Browse Topic: Side impact crashes

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RAMP BRACKET ANGLE OPTIMIZATION COUPLED WITH IMPROVED HEAD ROOM2024-26-001601/16/2024
Restraint systems in automotives are inevitable for the safety of passengers. Curtain airbag is one such restraint system in automotives that reduces the risk of injury to passengers during crash, without which head injury is inevitable during side crash of a vehicle. So successful deployment of Curtain airbag (henceforth called as CAB) is very important in automotive safety during crash. This paper dwells about the optimization done in ramp bracket angle with successful deployment of Curtain airbag. This optimization has paved the way for increasing the head-roominess by ~15% and to respect the safety and styling intent in the vehicle successfully. Providing a ramp bracket at the lower bottom side of CAB guides the airbag successfully during deployment. Ramp bracket angle plays a vital role in guiding the airbag inside the passenger’s cabin without any obstruction. This paper challenges the conventional ramp bracket angle followed for CAB deployment with an alternate angle and has
D, GOWTHAM, L, DHARSHAN, bornare, harshad, RITESH, KAKADE, Deoli, Manish, BHASKARARAO, PATHIVADA, GANGAPURAM, SURESH, Kakani, Phani Kumar
Importance of Pole Side Impact Test for Assessment of Curtain Airbags2024-26-001901/16/2024
Government of India, in 2017, mandated a Side Impact Test (AIS 099 technically aligned to UN ECE Regulation No. 95.03 series of amendments) on M1 category Passenger Vehicles to ensure protection of occupants in lateral impact accident scenarios. Later, in 2022, a draft notification has been issued by the Government mandating installation of 6 airbags (2 No.of thorax side airbags, 2 No. of head protection or curtain airbags in addition to already mandated installation of Driver and Passenger Airbags) in all such passenger vehicles. However, the vehicles fitted with side thorax airbag and curtain airbags are proposed to be assessed as per AIS099 test only. Curtain Airbags are typically installed to protect occupant’s head from severe injuries in narrow object impacts simulated in Pole Side Impact Test Configurations. However, at present, India has not notified an equivalent standard to UN R135 demanding performance of the vehicle in pole side impact scenarios. Typically, OEMs may need to
Jaju, Divyan, Kulkarni, Dileep, Mahindrakar, Rahul, Mahajan, Rahul
Injury Severity Prediction Algorithm of SUBARU Fleet Model for Advanced Automatic Collison Notification2022-01-100503/29/2022
Recently, with the evolution of telemetry technology in vehicles, Advanced Automatic Collision Notification (AACN) that detects patients at risk of serious injury in the event of an accident and transports them to the trauma center at an early stage may greatly improve the treatment of patients. An Injury Severity Prediction (ISP) algorithm for AACN was developed using a logistic regression model to predict the probability of sustaining Injury Severity Score (ISS) 15+ injury. National Automotive Sampling System Crashworthiness Data System (NASS-CDS: 1999-2015) and model year 2000 or later were filtered for new case selection criteria, which were based on vehicle body type, to match Subaru’s fleet. This proposed algorithm uses crash direction, change in velocity, multiple impacts, seat belt use, vehicle type, presence of any older occupant, presence of any female occupant, and presence of the right-sided passenger. Variable selection techniques were used to construct the final ISP
Ejima, Susumu, Goto, Tsukasa, Zhang, Peng, Cunningham, Kristen, Wang, Stewart
A Study of High Refinement Simulation Prediction on the CAB Development for FMVSS226 Ejection Mitigation Performance2022-01-092203/29/2022
In the side impact crash accident, the curtain airbag (CAB) plays a significant role in the occupant head protection. With the increasing of the rollover accidents, the CAB development is requested to be able to protect the occupant head throughout the whole rollover accident, and to ensure that the occupant head is not partially or totally ejected from the vehicle. NHTSA released the FMVSS226 Standard in 2011, defined the requirements for ejection mitigation systems, which limits the linear travel of headform by 100mm. In China regulations, there are similar requirements starting in 2021. The difference is that it can be replaced by meeting the pressure holding requirements of 6s (up to 50% of the average pressure of 40-70ms). Therefore, on the basis of the existing airbag design, adding the rollover protection function becomes a new challenge for the airbag development. During the development of the curtain airbag, the cushion design, inflator type, and the fold pattern, all have an
