High-Speed Cameras in Automotive Crash Testing

Since the early 1990s, high-speed cameras have been a driving force in automotive crash testing and collision test analysis. A significant leap forward was the transition from film-based to digital high-speed cameras, which provided instant playback and dramatically reduced turnaround times.​

AOS Technologies AG played a pivotal role in this evolution with the introduction of the VITcam - the world's first self-contained, battery-operated high-speed camera. This innovation enabled secure onboard recording in crash tests, with the camera enduring forces up to 100g. The VITcam has been utilized in countless crash tests, both on sleds and mounted in various positions within vehicles.​

AOS Technologies continues to deliver high-performance cameras that meet the demanding requirements of both offboard and onboard automotive crash testing.

For offboard use, the J-PRI camera—with its 5-megapixel resolution and frame rates up to 2,000 frames per second—captures the high-resolution images required for detailed analysis.

For onboard use, compact cameras offering Full HD resolution at up to 25,000 frames per second provide crisp, clear footage, even under the most challenging conditions in any collision test.

Beyond cameras, AOS expanded its expertise to develop crash test accessories, including onboard LED lighting, synchronization equipment, specialized cabling, and custom features tailored for high-speed crash testing. Today, many customers are operating the fourth generation of AOS cameras, relying on the company's dependable service and innovative solutions.

With fast turnaround times of digital high speed cameras, the ease of use compared to 16mm film cameras and the cost /recording coming down significantly efficient research in automotive crash testing was now possible. With more and more diverse products for off board testing, onboard vehicle testing, sled testing just to name a few a growing data base for designing new vehicle safety standards was emerging. Soon standard organization such as NCAP rated vehicle safety that became an important marketing tool for car manufactures.

Today’s increased vehicle safety and the achievements documented in the New Car Assessment Program (NCAP) would not have been possible without the substantial role of high-speed imaging. Modern automotive safety equipment and systems rely heavily on the data captured by high-speed cameras during countless crash tests.

Cameras must fulfill many roles and function reliably under extreme conditions. In costly crash tests, onboard cameras are required to withstand high shock levels -up to 150g-while continuing to operate and record data reliably.

Recording a bicycle impact against a concrete wall requires meticulous preparation to accurately document the complex deformations and stresses experienced by the test dummy and the bicycle frame. One of the most critical aspects of such a setup is selecting an appropriate frame rate—here, 2000 frames per second—paired with a high-resolution sensor capable of covering a wide field of view.

The AOS J-PRI camera, equipped with a 5-megapixel sensor and capable of recording at 2000 fps, delivers exceptional clarity and detail. This makes it ideal for capturing high-speed events where every millisecond counts. In this scenario, the J-PRI revealed the immense dynamic forces acting on both the machine and the body, helping engineers better understand the mechanisms of injury and structural failure.

In tests like these, high-speed cameras operate alongside a variety of external sensors and system-relevant signals. AOS cameras are engineered to integrate seamlessly into complex test environments, offering a broad range of interfacing options—including compatibility with trigger signals, IRIG-B, and other time synchronization protocols.

Whether it's frontal impacts, side collisions, or rollover crash scenarios, AOS consistently provides the right combination of camera performance and tailored accessories to meet the diverse demands of modern safety testing