbag tests on mannequins ranging in size from a small child to a small statured woman.

Ease of use is highly emphasized throughout the project. The components of the fixture are adjusted manually and can be performed by one person.

Requirements and Assumptions

  • Windshield must rotate from 20 to 60 degrees with resolution of 0.5 degrees and vertically from 500 mm (20 in.) to 1150 mm (45 in.) measured from the floor to the bottom edge of the windshield
  • The dashboard must move from 100 mm (3.9 in.) above the floor to 900 mm (35.4 in.), and side to side 102 mm (4 in.)
  • The seat must have a range forward and back of 610 mm (24 in.), up and down 203 mm (8 in.)
  • One person should be able to adjust the fixture for a different test in an average of 10 minutes or less
  • Once set, components shall not move more than 1 mm after 3 deployments
  • The fixture will be set up/adjusted by one person.
  • The fixture will be able to withstand 8-10 years of use with 200-300 tests each year.

System

Each subsystem allows for the testing buck to replicate various sized vehicles:

  1. Windshield: Adjustable in Z direction, adjustable angle around Y-axis.
  2. Dashboard: Adjustable in Y and Z directions
  3. Seat: Adjustable in X and Z directions
  4. Floorboard: Adjustable angle
  5. Frame: Composed of 1.5" x 3" square tube steel
Frame and system buck

Testing Results and Verifications

Windshield Tests

Requirement Result
Lowest and Highest Vertical Min: 20.75" Max: 45.30"
Min and Max Angle Max 65.5 Degrees Min: 5 Degrees

Seat Tests

Requirement Result
Max vertical 11.250"
Total Forward and Backward 31.375"

Fixture Tests

Requirement Result
Average Adjustment Time 8 min 21 sec

Dashboard Tests

Requirement Result
Lowest and Highest Vertical Low: 3.875" High: 36.25"
Horizontal 4"

*The component movement test will be performed at a later time at Autoliv

Derek Hatch: derekhat16@gmail.com Presli Hutchison McKay Ogden

Special thanks to faculty and advisors: Blair Martin, Spencer Wendel, and Cole Sorenson, and sponsor, Quin Soderquist