Shan, Jinhui, Xue, Lele, Wang, Cheng
Structural design of a full-body composite monocoque chassis based on the type of carbon fiber fabrics2022-01-044403/29/2022
The number of stacked layup and orientation of carbon fiber/epoxy in a sandwich panel with the aluminum honeycomb core was optimized using finite element method (FEM) to improve the structural performance of the monocoque chassis for the electric Formula SAE (FSAE) racecar. To establish the selection criteria for fabrics and orientations, the single unidirectional (UD) and woven plies (W) were simulated under tensile and simple shear tests to determine their off and on-axis properties. Simulation results revealed that the unidirectional ply enhances the overall strength of laminate while woven ply is responsible for shear strength. Thus, the combination of unidirectional and woven plies was proposed. The four anisotropic laminates consisting of four plies with different orientations were simulated under three-point bending and plate twist tests to determine the flexural rigidity and twist stiffness (D66), respectively, and their mechanical properties were compared to the quasi
Sratong-on, Pimpet
Child Restraint Systems (CRS) with Minor Installation Incompatibilities in Far Side Impacts2021-01-091504/06/2021
Side impacts are disproportionately injurious for children compared to other crash directions. Far side impacts allow for substantial translation and rotation of child restraint systems (CRS) because the CRS does not typically interact with any adjacent structures. The goal of this study is to determine whether minor installation incompatibilities between CRS and vehicle seats cause safety issues in far side crashes. Four non-ideal CRS installation conditions were compared against control conditions having good fit. Two repetitions of each condition were run. The conditions tested were: 1) rear-facing (RF) CRS installed with a pool noodle to create proper recline angle, 2) RF CRS with narrow base, 3) forward-facing (FF) CRS with gap behind back near seat bight (i.e., vehicle seat angle too acute for CRS), 4) FF CRS with gap behind back near top of CRS (i.e., vehicle seat angle too obtuse for CRS). Second row captain’s chairs were set up at 10° anterior of lateral. A sled pulse target
Mansfield, Julie, Kwon, HyunJung, Kang, Yun Seok
A Comparative Life Cycle Assessment of Magnesium Front End Autoparts: A Revision to 2010-01-0275SAE-PP-0018501/29/2021
The Magnesium Front End Research and Development (MFERD) project under the sponsorship of Canada, China, and USA aims to develop key technologies and a knowledge base for increased use of magnesium in automobiles. The primary goal of this life cycle assessment (LCA) study is to compare the energy and potential environmental impacts of advanced magnesium based front end parts of a North American-built 2007 GM-Cadillac CTS using the current steel structure as a baseline. An aluminium front end is also considered as an alternate light structure scenario. A “cradle-to-grave” LCA is conducted by including primary material production, semi-fabrication production, autoparts manufacturing and assembly, transportation, use phase, and end-of-life processing of autoparts. This LCA study was done in compliance with international standards ISO 14040:2006 [1] and ISO 14044:2006 [2]. While weight savings result in reductions of energy use and climate change emissions during the use phase of the car
Mutagaana, Festo
Evaluation of Occupant Kinematics during Low- to Moderate-Speed Side Impacts2020-01-122204/14/2020
While nearly 50 percent of occupants in side-impact collisions are in vehicles that experience a velocity change (delta-V) below 15.0 kph (9.3 mph), full scale crash testing research at these delta-Vs is limited. Understanding occupant kinematics in response to these types of side impacts can be important to the design of side-impact safety countermeasures, as well as for evaluating potential interactions with interior vehicle structures and/or with other occupants in the vehicle. In the current study, two full-scale crash tests were performed utilizing a late-model, mid-size sedan with disabled airbags. The test vehicle was impacted by a non-deformable moving barrier on the driver side at an impact speed of 10.0 kph (6.2 mph) in the first test and then on the passenger side at an impact speed of 21.6 kph (13.4 mph) in the second test, resulting in vehicle lateral delta-Vs of 6.1 kph (3.8 mph) and 14.0 kph (8.7 mph), respectively. As can occur in real-world collisions, the initial
