Revolutionizing Vehicle Safety: Mercedes-Benz and Fraunhofer Society Unveil Groundbreaking Transparent Crash Tests

Mercedes-Benz is the first car manufacturer to carry out an X-ray crash test. Its partner in the X-ray crash test is the Ernst Mach Institute of the Fraunhofer Gesellschaft. In the crash test, all processes in vehicle structures and dummies are visible for the first time. A powerful linear accelerator generates up to 1,000 high-resolution images per second.

(IN BRIEF) Mercedes-Benz, in collaboration with the Fraunhofer Society, conducts the world’s first X-ray crash test using a real car at the Ernst Mach Institute in Freiburg. This groundbreaking demonstration unveils previously hidden internal deformation processes during crashes, providing valuable insights for improving vehicle safety. Powered by a powerful linear accelerator, the X-ray technology captures up to 1,000 high-resolution images per second, offering unparalleled clarity in analysis. The success of this test marks a significant milestone in automotive safety research, showcasing Mercedes-Benz’s commitment to innovation and occupant protection.

(PRESS RELEASE) STUTTGART/ FREIBURG, 13-Mar-2024 — /EuropaWire/ — Witnessing the collision of a vehicle at 60 km/h with a loud bang is always a moment of anticipation, even for seasoned experts. However, the recent side impact test conducted by Mercedes-Benz, one of the world’s most successful automotive companies, at the Ernst Mach Institute (EMI) in Freiburg has added an unprecedented dimension to crash testing. Collaborating with the Fraunhofer-Institute for High-Speed Dynamics, Mercedes-Benz has achieved a remarkable feat – the world’s first X-ray crash with a real car.

In this groundbreaking demonstration, a powerful linear accelerator, functioning as an X-ray camera, captures every intricate detail of the collision process. The crash barrier collides with the orange C-Class saloon, while simultaneously, the linear accelerator beams X-rays through the vehicle structure and dummies. For the first time, all processes within the vehicle and its occupants during a crash become visible, offering invaluable insights into previously hidden deformations and dynamics.

“The Mercedes-Benz X-ray crash sets a milestone in the development tools of the future. With a direct view into the hidden interior, it can help to draw important conclusions for the further improvement of vehicle safety. Mercedes-Benz thus confirms its role as a safety pioneer in automotive engineering.” remarked Markus Schäfer, Member of the Board of Management of Mercedes-Benz Group AG and Chief Technology Officer.

The successful X-ray crash not only unveils previously inaccessible information but also offers a glimpse into the future of crash testing technology. Dr. Malte Kurfiß, Head of the Crash Test Centre at Fraunhofer EMI, emphasized, “The successful X-ray crash provides us with valuable insights to further optimize our technology for capturing previously inaccessible information. Fraunhofer EMI is thus consistently pursuing its strategy of using high-speed X-ray imaging to make dynamic processes visible.”

With the utilization of ultrashort X-ray technology powered by a linear accelerator, up to 1,000 high-resolution images per second can be captured, providing unparalleled clarity and precision in analysis. This technological advancement enables researchers to observe detailed deformation processes without motion blur, significantly enhancing the understanding of crash dynamics and occupant safety.

Prof. Dr. Paul Dick, Director of Vehicle Safety at Mercedes-Benz AG, highlighted the transformative potential of X-ray imaging, stating, “The world’s first X-ray crash shows that X-ray technology can provide revealing new insights. We learn what happens inside a vehicle and to the dummies during an accident. The X-ray images also offer the opportunity to further improve the model quality of the digital prototypes.”

Safety has always been at the forefront of Mercedes-Benz’s philosophy, evident in their extensive crash testing programs. From the first crash test in 1959 to the recent public demonstration of two fully electric vehicles colliding, Mercedes-Benz continues to uphold its “Real Life Safety” ethos, ensuring the highest standards of occupant protection regardless of the drive system.

Mercedes-Benz currently carries out up to 900 crash tests per year and around 1,700 “sled tests” at the Vehicle Safety Technology Centre in Sindelfingen. In this crash simulation, a test sled is accelerated and braked. A test object (vehicle body shell or assembly) is mounted on the sled and subjected to the forces arising during a real vehicle crash. These sled tests allow non-destructive testing of individual components, especially restraint systems such as seat belts.

And the world’s first public crash test on two fully electric vehicles in autumn 2023 shows that safety at Mercedes-Benz is not a question of the drive system. EQA and EQS SUV models crash into each other in a real accident scenario at a speed of 56 km/h and an overlap of 50 per cent. The test confirms the high level of occupant protection: The passenger cell and high-voltage battery of both vehicles remain intact as intended, the doors can be opened, and the high-voltage systems switch off automatically. Further information here.

As Mercedes-Benz pioneers the integration of X-ray technology in crash testing, the journey towards enhanced vehicle safety takes a significant stride forward, promising a future where every aspect of crash dynamics is meticulously understood and optimized.

About the Fraunhofer-Institute for High-Speed Dynamics, the Ernst Mach Institute (EMI)

The Fraunhofer EMI specialises in the physics, engineering and computer science of fast processes in experiments and simulations. The aim is to develop solutions for industrial applications with a focus on reliability, safety, resilience, efficiency and sustainability.

The Fraunhofer EMI deals with crash, impact and shock wave phenomena across all materials. Adopting a comprehensive approach, the institute analyses and optimises the entire range of materials and microstructures through to complex structures. Applications range from materials to components, cars, aeroplanes, satellites, buildings, urban systems and infrastructure networks.

The Fraunhofer Society is the leading organisation for applied research in Europe. Under its umbrella, 76 institutes and research facilities work at locations throughout Germany. More than 30,000 employees generate an annual research volume of more than 2.9 billion euros.

Media contacts:

Tim In der Smitten
Communications Automated Driving & Safety – Safety
tim.in_der_smitten@mercedes-benz.com
+49 151 58617626

Matthias Struck
Manager Communications Automated Driving & Safety – Overall Vehicle
matthias.struck@mercedes-benz.com
+49 176 30925774

SOURCE: Mercedes-Benz Group AG