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This paper describes the development of a sled-to-sled test methodology to simulate the occupant responses in different side impact cart test modes. For evaluation of various inflatable restraints (Thorax SAB, Head-Thorax Combo SAB, Pelvis-Thorax Combo SAB), the simulation of ‘gap closure’ between dummy and door is desirable to achieve satisfactory SAB performance, besides obtaining good correlation of occupant responses between full-vehicle tests and sled tests. This methodology uses a combination of three sleds - Bullet, Door, and Seat sleds to simulate the entire door velocity profile in two phases - Phase I: Gap Closure till Door-Dummy contact occurs, Phase II: Door-to-Dummy contact till separation. The initial pre-crash distance between dummy-to-door trim is achieved by positioning the Door sled relative to the Seat sled (with dummy).

A dynamic component test methodology using a door sub-system was developed to simulate the outside door handle/latch responses (accelerations and deformations) as in a full-vehicle NHTSA FMVSS 214 side impact test. The test methodology consists of a door sub-system (with door inner components) which is allowed to pivot by means of a hinge at the top of the door. The lateral structural load path affecting the door/rocker response was accounted and simulated (obtained from full-vehicle FE analysis) in this methodology by means of an energy absorbing material (Aluminum honeycomb) of predetermined stiffness. A bullet sled simulating the Moving Deformable Barrier (MDB) surface and stiffness at the same relative location to the door/rocker (as in full-vehicle test) strikes the stationary hinged door at an initial velocity of approx. 30 mph (longitudinal component of crab cart velocity of 33.5 mph).