George, Juff, Davis, Mathieu, Sharpe, Sarah, Olberding, Joseph, Imler, Stacy, Bove, Robert
Likelihood of Spinal Disc Herniations in Occupants Involved in Real World Side Impacts2020-01-052604/14/2020
The prevalence of spinal disc herniations in people with no spinal symptoms have been reported to increase with age; from about 20% in those below 40 years to about 30% in those above 40 years. Spinal disc herniations are usually associated with degenerative changes. Though rare, spinal disc herniations can also be caused by trauma. With an increasing number of older people on U.S. roads with a concomitant increase in the probability of getting injured in a vehicle collision, it is reasonable to expect that some of these occupants can present with clinical findings of spinal disc herniations after a side impact, and attribute these findings to the impact. In this study, we looked at the relationship between real world side impacts and the occurrence of spinal injuries, in particular disc herniations, in occupants involved in such impacts. We examined the reported occurrence of all spine injuries in side impact crashes in the National Automotive Sampling System - Crashworthiness Data
Lam, Tack, Ivarsson, B. Johan
Methods for Quantifying the Impact Severity of Low-Speed Side Impacts at Varying Angles2020-01-064104/14/2020
Accurately quantifying the severity of minor vehicle-to-vehicle impacts has commonly been achieved by utilizing the Momentum Energy Restitution (MER) method. A review of the scientific literature revealed investigations assessing the efficacy of the MER method primarily for: 1) inline rear-end impacts, 2) offset rear-end impacts, and 3) side impacts configured with the bullet vehicle striking the target vehicle at an approximate 90° angle. To date, the utility of the MER method has not been thoroughly examined and readily published for quantifying oblique side impacts. The aim of the current study was to analyze the effectiveness of the MER method for predicting the severity of side impacts at varying angles. Data were collected over a series of 12 tests with bullet-to-target-vehicle contact angles ranging from approximately 45° to 315° with corresponding impact speeds of approximately 12.5 km/h (7.8 mph) to 16.1 km/h (10.0 mph). Vehicle damage profiles were documented after each test
Brink, Justin, Swinford, Scott, Furbish, Christopher, Jones, Brian, Welcher, Judson, Anderson, Robert
Further Non-Deployment and Deployment Laboratory Experiments Using a Toyota Auris 2007 Event Data Recorder2020-01-132904/14/2020
The experimental campaign discussed in publication 2019-01-0635 was extended to emulate more vehicle parameters and also to increase severity leading to deployment event. The engine speed (RPM) and Accelerator Pedal Position (APP) were emulated using LabVIEW and added to the previously reported emulated parameters of wheel speeds and brake status. Overlapping non-deployment events were generated and the EDR data is presented enriched with additional (faster) CAN bus data sniffed from the vehicle harness. While the non-deployment events were still generated using the rubber mallet in pendulum configuration as in 2019-01-0635, a series of tests were performed using an Izod pendulum to incrementally increase event severity until deployment event was generated. The Izod pendulum was instrumented with a rotational potentiometer to measure its instantaneous angle while laboratory accelerometers were used to separately measure acceleration. The Air bag Control Module (ACM) was mounted in a
Tabone, Miguel, Farrugia, Mario
Investigation of a Test Method to Reproduce Car-to-Car Side Impacts2020-01-122104/14/2020
A side impact is one of the severest crash configurations among real-world accidents. In the US market, even though most vehicles have achieved top ratings in crash performance assessment programs in recent years, there has hardly been any sign of a decline in side-impact fatalities for the last few years, according to statistics retrieved from the National Highway Traffic Safety Administration’s Fatality Analysis Reporting System. In response to this trend, the Insurance Institute for Highway Safety (IIHS) is planning to introduce a new test protocol for side impact assessment. One of the points to be clarified in current side impact tests is whether the present side moving deformable barrier (MDB), which includes the barrier face and cart, faithfully reproduces a real-world car-to-car crash. Hence, this study identifies key factors for reproducing car-to-car side impacts based on a series of parametric computer aided engineering (CAE) investigations of the barrier face dimensions and
