Abstract
Sled testing is widely used methodology in the development, verification and validation of Occupant Restraint system (ORS) design specifications, packaging and feasibility assessment study for robust occupant safety performance requirements during the early vehicle design phase. The sled tests involves fabrication of a program specific buck (ruggedized BIW) for mounting the components such as seats, dashboard, steering system, seatbelts etc. Multiple tests can be conducted to study the sensitivity of restraints systems on occupant injury with no damage to vehicle body structure [1]. The objective of this study was to develop a single test fixture which can replicate the interior environment of multiple vehicle programs. This test fixture should be modular to incorporate different mounting locations of test components with minimal structural modifications and position adjustments. The modular test fixture was conceptualized considering multiple vehicle programs and finalized based on CAE analysis of the fixture structure. This modular test fixture can be used for testing different vehicle configurations ranging from a small car to a large utility vehicle with only relative position adjustments between the different restraint components, providing considerable savings in time and cost.