Image of a crash test dummy standing in front of a test vehicle in a proving ground facility

Vehicle Safety Engineering

Improving vehicle safety worldwide is a top priority in the automobile industry. This includes the development and supply of reliable restraint systems, as well as advanced simulations to assess interior, occupant, and pedestrian safety.

Let's create a safe tomorrow together.

Picture of Thomas Kühl, Head of Safety Engineering Services in Alzenau

Thomas Kühl

Expert for Passive Safety Systems

System engineering

Passive safety systems

  • Safety Testing
  • Simulation CAE crash model
  • Algorithm adaptation  Airbag Control Unit
  • Integrated safety systems
Illustration of passive safety systems covering various topics such as passive safety systems, simulation, and testing

Simulation and testing

  • CAE model set-up & parameter study
  • Crash structure pulse simulation
  • Component set-up and validation
  • Status occupant simulation and testing
  • Crash test for final release
Picture of a 3D animation and real-life crash test comparison In the field of system engineering for automotive safety. Safety testing is complemented by advanced CAE crash models, enabling precise simulation of impact scenarios. Algorithm adaptation for the Airbag Control Unit ensures accurate deployment timing and integration with other protective measures. Modern vehicles rely on integrated safety systems, where simulation and physical testing work hand in hand. This includes CAE model set-up and parameter studies to predict crash behavior, crash structure pulse simulations to analyze energy absorption, and component set-up with rigorous validation. Occupant simulation and testing are continuously monitored to verify restraint performance, culminating in full-scale crash tests for final release and certification.
0:6

Simulation

Numerical simulation

3D visualization of a crash test dummy inside a vehicle. The numerical simulation workflow evaluates interior cockpit and greenhouse head-impact scenarios to understand injury metrics and optimize trim and restraint systems. Beyond in-cabin safety, pedestrian protection is assessed through parametric models that analyze contact conditions, energy absorption, and compliant front-end designs. To address vehicle dynamics in extreme events, rollover sensor and actuator design is simulated to ensure timely detection, robust signal processing, and reliable deployment of protective mechanisms, thereby improving overall system performance and occupant outcomes.
  • Occupant and crash CAE simulation
  • Interior cockpit greenhouse head impact
  • Pedestrian protection
  • Roll over sensor and actuator design

Interior simulation

3D visualization of a crash test dummy inside a vehicle to analyze cockpit head protection and optimize greenhouse trim parts to enhance passenger safety and comfort. Additionally, parameter variation is applied to evaluate different design scenarios and improve overall performance. Actuator design and functionality are also key elements, ensuring precise control and realistic simulation of impact forces during crash events.
  • Cockpit head protection
  • Greenhouse trimpart optimization
  • Parameter variation
  • Actuator design and function

Roll over protection

3D visualization of the vehicle for rollover protection analysis to study roll behavior under parameter variation, enabling engineers to predict dynamic responses in different scenarios. Various rollover cases and environmental conditions are simulated to assess structural integrity and occupant safety. Advanced sensing signals feed algorithms that detect critical thresholds, ensuring timely activation of protective measures. The design and function of restraint systems are optimized to provide maximum occupant protection during rollover events, integrating sensor data with robust mechanical performance.
  • Roll behavior with parameter variation
  • Roll over cases and environment
  • Sensing signals for algorithm
  • Design and function restraint system

Pedestrian protection

  • Head and leg protection
  • Passive protection by design
  • Parameter variation
  • Active protection systems
3D visualization of a crash test dummy impacting the vehicle front and hood for pedestrian protection analysis to evaluate head and leg injury risks. Passive protection by design focuses on optimizing structural geometry and material compliance to reduce impact severity. Parameter variation enables engineers to study different configurations and improve energy absorption characteristics. In addition, active protection systems—such as deployable hoods and external airbags—are integrated to further minimize injury potential, combining sensor-driven algorithms with rapid actuation for enhanced pedestrian safety.
0:2

Contact us!

Let's discuss which safety project we can do together!
Picture of Thomas Kühl, Head of Safety Engineering Services in Alzenau

Thomas Kühl

Expert for Passive Safety Systems
E-Mail
Picture of Uwe Gierath, Head of sales at Safety Engineering Services, Alzenau

Uwe Gierath

Head of Sales
E-Mail

Do you want to know more?

*If the contact form does not load, please check the advanced cookie settings and activate the functional cookies for the purpose of contact management.