Browse Topic: Frontal collisions

Items (436)
This SAE Recommended Practice describes the test procedures for conducting frontal impact restraint tests for heavy truck applications. Its purpose is to establish recommended test procedures that will standardize restraint system testing for heavy trucks. Descriptions of the test set-up, test instrumentation, photographic/video coverage, and the test fixtures are included.
Truck Crashworthiness Committee
Fuel Tank Dynamic Strain Measurement Using Computer Vision Analysis2020-01-09244/14/2020
Stress and strain measurement of high density polyethylene (HDPE) fuel tanks under dynamic loading is challenging. Motion tracking combined with computer vision was employed to evaluate the strain in an HDPE fuel tank being dynamically loaded with a crash pulse. Traditional testing methods such as strain gages are limited to the small strain elastic region and HDPE testing may exceed the range of the strain gage. In addition, strain gages are limited to a localized area and are not able to measure the deformation and strain across a discontinuity such as a pinch seam. Other methods such as shape tape may not have the response time needed for a dynamic event. Motion tracking data analysis was performed by tracking the motion of specified points on a fuel tank during a dynamic test. An HDPE fuel tank was mounted to a vehicle section and a sled test was performed using a Seattle sled to simulate a high deltaV crash. Multiple target markers were placed on the fuel tank. The motion of these markers was captured using high speed video cameras. The high speed videos were processed using the OpenCV computer vision library. Using OpenCV, the high speed videos were imported, and the position of the central location of each target marker was extracted frame by frame from the high speed videos. Once the position was known, the strain was computed using the change in relative position between two marker positions. Results of the testing showed that the acceleration-induced strain is low, generally less than the material yield strain. It was noted that reliable and accurate results require that the camera be placed normal to, or at a shallow angle to, the points being tracked. In addition, curved surfaces lead to limited fidelity of strain data due to the varying focal length of the points being tracked and measurement increased sensitivity. This method is similar to a “typical” tensile test in which displacement is tracked between two pre-established points on a sample. As such, the methodology was replicated on a tensile specimen to validate the methodology.
Fleming, MarkKrishnaswami, RamNakamoto, Kunihiro
The Effects of Small Seat Swiveling Angles on Occupant Responses during a Frontal Impact2020-01-05714/14/2020
In highly automated vehicles (HAVs), new seat configurations may be desirable to allow occupants to perform new activities. One of the current HAV concepts is the swiveled seat layout, which might facilitate communication between occupants. The main objective of this study was to investigate the effects of seat swiveling angles on occupant kinematics and injury risk predicted by a Human Body Model (HBM) during a frontal impact. A detailed 50th percentile male HBM (GHBMC M50-O) was subjected to two frontal crash pulses in a sled setup. The model was positioned on a semi-rigid seat and restrained using a pre-inflated airbag and a three-point seatbelt. Simulations included four seat swiveling angles (0, -10, -20, and -30 degrees), three occupant positions (Sedan driver, large VAN driver or Laptop user), two airbag initial locations (nominal or matching the head Y location), and the inclusion of lateral supports on the seat pan. The effects of the seat swiveling angle were similar for all occupant positions. With the airbag in the nominal location, higher seat swiveling angles led to a higher head lateral displacement and a higher risk of head injury, especially for the BrIC criterion. The Sedan driver position had higher BrIC and a larger head lateral excursion than the other two positions. This could be mitigated by aligning the airbag location with the head. Pelvic fractures were also predicted for the configurations with the highest swiveling angles. These fractures were limited by the use of seat pan lateral supports. Overall, the model responses were sensitive to both seating configurations and occupant postures, and the results suggest that swiveled seating may increase the injury risk, especially for the head and pelvis. However, simple countermeasures, such as adapted airbag location or adding lateral seat pan supports, seemed possible to mitigate the risk.
Grébonval, CyrilleTrosseille, XavierPetit, PhilippeWang, XuguangBeillas, Philippe
This recommended practice provides common data output formats and definitions for a variety of data elements that may be useful for analyzing the performance of automated driving system (ADS) during an event that meets the trigger threshold criteria specified in this document. The document is intended to govern data element definitions, to provide a minimum data element set, and to specify a common ADS data logger record format as applicable for motor vehicle applications. The data elements defined in this document are unique to Levels 3, 4, or 5 ADS features, as defined by SAE J3016, and provide additional background of the events leading up to a crash or crash-like event. The data from sensors such as camera(s), LiDAR(s) etc. will provide information in the absence of a human driver. The data included in the ADS data logger is expected to be used in conjunction with the SAE J1698 EDR record and traditional accident reconstruction analysis. The event data recorder (EDR) and ADS data logger will capture information leading up to the triggered event, at a minimum. ADS technology is still being developed and is not yet commercially deployed. Therefore, this SAE Recommended Practice is intended as a guide toward standard practice and is subject to change to keep pace with experience and technical advances.
