Design and development of helmet testing rig for impact loading

According to WHO (World health organization), around 4000 fatalities occur in pakistan every year either due to wearing of no helmets or due to low quality helmets. And we know that in Pakistan there are no such organization that works on helmet testing. So this is our first and foremost duty t

Project Title

Design and development of helmet testing rig for impact loading

Project Area of Specialization

Mechanical Engineering

Project Summary

According to WHO (World health organization), around 4000 fatalities occur in pakistan every year either due to wearing of no helmets or due to low quality helmets. And we know that in Pakistan there are no such organization that works on helmet testing. So this is our first and foremost duty to take initial step and make a helmet testing rig that will identify the quality of different commercially available helmets.

  The main objective of this Final Year project is to design an helmet testing rig that measures the impact loading on different commercially available helmets. "SNELL International standards" are follow as a basic criterion to either accept or reject the different types of bike helmets. According to SNELL Standars if peak acceleration imparted to helmet is crossed 300G's the helmet is rejected otherwise it is safe.

Furthermore there are different sensing and control elements are used to accomplish this task including shock sensors, accelerometer etc.

All computational impact tests were performed using the explicit finite element software ANSYS with appropriate foam and composite material models. The “SNELL STANDARDS” were adopted in both experimental and numerical tests.

Project Objectives

Following are the main objectives of Helmet testing rig:

1. Design and development of "Helmet Testing Rig" for impact  loading on helmets.

2. Conducting impact test on three different positions of helmet.

3. FEM Simulation of impact loading on helmet.

4. Comparison of experimental and simulated data.

Project Implementation Method

Following are the main steps toward the implementation of this project:

First step is the manufacturing of Headform by using Sand casting of the Aluminium.

Second step involves the placement of sensor and accelerometer in Headform.

Third step is the manufacturing of outer assembly of the test rig and anvils.

Fourth step is the complete assembly of headform, anvil and the outer part of rig.

Fifth step is for testing and taking experimental data.

And the final step involves the comaprison of experimental and simulated data. 

Benefits of the Project

The major benefits of "Helmet Testing Rig" are as follow:

1. By using this rig, we can check the quality of different Commercially available helmets and can check that either the different types of helmets available in market satisfies the international standards or not.

2. This project can reduce the risk of death by providing a bike users a complete information that which companies helmets available in market are Good enough to bear impact or not/ or satisfies the international standards or not.

3. This Helmet Testing Rig is easily operated by everyone.

Technical Details of Final Deliverable

By using accelerometer we get the G's that imparted in the helmet. And by using Shock sensor we get impact force in the helmet. Then by using two to three different softwares including ANSYS, Labview, and Abbacus we get the simulated data of G's and the impact force that imparted in the helmet. Finally we compare the experimental and simulated results. And based on SNELL Standard we can comment the Quality of the helmet.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Health

Other Industries

Manufacturing

Core Technology

Others

Other Technologies

Robotics

Sustainable Development Goals

Good Health and Well-Being for People

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com