Inside Magna’s Crash-Test Dummy Lab: A Peek into the World of Vehicle Safety
Crash testing is an essential part of ensuring vehicle safety, and Magna, a tier-one supplier in the automotive industry, has a state-of-the-art crash-test dummy lab in Sailauf, Germany. This lab, operated by ACTS GmbH & Co. KG, a subsidiary of Magna, is where cars are thrown at walls, EV batteries are subjected to intense torture, and crash dummies are put through traumatic experiences to determine the safety of vehicles.
Crash dummies, or Anthropomorphic Test Devices (ATDs), are not your ordinary mannequins. They are sophisticated human-shaped data-gathering tools with sensors and recording devices that can measure up to 160 channels of activity during a crash. Magna’s crash lab runs approximately 600 dummy-crewed crash tests per year, resulting in about 3,200 injury events for the dummies. These dummies come in various sizes and shapes to simulate different scenarios, including men, women, children, and specialty pieces like standalone torsos and legs.
The crash-testing facility also conducts pedestrian safety tests using a legform device. This girthy column with impact sensors is designed to measure the impact of being hit by a car. Additionally, EV batteries undergo intense torture testing to ensure their safety. These batteries are subjected to 10,000 power cycles and simulations of years of use. The most exciting test is the nail test, where an EV battery is spiked with a 6-millimeter nail to force a short circuit and observe its reaction.
Magna’s crash-test dummies are not disposable; they are rebuilt and recalibrated after every crash. They can essentially live forever since they are modular and rebuilt so often. However, they are typically rebuilt completely after 10 to 20 accidents. The cost of these dummies is no joke, with some dummies valued at over a million dollars. The complexity and sophistication of these dummies have come a long way since their inception in the 1960s. Governments set crash-measurement standards to which these dummies are built.
In addition to crash testing, Magna performs a range of functions for car companies, from manufacturing vehicles like the BMW Z4 and Toyota Supra to developing EV batteries, supercar transmissions, and collision-warning sensors. The company’s expertise extends to managing supply chains and conducting research and development of car parts. With its extensive capabilities, Magna plays a crucial role in validating cars for crashworthiness at various stages of development.
While the crash-test dummy lab at Magna may resemble a scene from Westworld’s basement, it is far from sinister. It is a place where advanced technology and meticulous testing ensure the safety of vehicles and their occupants. By pushing the boundaries of crash testing, Magna contributes to making our cars safer, providing peace of mind for drivers and passengers alike.