Event Data Recorder Committee
Head and Neck Loading Conditions over a Decade of IIHS Rear Impact Seat Testing2019-01-12274/2/2019
Rear-end impacts are the most common crash scenario in the United States. Although automated vehicle (AV) technologies, such as frontal crash warning (FCW) and automatic emergency braking (AEB), are mitigating and preventing rear-end impacts, the technology is only gradually being introduced and currently has only limited effectiveness. Accordingly, there is a need to evaluate the current state of passive safety technologies, including the performance of seatbacks and head restraints. The objective of this study was to examine trends in head and neck loading during rear impact testing in new vehicle models over the prior decade. Data from 601 simulated rear impact sled tests (model years 2004 to 2018) conducted as a part of the Insurance Institute for Highway Safety (IIHS) Vehicle Seat/Head Restraint Evaluation Protocol were obtained. This dynamic evaluation involves a simulated rear-end crash using a Biofidelic Rear Impact (BioRID IIg) ATD positioned in the seat attached to a crash simulation sled and accelerated to represent a rear crash with a delta-V of approximately 15.6 kph (15.6 ± 0.26 kph). Head and neck injury metrics were calculated for all tests to evaluate trends in the test ATD responses across model years. Reductions in HIC 15, Nij, and upper neck tensile forces were observed across all model years. Nkm, upper neck flexion moments, extension moments, and shear forces were found to show little or no change by model year. Reductions in time to initial contact with the head restraint were observed and likely contributed to reduced head accelerations and neck tensile forces. Given the anticipated persistence of rear-end impacts and potential changes to the vehicle interior layout with improving AV technology, the data should be considered by designers, researchers, and evaluators looking to project future crash and injury rates in rear-end impacts.
Scanlon, John M.Isaacs, JessicaGarman, Christina
Risk of Concussion in Low- to Moderate-Speed Frontal and Rear-End Motor Vehicle Collisions Evaluated Using Head Acceleration-Based Metrics2019-01-12184/2/2019
Over the past decade, there has been an increase in awareness and concern about the occurrence and long-term effects of concussions. Traumatic brain injury (TBI)-related emergency department (ED) visits associated with motor vehicle collisions, including patients with a diagnosis of concussion or mild TBI (mTBI), have increased while deaths and hospital admissions related to TBI have decreased. The diagnostic criteria for concussion have evolved and broadened, and based on current assessments and diagnostic imaging techniques, there are often no objective findings, yet a diagnosis of concussion may still be rendered. Clinical assessment of concussion may be based only on patient-reported symptoms and history, making it difficult to objectively relate the reported increase in TBI-related ED visits due to motor vehicle collisions to specific collision parameters. This study aims to perform a scientific evaluation of concussion risk during motor vehicle collisions, strengthened by objective, quantitative data, specifically focusing on head acceleration-based metrics. Data from full-scale passenger vehicle crash tests are reported for frontal and rear-end collisions with delta-Vs ranging from 6.0 to 19.0 kph (3.7 to 11.8 mph) and 5.6 to 19.5 kph (3.5 to 12.1 mph), respectively. Head linear and rotational kinematic data were recorded from instrumented Hybrid III 50th percentile male anthropomorphic test devices (ATDs) restrained in the driver’s seats. Several acceleration-based metrics currently used to assess risk of concussion were calculated and compared to published injury risk relationships that have been developed from field accident data, human subjects, and biomechanical models. Overall, the magnitudes of acceleration were low and the injury metrics corresponded to a negligible risk of concussion in these low- to moderate-speed collisions.
Pasquesi, Stephanie A.Bruno, AlexanderCourtney, AmyImler, Stacy M.Smedley, JaninePrange, Michael T.
Innovative Knee Airbag (KAB) Concept for Small Overlap and Oblique Frontal Impacts2019-01-06214/2/2019
Considerable research has been conducted in terms of attempting to reduce lower leg injury risk in full frontal impacts, in some cases by the use of a knee airbag (KAB). However, there has been limited research into the performance of KAB systems during a crash test with increased oblique loading, such as the IIHS small overlap frontal test, an oblique moving deformable barrier test (OI) being researched by NHTSA, and a mobile progressive deformable barrier test (MPDB) that is expected to be implemented by Euro NCAP in the next few years. The objective of the current numerical study was concentrated on the evaluation of an innovative KAB concept design intended to reduce ATD right inboard lower leg/foot responses under small overlap and oblique loading conditions. A novel appendage KAB concept design was developed with the help of morphing and computational studies which were performed with different ATD sizes. In the study, one of the lower leg/foot responses was monitored and compared over a conventional KAB design. Cases investigated in the study showed that the novel appendage KAB concept design acts as a conventional KAB in full frontal impact modes (similar right inboard femur responses) and has the potential to reduce right inboard lower leg/foot responses by an average 16% (small overlap impact mode) and 20% (oblique impact mode) over the conventional KAB design. Furthermore, it was noted that the novel design could potentially be adapted to achieve targeted right inboard lower leg responses in full, offset and oblique frontal crash tests with minimal impact on the left outboard responses.
