Abstract: In order to reduce the test cost of new car and its components at development stage, a new type of crash test device, head-on colliding sled, is developed in this paper. Firstly, a 3D model for each module of colliding sled is established with software SolidWorks. Then software HyperWorks and LS-dyna are used for mesh creation and finite element analysis to obtain the deceleration waveform of collision. Next, on the basis of simulation results the test device designed is produced with an electric control system developed for realizing four main functions of test sled: reset, pre-release, release and braking. Finally, the suitable buffering and energy-absorbing module is chosen according to simulation results to perform collision test for verification. The results show that the test device developed can operate normally and reproduce the collision deceleration waveform meeting the requirements of the national and international regulations, achieving the expected results.

Key words: collision test, deceleration waveform, modeling and simulation, FEA, control system