Takeo, Matsuyama, Ootani, Ryuji, Ueda, Toshiyuki, Hirayama, Shigeru
An Evaluation of Near- and Far-Side Occupant Responses to Low- to Moderate-Speed Side Impacts2020-01-121804/14/2020
Many side-impact collisions occur at speeds much lower than tests conducted by the National Highway Traffic Safety Administration (NHTSA) and the Insurance Institute for Highway Safety (IIHS). In fact, nearly half of all occupants in side-impact collisions experience a change in velocity (delta-V) below 15 kph (9.3 mph). However, studies of occupant loading in collisions of low- to moderate-severity, representative of many real-world collisions, is limited. While prior research has measured occupant responses using both human volunteers and anthropometric test devices (ATDs), these tests have been conducted at relatively low speeds (<10 kph [<6.2 mph] delta-V). This study evaluated near- and far-side occupant response and loading during two side impacts with delta-V of 6.1 kph and 14.0 kph (3.8 mph and 8.7 mph). In each crash test, a Non-Deformable Moving Barrier (NDMB) impacted the side of a late-model, mid-sized sedan in a configuration consistent with the IIHS side-impact crash-test
Toney-Bolger, Megan, Sherman, Sarah, Isaacs, Jessica, Garman, Christina, Dibb, Alan
Evaluation of Laminated Side Window Glazing Coding and Rollover Ejection Mitigation Performance Using NASS-CDS2020-01-121604/14/2020
Occupant ejection has been identified as a safety problem for decades, particularly in rollover crashes. While field accident studies have repeatedly demonstrated the effectiveness of seat belts in mitigating rollover ejection and injuries, the use of laminated glass in side window positions has been suggested as a means to mitigate occupant ejection. Limited data is available on the field performance of laminated glass in preventing ejection. This study utilized 1997-2015 NASS-CDS data to investigate the reliability of the glazing coding variables in the database and determine if any conclusions can be drawn regarding the effect of different side window glazing types on occupant ejection. An initial query was run for 1997-2016 model year vehicles involved in side impacts to evaluate glazing coding within NASS-CDS. Sixteen individual cases were identified where the first-row side window glass was coded as both laminated and as in-place and holed, out-of-place and not holed, out-of
Parenteau, Chantal, Smedley, Janine, Campbell, Ian C., Carhart, Michael
Calculating Vehicle Side Structure Stiffness from Crash Test Data: Effects of Impactor Characteristics2020-01-064004/14/2020
This research examines the effects of impactor characteristics on the calculated structural stiffness parameters A and B for the struck sides of late-model vehicles. This study was made possible by crash testing performed by the National Highway Traffic Safety Administration involving side impacts of the same vehicle line with both a rigid pole and with a moving deformable barrier. Twenty-nine crash test pairs were identified for 2018 model-year vehicles. Of 60 total tests, 49 were analyzed. Test data for 19 vehicles impacted in both modes resulted in A and B values considered to be valid. Classifying these 19 vehicles according to the categories defined by Siddall and Day, only Class 2 multipurpose vehicles were represented by enough vehicles (10) to search for trends within a given vehicle category. For these vehicles, more scatter in the results was observed in both A and B values for the MDB impacts compared to the pole impacts. A causal relationship between stiffness values in the
Struble, Donald E., Struble, John D.
Comparison of Head Kinematics of Bicyclist in Car-to-Bicycle Impact2020-01-093204/14/2020
This study focused on European NCAP activities of introducing a new head protection evaluation procedure, as proposed by BASt (Federal Highway Research Institute - GERMANY). Various kinds of E-bikes are available in the market, ranging from E-bikes that have a small motor to assist the rider’s pedal-power i.e., pedelecs to somewhat more powerful E-bikes which is similar to a moped-style scooter. This paper focused on identifying the factors influencing bicyclist head kinematics during bicycle vs. passenger vehicle (PV) collisions at the intersection. Two AM50 bicyclist FE models are developed using i) GHBMC Human Body Model (HBM) and ii) WorldSID (WS) side impact dummy. Head kinematics of bicyclists of pedal-assist E-bike and normal bike were compared using CAE simulation. It is found that the vehicle’s impact velocity, type of bicycle, the mass of E-bike and bicycle traveling speed will influence the head kinematics.