Makwana, RahulJindal, Pardeep
Estimation of the Relative Roles of Belt-Wearing Rate, Crash Speed Change, and Several Occupant Variables in Frontal Impacts for Two Levels of Injury2019-01-12194/2/2019
Driver injury probabilities in real-world frontal crashes were statistically modeled to estimate the relative roles of five variables of topical interest. One variable pertained to behavior (belt-wearing rate), one pertained to crash circumstances (speed change), and three pertained to occupant demographics (sex, age, and body mass index). The attendant analysis was composed of two parts: (1) baseline statistical modeling to help recover the past, and (2) sensitivity analyses to help consider the future. In Part 1, risk functions were generated from statistical analysis of real-world data pertaining to 1998-2014 model-year light passenger cars/trucks in 11-1 o’clock, full-engagement frontal crashes documented in the National Automotive Sampling System (NASS, 1997-2014). The selected data yielded a weighted estimate of 1,269,178 crash-involved drivers. Those data were parsed for four subpopulations: two levels of belt use (properly-belted vs. unbelted) and two levels of driver injury (moderate-to-maximum, MAIS2+ vs. serious-to-maximum, MAIS3+). For each subpopulation, a baseline statistical model was generated via logistic regression, cast as a function of the studied variables. Each risk function was assessed for statistical significance (p-value for each term) and statistical associativity (Goodman-Kruskal Gamma). The four resulting risk functions had some statistical insignificance and fair fidelity, with Gammas ranging from 0.54 to 0.73. However, the risk functions demonstrated excellent fidelity for estimating aggregate injury rates (function-estimated vs. directly-estimated). They were accordingly applied in Part 2. In Part 2, sensitivity studies were conducted by (a) perturbing the studied variables in the NASS dataset to generate thousands of hypothetical NASS files, (b) applying the risk functions to estimate attendant net injury rates, and (c) relating the net injury rates to the variations. Specifically, net injury rates and mean statistics were generated for 15,552 hypothetical NASS datasets involving both belted and unbelted drivers. Those data were then normalized by the means of the baseline NASS file. Finally, power functions were developed to relate the resulting dimensionless net injury-rate data to the five dimensionless predictor variables. Those functions demonstrated excellent fidelity (R2≥0.95), and their exponents helped quantify the relative role of the five studied variables. Belt-wearing rate and speed change were determined to be the most influential, followed by age, body mass index, and sex. These findings might help guide engineers and regulators.
Laituri, TonyHenry, ScottLi, Guosong
Evaluation of Occupant Kinematics in Low- to Moderate-Speed Frontal and Rear-End Motor Vehicle Collisions2019-01-12264/2/2019
Low- to moderate-speed motor vehicle collisions are a common crash type and are sometimes associated with injury complaints. Understanding occupant motion (kinematics) in response to low- and moderate-speed motor vehicle collisions is important for evaluating occupant interactions with interior vehicle structures, including the restraint systems, with the ultimate goal of assessing injury potential. Furthermore, quantitative occupant kinematic data from full-scale crash testing of late-model passenger vehicles is limited for collisions at low- to moderate-speeds. The current study reports kinematic data from full-scale frontal and rear-end crash tests of late-model, mid-size sedans with delta-Vs ranging from 6.0 to 19.0 kph (3.7 to 11.8 mph) and 5.6 to 19.5 kph (3.5 to 12.1 mph), respectively. For each test vehicle, the motion of a Hybrid III 50th-percentile male anthropomorphic test device (ATD) restrained in the driver seat was recorded using high-speed onboard video. Motion tracking of the video was used to evaluate the excursion and velocity of each ATD’s head, shoulder, elbow, and knee with respect to the vehicle interior. Restraint loads were recorded via load cells placed on the driver’s torso and lap belts. For both the frontal and rear-end collisions, the maximum excursion and velocity of the ATD with respect to the occupant compartment generally increased with increasing delta-V. During the occupant rebound phase of the rear-end collisions, the maximum excursion and velocity of the ATD also generally increased with increasing delta-V and was generally less than its initial rearward excursion and velocity.
Bruno, AlexanderToney-Bolger, MeganGeorge, JuffKoller, JeffreyFilatov, AntonOlberding, Joseph
Validation of Crush Energy Calculation Methods for Use in Accident Reconstructions by Finite Element Analysis09-06-02-000910/4/2018
The crush energy is a key parameter to determine the delta-V in accident reconstructions. Since an accurate car crush profile can be obtained from 3D scanners, this research aims at validating the methods currently used in calculating crush energy from a crush profile. For this validation, a finite element (FE) car model was analyzed using various types of impact conditions to investigate the theory of energy-based accident reconstruction. Two methods exist to calculate the crush energy: the work based on the barrier force and the work based on force calculated by the vehicle acceleration times the vehicle mass. We show that the crush energy calculated from the barrier force was substantially larger than the internal energy calculated from the FE model. Whereas the crush energy calculated from the vehicle acceleration was comparable to the internal energy of the FE model. In full frontal impact simulations, the energy of approach factor (EAF) has a linear relation with the residual crush, which had been validated in previous experimental studies. In our study using FE analysis, we found that the slope of EAF versus the residual crush was comparable with that of the dynamic crush energy versus the dynamic crush for crashes at 55 km/h. Using this slope and the residual crush from a 55 km/h impact test, the slope and the intercept of the EAF vs. residual crush can be determined using only one crash test. A database of the slopes and the intercepts was made using Japan New Car Assessment Program (JNCAP) tests. In offset impact simulations, the crush energy calculated from the crush profile agreed with the internal energy of the car FE model when at least one front rail was involved. In oblique impacts, the correction factor for crush energy is not necessary within 20 degrees of principal direction of force of the car’s longitudinal axis.
Numata, ShusukeMizuno, KojiIto, DaisukeOkumura, Dai
Correlation of “Non-Zero” Speedometer Readings with EDR Data2018-01-05224/3/2018
Observations made during forensic automotive crash investigations have identified instances of non-zero, post-crash speedometer readings and created questions as to the validity of the indicated speed relative to the vehicle speed at impact. Previously published work has addressed many issues related to the reliability of non-zero, post-crash speedometer readings identified in vehicles as well as motorcycles. Much of this work established criteria that related the reliability of the post-crash needle position to the design of the stepper motor that controls the needle. Part of this criteria is related to the static torque associated with the speedometer needle shaft rotation due to outside (crash) forces. The published criteria were evaluated in staged crash tests which investigated the ability to maintain needle position under longitudinal and lateral forces after an electrical power loss. In an effort to extend the science, this paper compares non-zero, post-crash speedometer readings with event data recorder (EDR) data from twenty-one real-world crashes where both non-zero, post-crash speedometer readings and EDR data were available. Results from this study suggest a positive correlation between non-zero speedometer readings and vehicles experiencing both an electrical power loss and a single impact. However, this study also shows a negative correlation between non-zero speedometer readings and vehicles experiencing an electrical power loss and multiple impacts. Eighteen of the twenty-one vehicles had valid pre-crash EDR speeds. Of those eighteen vehicles, the speedometer position and EDR speed were within ±15% for fourteen of the vehicles. The current study also demonstrates that non-zero tachometer readings do not always improve confidence levels of non-zero speedometer readings. While the post-crash needle position may provide a good estimate of the travel speed of the vehicle at the time of power loss, there are numerous other factors which must be considered prior to accepting these readings.
Yannaccone, John R.Kinder, Robert
A Tailor Welded Blanks Design of Automotive Front Rails by ESL Optimization for Crash Safety and Lightweighting2018-01-01204/3/2018
Utilizing the tailor welded blanks (TWBs) design along with the latest AHSS grades for the front rails on a sedan was studied to reduce the weight of the vehicle and improve the crash safety performance. To find the most efficient material usage, the front rail parts were tailored into multiple blanks with varying thickness. A structural thickness optimization study of the tailored front rails was conducted for IIHS moderate overlap frontal crash, and the tailored blank thickness was set as design variable. The equivalent static loads (ESL) method was adopted for the thickness optimization, which allows many design variables to be optimized simultaneously. The torsion and bending stiffness of the sedan body in prime were set as design constraints, and would not be compromised. The optimal thickness configurations of the TWB designs by ESL optimization suggest that the weight of the frontal rails can be reduced by more than 30% while still maintaining the crash safety performance. These TWB designs were validated by US-NCAP full frontal impact and show similar performance with baseline. A 3rd gen AHSS, NEXMET™1000, was selected on four parts of the front rails to replace the baseline HSLA350. The optimal tailored frontal rail design using NEXMET™1000 grade was obtained through ESL thickness optimization and validated by US-NCAP full frontal impact. Compared with HSLA350, the NEXMET™1000 grade offers better crash safety performance with more weight reduction potential. An optimal thickness coefficient is proposed in this study to evaluate the material efficiency of the tailored blanks and the amount of thickness changes required for each blank to reach the most efficient material usage. The optimal TWB thickness configurations for HSLA350 and NEXMET™1000 grades through ESL were evaluated using this optimal thickness coefficient. The critical locations on front rails for crash safety were identified and the amount of thickness changes needed characterized. The tailor welded blanks technology can be implemented in the front rail design to reduce weight and improve crash safety. This optimal thickness coefficient can guide the automotive design for lightweighting.
Liang, JianyongPowers, JonathanStevens, Scott
Frontal, Lateral, and Free-Operation Impacts of Amusement Bumper Cars: Vehicle Kinematics and Occupant Kinematics2018-01-05434/3/2018
This study conducted a series of rear-impact, side-impact, barrier, and free-operation collisions using a bumper car ride at an active amusement park. Two conditions were studied: staged and free operation. Each staged test included a bullet (impacting) vehicle operated by a rider and a target (impacted) static vehicle or structure. Impact configurations of frontal collisions of the bullet vehicle into the rear and side of a target vehicle were consistent with the existing literature. The free operation condition involved collisions which were not pre-determined, and operators may not have been prepared for collision timing, magnitude, and direction. Results demonstrated high repeatability for vehicle parameters, such as impact velocity, change in velocity, and peak acceleration. Peak changes in velocity during vehicle-to-vehicle collisions were 2.2-2.5 m/s (8-8.9 km/hr; 5-5.5 mph) for the target vehicle and 1.6-1.8 m/s (5.6-6.4 km/hr; 3.5-4 mph) for the bullet vehicle, while those during vehicle-to-retaining barrier collisions were approximately 3.6 m/s (13 km/hr; 8 mph). Coefficients of restitution and overall vehicle and occupant kinematics were similar to prior bumper car studies, and collision magnitudes were similar in the free-operation test to the staged, single-axis collisions. Bumper cars present a model environment to study vehicle and occupant kinematics in vehicle collisions that are within human tolerance and include aware but possibly unprepared occupants. This is relevant to establishing occupant kinematics in and limits to autonomous vehicle emergency handling maneuvers.
Bussone, William R.Moore, TaraLocey, CaitlinCargill, Robert
Simulation Driven Optimization of Automotive Floor Console Mounting Brackets – An Overview2018-01-10204/3/2018
Floor consoles or Center consoles are an indispensable part of Automotive Cockpit systems in modern passenger vehicles. It occupies space between the front seats in the car and has a lot of utilities and functionalities. The center console design can be very simple as just providing an enclosure for the gear shifter and parking brake and as complex as having storage bins with armrest which can slide. Now-a-days a lot of functionalities are being provided by the center console such as housing the AC vents at the rear, provision for USB and power outlets etc. All these utilities within the center console demand a certain amount of structural rigidity to meet the functional requirements as well as applicable regulatory requirements. The console mounting bracket usually serves to attach the plastic center console to the steel underbody. It also acts as a load carrier for the console and its design influences the overall stiffness and modal characteristics of the console system. In this paper, two different CAE optimization strategies are applied to two variants of console for a passenger minivan application. For one console model, topology optimization strategy is applied to optimize the material on its mounting bracket. In the other console model, which is relatively complex, topography optimization strategy is applied to its mounting bracket for meeting the functional requirements of the console assembly. The critical functional requirements are validated through CAE techniques and correlation with physical test for one of the variants is highlighted in this paper.