Pal, Chinmoy, Hirayama, Shigeru, Vallabhaneni, Pratap Naidu, Vimalathithan, Kulothungan, Manoharan, Jeyabharath
Innovative Active Head Restraint System in a Car: Safety Assessment with Virtual Human Body Model2020-01-097904/14/2020
The aim of this study is to use numerical simulations for safety assessment of an innovative active head restraint system. This system was developed to protect the head and neck of an occupant in a car without a head airbag during a side impact. Its FE model is created and embedded it in a model of a small car with a side airbag. The dynamics of the head restraint activation are also taken into account. The virtual human body model Virthuman is used to represent occupants. The model is scaled for pre-selected human individuals to cover large numbers of occupants of different sizes. It extends conventional virtual evaluation of new safety designs via existing pre-defined mono-purpose side dummies and their FE models. The benefit of the head restraint system is evaluated in side impact scenarios inspired by the pole tests performed by EuroNCAP. Transversal impacts to a pole at 29 and 32 km/h are considered at 90° and 75° angles from driver and the opposite side. Also, the far side impact
Vychytil, Jan, Hlucha, Jana, Kovar, Ludek, Kostikova, Martina, Moravcova, Pavlina, Bucsuhazy, Katerina
Investigating Combined Thoracic Loading Using the Elderly Female Dummy (EFD)2019-22-001703/31/2020
The Elderly Female Dummy (EFD) is an omni-directional ATD developed to represent a vulnerable population. The EFD it is able to be 3D printed and quickly altered to meet design requirements. A recent side impact sled test series suggested that small, elderly females may be at risk of thoracic injuries in side impact crashes due to combined loading from the belt pre-tensioner and side airbag. The EFD was altered to add four IR-TRACCs to the thoracic region to allow both x-axis and y-axis displacement to be evaluated in a similar test. While the IR-TRACCs did record the displacement due to combined loading, the rate of displacement and timing of the peak displacements did not match external chestband outputs. The next step for the EFD is to revise the locations of IRTRACCs in the thorax and begin component testing in lateral and frontal directions to improve thoracic biofidelity.
Beebe, Michael, Sullenberger, Kris, Burleigh, Mark, McCarthy, Joe, Bolte IV, John H
Passenger Vehicle Dynamic Response and Characterization of Side Structure during Low- to Moderate-Speed Side Impacts2019-01-042004/02/2019
A significant portion of real-world passenger vehicle side impacts occur at lower speeds than testing conducted by the National Highway Traffic Safety Administration (NHTSA) or the Insurance Institute for Highway Safety (IIHS). Test data from low- to moderate-speed side impacts involving late-model passenger vehicles is limited, making the evaluation of vehicle impact response, occupant loading, and injury potential challenging. This study provides the results of low- to moderate-speed impact testing involving a late-model mid-size sedan. Two full-scale Non-Deformable Moving Barrier (NDMB) side impact crash tests were conducted at speeds of 6.2 mph (10.0 kph) and 13.4 mph (21.6 kph). Instrumentation on the late-model sedan used for the test series included tri-axis accelerometers and seat belt load cells. In both tests, instrumented Hybrid III 50th percentile-male Anthropomorphic Test Devices (ATDs) were restrained in the driver and passenger seats using the standard three-point seat
Skiera, Jason, Crosby, Charles, Bare, Cleve, Paradiso, Marc, Campbell, Gregory
Performance of Event Data Recorders Found in Toyota Airbag Control Modules in High Severity Frontal Oblique Offset Crash Tests2019-01-063304/02/2019
This paper presents an in-depth analysis of the performance of Event Data Recorders (EDRs) found in the Airbag Control Modules (ACMs), as tested in support of the National Highway Traffic Safety Administration’s Frontal Oblique Offset Program. Previous studies have examined EDR performance in high severity full-frontal barrier crash tests and moving deformable barrier side impact tests. This paper presents data from a high severity oblique frontal impact test in which the vehicle was struck by a moving deformable barrier. This paper examines the results of EDR data downloaded from two 2015 model year Toyota Highlanders, and the results of EDR reported change in velocity (delta-v), to vehicle mounted accelerometers and reference instrumentation. This paper will analyze EDR performance in reporting: Seatbelt buckle status, Occupant Size Classification, Front Passenger, Airbag and seatbelt pretensioner deployment time(s), Longitudinal delta-v, and Lateral acceleration/crash pulse.
Bortles, William, Hostetler, Ryan
Comparative Responses of the PIPER 6YO Human Body Model and the Q6 ATD for Simulated Frontal and Lateral ImpactsSC18-22-000611/12/2018
Abstract - Adult and pediatric human body models have focused on developing accurate representation of the human body in terms of anthropometry and kinetics/kinematics in correlation with published PMHS (Post-Mortem Human Subjects) data. This study focuses on comparing the PIPER 6-year-old human body finite element (FE) model with a Q6 FE model to generate comparable metrics. The FE models were simulated in a vehicle environment by positioning them on two different child booster seats with a 3-point lap-shoulder belt for frontal and lateral impacts. The overall kinematic response (head excursion) of the PIPER human body model (HBM) mimics the behavior of the Q6 ATD. However, there is a significant difference in the NIJ values between the PIPER HBM and Q6 ATD (minimum reduction of 67% in PIPER HBM). The head-neck complex of the PIPER is seen to be more flexible (minimum reduction of 12% in neck forces and 64% in neck moments) as compared to the Q6.