Taruvai Sankaran, RaghuramanS, ArunkumarArunachalam, MuthukumarGudla, harinadh
Optimizing Occupant Restraint Systems for Tactical Vehicles in Frontal Crashes2018-01-06214/3/2018
The objective of this study was to optimize the occupant restraint systems for a light tactical vehicle in frontal crashes. A combination of sled testing and computational modeling were performed to find the optimal seatbelt and airbag designs for protecting occupants represented by three size of ATDs and two military gear configurations. This study started with 20 sled frontal crash tests to setup the baseline performance of existing seatbelts, which have been presented previously; followed by parametric computational simulations to find the best combinations of seatbelt and airbag designs for different sizes of ATDs and military gear configurations involving both driver and passengers. Then 12 sled tests were conducted with the simulation-recommended restraint designs. The test results were further used to validate the models. Another series of computational simulations and 4 sled tests were performed to fine-tune the optimal restraint design solutions. The sled tests with the optimized seatbelt and airbag designs provided significant improvement of occupant protection from the baseline tests in terms of the head, neck, chest, and lower extremity injury measures. Using a baseline seatbelt without an airbag, the ATD tended to contact the steering wheel or the instrument panel, or sustained a significant head whipping motion inducing large head and neck injury measures. By adding the airbag and reducing the load limit in the seatbelt, the injury measures were improved significantly. This study demonstrated the benefit of adding a properly designed airbag and advanced seatbelt to improve the occupant protection in frontal crashes under an environment representing a light tactical vehicle.
Hu, JingwenRitchie Orton, NicholeChen, CongReed, MatthewRupp, JonathanGruber, RebekahClark, DavidScherer, Risa
Application of Extreme Value Theory to Crash Data Analysis2017-22-001111/13/2017
A parametric model obtained by fitting a set of data to a function generally uses a procedure such as maximum likelihood or least squares. In general this will generate the best estimate for the distribution of the data overall but will not necessarily generate a reasonable estimation for the tail of the distribution unless the function fitted resembles the underlying distribution function. A distribution function can represent an estimate that is significantly different from the actual tail data, while the bulk of the data is reasonably represented by the central part of the fitted distribution. Extreme value theory can be used to improve the predictive capabilities of the fitted function in the tail region. In this study the peak-over-threshold approach from the extreme value theory was utilized to show that it is possible to obtain a better fit of the tail of a distribution than the procedures that use the entire distribution only. Additional constraints, on the current use of the extreme value approach with respect to the selection of the threshold (an estimate of the beginning of the tail region) that minimize the sensitivity to individual data samples associated with the tail section as well as contamination from the central distribution are used. Once the threshold is determined, the maximum likelihood method was used to fit the exceedances with the Generalized Pareto Distribution to obtain the tail distribution. The approach was then used in the analysis of airbag inflator pressure data from tank tests, crash velocity distribution and mass distribution from the field crash data (NASS). From the examples, the extreme (tail) distributions were better estimated with the Generalized Pareto Distribution, than a single overall distribution, along with the probability of the occurrence for a given extreme value, or a rare observation such as a high speed crash. It was concluded that the peak-over-threshold approach from extreme value theory can be a useful tool in the vehicle crash, biomechanics and injury tolerance data analysis and in estimation of the occurrence probability of an extreme phenomenon given a set of accurate observations.
Xu, LanNusholtz, Guy
Study of an Enhanced Body of Small Vehicle in Frontal Crash Test and IIHS Small Overlap Test2017-01-14683/28/2017
Previous work identified a relationship between vehicle drop and dummy injury under the high-speed frontal impact condition [1]. The results showed that vehicle drop greater than 60mm made the dummy injury worse. Moreover, that work identified the front side member as the crucial part affecting the vehicle drop. In this study, the body structure mechanism was studied to reduce vehicle drop by controlling the front side member, shotgun, and A-pillar. By analyzing full vehicles, it was recognized that the arch shape of the front side member was very important. Furthermore, if the top of the arch shape of front side member, shotgun, and A-pillar were connected well, then the body deformation energy could lift the lower part of A-pillar, effectively reducing vehicle drop. This structure design concept is named “Body Lift Structure” (BLS). The BLS was applied to B and C segment platforms. Additionally, a “Ring” shape was defined by the front side member, dash panel, and A-pillar. The BLS was combined with the Ring shape into a “Body Lift Ring Structure” (BLRS) that could protect the passengers under the IIHS small overlap condition. The BLRS was invented by utilizing the TRIZ problem-solving method. The new platform improved the performance of vehicle drop. This improved performance allowed for a design which achieves a “Good” IIHS small overlap rating, while reducing mass by 12.3 kg, by reducing the amount of countermeasures applied to achieve this rating.
KIm, Do Hoi
Influence of Honeycomb Cellular Meso-structure on Frontal Crash Analysis for Passenger Vehicle2017-01-13013/28/2017
Frontal collisions account for majority of car accidents. Various measures have been taken by the automotive OEMs’ with regards to passive safety. Honeycomb meso-structural inserts in the front bumper have been suggested to enhance the energy absorption of the front structure which is favorable for passive safety. This paper presents the changes in energy absorption capacity of hexagonal honeycomb structures with varying cellular geometries; under frontal impact simulations. Honeycomb cellular metamaterial structure offers many distinct advantages over homogenous materials since their effective material properties depend on both, their constituent material properties and their cell geometric configurations. The effective static mechanical properties such as; the modulus of elasticity, modulus of rigidity and Poisson’s ratio of the honeycomb cellular meso-structures are controlled by variations in their cellular geometry. While the crushing responses in terms of energy absorption and densification of strains have been extensively researched and reported, a gap has been identified in the generalized study of honeycombs with controlled varying of geometric parameters. Unit assembly model technique is used to evaluate the performance of the honeycomb inserts in frontal impact simulations. This paper addresses the study through a series of finite element (FE) simulations where the cell angles and the wall thicknesses are varied. Sensitivity analysis of absorbed energy has been done; to determine the parameters enhancing the crushing energy absorption of honeycombs.
Patil, Deepak A.Buddhe, Hrishikesh
Crush Energy and Stiffness in Side Impacts2017-01-14153/28/2017
Crash tests of vehicles by striking deformable barriers are specified by Government programs such as FMVSS 214, FMVSS 301 and the Side Impact New Car Assessment Program (SINCAP). Such tests result in both crash partners absorbing crush energy and moving after separation. Compared with studying fixed rigid barrier crash tests, the analysis of the energy-absorbing behavior of the vehicle side (or rear) structure is much more involved. Described in this paper is a methodology by which analysts can use such crash tests to determine the side structure stiffness characteristics for the specific struck vehicle. Such vehicle-specific information allows the calculation of the crush energy for the particular side-struck vehicle during an actual collision – a key step in the reconstruction of that crash. Based on fundamental principles of physics and engineering, this methodology provides transparency in the calculation of side structure stiffness parameters for the particular vehicle of interest. Additionally, sample calculations are presented. Utilizing widely available computational tools and publicly available test data, the method was applied to a representative sample of recent-model vehicles. The results of this study show that variability in side structure stiffness from vehicle to vehicle appears to be real – not an artifact of computational method or data uncertainty – and not necessarily related to vehicle size or weight, for example. Independent tests of comparable vehicles, while few in number, produce remarkably similar stiffness results. Supported by sensitivity analyses, various simplifications are presented that in most cases will allow a good approximation to more rigorously-derived results.
Struble, John D.Struble, Donald E.
An Assessment of Inflatable Seatbelt Interaction and Compatibility with Rear-Facing-Only Child Restraint Systems2017-01-14453/28/2017
Ford Motor Company introduced the inflatable seatbelt system in 2011 and the system is now available in the second row of several Ford and Lincoln models. An important consideration is the interaction of the inflatable seatbelt system with child restraint systems (CRS). A comprehensive series of frontal impact sled tests, using a standardized test method, was conducted to compare the performance of rear-facing-only CRS installed using an inflatable seatbelt to the same CRS installed using a standard seatbelt. CRS models from several manufacturers in the North American market were tested both with and without their bases. CRABI 12 month old or Hybrid III 3 year old anthropomorphic test devices (ATD) were restrained in the CRS. The assessment included the ability to achieve a satisfactory installation with the inflatable seatbelt, comparisons of ATD and CRS kinematics, CRS system integrity, and comparisons of ATD responses. In all cases, acceptable installations of the CRS were achieved with the inflatable seatbelt system. When installed with the base, there was a statistically significant reduction in HIC36 for the ATDs restrained using the inflatable seatbelt compared to those installed using the standard seatbelt. The differences in peak resultant chest accelerations for the two seatbelt systems were not statistically significant and minor differences were noted in CRS and ATD kinematics. When installed without the base, HIC36 and peak resultant chest acceleration did not have statistically significant differences and kinematics were comparable. No system integrity issues were identified in CRS installed using inflatable seatbelts for either the installations with or without the base.
Pline, KevinBoard, DerekMuralidharan, NirmalSundararajan, SrinivasanEiswerth, EricSalciccioli, KatieBaker, Noelle
Analysis of Driver Kinematics and Lower Thoracic Spine Injury in World Endurance Championship Race Cars during Frontal Impacts2017-01-14323/28/2017
This study used finite element (FE) simulations to analyze the injury mechanisms of driver spine fracture during frontal crashes in the World Endurance Championship (WEC) series and possible countermeasures are suggested to help reduce spine fracture risk. This FE model incorporated the Total Human Model for Safety (THUMS) scaled to a driver, a model of the detailed racecar cockpit and a model of the seat/restraint systems. A frontal impact deceleration pulse was applied to the cockpit model. In the simulation, the driver chest moved forward under the shoulder belt and the pelvis was restrained by the crotch belt and the leg hump. The simulation predicted spine fracture at T11 and T12. It was found that a combination of axial compression force and bending moment at the spine caused the fractures. The axial compression force and bending moment were generated by the shoulder belt down force as the driver’s chest moved forward. The axial compression force at the spine was also induced by the forces from the crotch belt and the leg hump. Based on these mechanisms, the modifications were made to help reduce the spine fracture risk. The seat back angle was raised, the shoulder belt anchor was lifted, the crotch belt anchor was moved forward, the seat pad thickness was increased and the seat pad stiffness was reduced. These modifications allowed more forward motion of the pelvis and reduced the shoulder belt down force, and generated no spine fracture.
Katsuhara, TadasukeTakahira, YoshikiHayashi, ShigekiKitagawa, YuichiYasuki, Tsuyoshi
Collision Deformation ClassificationJ224_201702 (Historical)2/23/2017
The purpose and scope of this SAE Recommended Practice is to provide a basis for classification of the extent of vehicle deformation caused by vehicle accidents on the highway. It is necessary to classify collision contact deformation (as opposed to induced deformation) so that the accident deformation may be segregated into rather narrow limits. Studies of collision deformation can then be performed on one or many data banks with assurance that the data under study are of essentially the same type.1 The seven-character code is also an expression useful to persons engaged in automobile safety, to describe appropriately a field-damaged vehicle with conciseness in their oral and written communications. Although this classification system was established primarily for use by professional teams investigating accidents in depth, other groups may also find it useful. The classification system consists of seven characters, three numeric, and four alphameric, arranged in a specific order. The characters describe the deformation detail concerning the direction, location, size of the area, and extent which, combined together, form a descriptive composite of the vehicle damage. The individual character positions are referred to by column number for identification and computer storage compatibility as illustrated in Figure 1. The definition of each classification is provided in subsequent sections. An Appendix is also provided to assist in application and interpretation.
Data Collection and Archiving Standards Committee
Truck Deformation ClassificationJ1301_201702 (Historical)2/23/2017
The scope and purpose of this SAE Recommended Practice is to provide a classification system for deformation sustained by trucks involved in collisions on the highway. Application of the document is limited to medium trucks, heavy trucks, and articulated combinations.1 The TDC classifies collision contact deformation, as opposed to induced deformation, so that the deformation is segregated into rather narrow limits or categories. Studies of collision deformation can then be performed on one or many data banks with assurance that data under study are of essentially the same type.2 Many of the features of the SAE J224 MAR80 have been retained in this document, although the characters within specific columns vary. Each document must therefore be applied to the appropriate vehicle type. It is also important to note that the Truck Deformation Classification (TDC) does not identify specific vehicle configurations and body types. The TDC is an expression, useful to persons engaged in vehicle safety, to appropriately describe a collision-damaged truck with conciseness in oral and written communications. The TDC is also a research tool; however, it has not been designed for use in impact energy computation. The research community is cautioned not to attempt direct conversion calculations from the TDC to energy equivalents required to duplicate the damage. The system consists of seven alphanumeric characters arranged in a specific order to form a descriptive composite of the vehicle damage (see Figure 1). The characters describe the principal force direction, location, specific area, type, and extent of damage. The individual character positions are referenced by column number for identification. The definition of each classification is provided in subsequent sections.
Data Collection and Archiving Standards Committee
Methodology to Derive National Estimates of Injuries and Fatalities in Road Traffic Crashes in India2017-26-00161/10/2017
The Road Accident Sampling System - India (RASSI) accident database being developed by an international consortium of manufacturers and safety researchers is currently India’s only source of in-depth crash data. The database includes information on accident, vehicle, and driver factors associated with each crash, which is collected through on-scene crash investigations conducted by trained crash investigators, from four key sample regions (Coimbatore, Pune, Ahmedabad, and Kolkata). As the RASSI database continues to grow, the next step is to ensure that the sample data can be reliably extrapolated to the whole of India. This paper is an initial attempt to develop national estimates by crash type based on a few sampling locations currently being investigated by the RASSI teams in India. RASSI data was treated as a stratified sample of Indian accidents, and the locations, where the crash data is being collected, were considered as primary sampling units. The “mark and recapture” statistical procedurefor population estimation was used to derive sampling weights by accident type and injury severity. Sampling weights were derived by comparing RASSI data with the police reported data from the sampling units for the same period. The weights were based on several factors, including crash types (single-/multiple-vehicle), injury severity, crash location (urban/rural) and type of road user (pedestrian/motorized two-wheeler/car). Data from police logs and RASSI were matched by selected strata (injury type/accident type), and the estimate of total population for that stratum was calculated using well-established statistical methods. Then, national estimates of the various single-vehicle accident types (collisions with fixed objects, rollover, pedestrian, motorcycle) and multiple-vehicle accident types (head-on, rear, side impact, and sideswipe) were derived. Driver contributing factors and consequences were also estimated. The derived estimates at an aggregate level were compared with published sources including MoRTH data to determine and improve adequacy and validity of the weights.
Padmanaban, JeyaRavishankar, R.Dandapani, Ajit
Body-in-White Reinforcements for Light-Weight Automobiles2016-01-03994/5/2016
Automotive OEMs are proactively working on vehicle light-weighting, powertrain optimization, alternate/renewable energy sources and combinations of the three to meet challenging corporate average fuel economy (CAFE) standards. Light-weighting of the body-in-white (BIW) is an obvious choice for vehicle light-weighting as this structure contributes to more than 30-35% of the total weight of a car. Changing manufacturing and assembly lines requires substantial investment. As such, OEMs are exploring short-term light-weighting strategies that do not require any major changes to the BIW. Local reinforcement for the BIW are pertinent solutions that does not require any major changes in the existing assembly lines. This paper focuses on the development of BIW reinforcement solutions using engineering thermoplastic materials that can be mounted at appropriate locations on a vehicle’s BIW to achieve significant weight savings without compromising crash performance. Various design and material configurations - including plastic, metal-plastic and composite-plastic structural members - mounted on the BIW are evaluated through CAE studies for various crash scenarios such as high-speed frontal crashes, side impact, pole impact and rollover. The CAE studies, performed using generic vehicle models, quantify the potential weight-savings in a vehicle by either replacing the existing reinforcements using a lighter system or by incorporating additional reinforcements in the BIW by down-gauging the existing BIW. Approaches to correlate the CAE studies using component level testing and validation of generic reinforcements are also investigated. Data from all of this work indicate that the use of BIW reinforcements can achieve significant weight reduction (∼ 1.5%) in a vehicle, while also ensuring no compromise in crash performance.
Munjurulimana, DineshKulkarni, AmitNagwanshi, DhanendraThambi, Joel LutherWinters, RuudDelaney, Matthew
Alternative Approaches to Occupant Response Evaluation in Frontal Impact Crash Testing2016-01-15404/5/2016
The National Highway Traffic Safety Administration has performed research investigating the Test Device for Human Occupant Restraint 50th male (THOR-50M) response in Oblique crash tests. This research is being expanded to investigate THOR-50M in the driver position in a 56 km/h frontal impact crash. Hybrid III 5th percentile adult female (AF05) anthropomorphic test devices (ATDs) were used in this testing to evaluate the RibEye Deflection Measurement System. The AF05 ATDs were positioned in the right front passenger and right rear passenger seating positions. For the right front passenger, the New Car Assessment Procedure (NCAP) seating procedure was used, except the seat fore-aft position was set to mid-track. For the right rear passenger, the seating followed the FMVSS No. 214 Side Impact Compliance Test Procedure. The NCAP frontal impact test procedure was followed with additional vehicle instrumentation and pre/post-test measurements. Results from this test series were compared with previous NCAP crash tests. The THOR-50M showed similar kinematics to the Hybrid III 50th but predicted a higher risk of chest and femur injury. The mid-track seat position of the right front passenger AF05 led to lower levels of femur compression loading due to additional distance to the dash. BrIC for the driver and front passenger showed higher injury risk than HIC15. In all vehicles, the rear seat AF05 predicted a substantially higher risk of head, neck and chest injury than the right front passenger. The AF05 RibEye output showed a higher peak deflection (x-axis) than the chest potentiometer.
Keon, Timothy
Uncertainty Optimization of Thin-walled Beam Crashworthiness Based on Approximate Model with Step Encryption Technology2016-01-04044/5/2016
Crashworthiness is one of the most important performances of vehicles, and the front rails are the main crash energy absorption parts during the frontal crashing process. In this paper, the front rail was simplified to a thin-walled beam with a cross section of single-hat which was made of steel and aluminum. And the two boards of it were connected by riveting without rivets. In order to optimize its crashworthiness, the thickness (t), radius (R) and the rivet spacing (d) were selected as three design variables, and its specific energy absorption was the objective while the average impact force was the constraint. Considering the error of manufacturing and measurements, the parameters σs and Et of the steel were selected as the uncertainty variables to improve the design reliability. The algorithm IP-GA and the approximate model-RBF (Radial Basis Function) were applied in this nonlinear uncertainty optimization. In order to improve the accuracy of the RBF model, a new step-encryption technology was proposed, in which the encryption points will be added to the current sample points according to the results of each iteration. As a result, when the uncertainty level was 5%, the optimal design vector [t, R, d] was [1.75mm, 3.25mm, 29.48mm], and the possible interval of the specific energy absorption was [841J/kg, 1028J/kg] while the possible interval of constraint was [49.12KN, 71.39KN]. And the optimum was verified with the exact solver. Therefore, this study can provide important references for the crashworthiness design of the front rails.
Du, Qianqian
Finite Element Analysis and Validation of Bus Seat Structure as per AIS023: Safety Features Evaluation of Bus Seat using Hybrid III Dummy2015-01-28699/29/2015
Buses are always one of the main and favorite sources of public transit. Thousands of people die or injure every year in bus accidents. Bus seat can also cause severe injury to the occupants in case of frontal impact. Seat structure of the bus should absorb sufficient energy to minimize the passenger injury. Most of the occupants seated in the second row or further back were injured by hitting the seat back in the row in front of them. In India, AIS023 (Automotive Industry Standards) is one of the several mandatory standards from CMVR (Central Motor Vehicles Rules) to ensure the seat strength and occupant safety during accidents. This standard specifies minimum and maximum deformations range for the seat back to minimize the passenger injury with adequate seat strength. Present study includes the Finite Element Analysis (FEA) and correlation of bus seat as per AIS023 test setup with LS-Dyna explicit tool. Reasonable correlation was found between test and simulation results. This correlated Finite Element (FE) model then used to calculate the injury levels using 50th percentile Hybrid III midsize male dummy. Final results ensure the safety capability of the seat structure in front impact. This procedure was used to enhance safety in passenger bus seats.
Sharma, SumitSharma, SandeepGupta, UmashankerJoshi, RaviPawar, Shailesh
This SAE Recommended Practice describes the test procedures for conducting frontal impact restraint tests for heavy truck applications. Its purpose is to establish recommended test procedures that will standardize restraint system testing for heavy trucks. Descriptions of the test set-up, test instrumentation, photographic/video coverage, and the test fixtures are included.
Truck Crashworthiness Committee
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