Sarfare, Shreyas, Maheshwari, Jalaj, Duong, Nhat, Belwadi, Aditya
Validation of Crush Energy Calculation Methods for Use in Accident Reconstructions by Finite Element Analysis09-06-02-000910/04/2018
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
Numata, Shusuke, Mizuno, Koji, Ito, Daisuke, Okumura, Dai
Four-Step Plastic Testing Protocol: Making Informed Design and Material DecisionsTBMG-3306610/01/2018
Medical devices across the United States must not only keep pace with advances in technology but also with the increased use of harsh solvents and disinfectants. However, many materials commonly used in medical devices aren't able to withstand these new cleaning protocols. The nearly decade-long effort to combat healthcare-associated infections (HAIs) through increased disinfection has resulted in the degradation of their protective housings, causing cracking, crazing, discoloration, and premature failure of devices. Manufacturers must look to materials with higher levels of chemical resistance to strengthen device integrity and protect patient safety.
Torsional Fluctuations Consideration while Design of Synchro Rings2018-01-182309/10/2018
In today’s manual transmissions of car, gearshift system requires high performance with particular emphasis on low effort, minimal travel and positive feel. To meet these targets, a high capacity multi cone synchronizers along with higher co-efficient of friction material used for lower gears. The design of synchronizer with these specifications is influenced by torsional fluctuations from engine. Excessive torsional vibrations leads to wobbling of synchro rings within the peripheral clearances with surrounding parts. Wobbling leads to abrasion wear of frictional area of synchro ring causing grating or crashing noise of gears during shifting. This paper presents the optimization of the multiple cone synchronizer design exposed to excessive torsional vibrations and validation of the same on test bench during development stage instead vehicle level validation.
Tawhare, Nitin, Aswale, Dhananjay, Ponkshe, Makarand
Predictive Estimation of Side Pole Impact Dummy Response Based on Linear Impactor SAB Performance2018-01-501806/18/2018
This article discusses steps to predictively estimate the responses of Anthropomorphic Test Device (ATD) in a side impact event, based on a Side Airbag (SAB) Force-Deformation (F-D) characteristics derived from the linear impactor test. A critical load management challenge that has been used to assess this predictive response process is the oblique pole impact test - part of the FMVSS 214 protocol. In this scenario, the ATD is assumed to have a free travel until it is stopped by the crushed and stacked up door against the rigid pole. Three critical energy management paths involved to manage the kinetic energy of the ATD at impact are assumed at the onset, namely, the door trim crush, ATD torso loading and most important efficient energy management of the SAB at a controlled force level. The SAB energy management is assumed critical and tied with the final response of the test ATD. In the study being reported, the amount of energy absorbed by the SAB and the reaction force of the SAB
Uduma, Kalu, Purushothaman, Dipu, Wu, Jianping, Beaudet, Brian, Keshtkar, Hamid
Influence of Driver Position and Seat Design on Thoracolumbar Loading During Frontal Impacts2018-01-054404/03/2018
Previous research has detailed contributing factors to thoracolumbar compression fracture injury risk during frontal impacts in motorsport drivers utilizing a nearly recumbent driving position (Katsuhara, Takahira, Hayashi, Kitagawa, & Yasuki, 2017; Trammell, Weaver, & Bock, 2006; Troxel, Melvin, Begeman, & Grimm, 2006). This type of injury is very rare for upright seated motorsport drivers. While numerous improvements have been made to the driver restraint system used in the National Association for Stock Car Auto Racing, Incorporated (NASCAR®) since 2000, two instances of lumbar compression fractures have occurred during frontal impacts. Through the use of computation modeling, this study explores the influence of initial driver position and seat ramp design on thoracolumbar loading during frontal impacts. Quasi-static component testing, dynamic component testing, an instrumented driver fit check, a seat ramp angle survey, and sled testing were conducted to provide computational
Patalak, John, Davis, Matthew, Gaewsky, James, Stitzel, Joel, Harper, Matthew
Plug-in hybrid brings Honda into sharper Clarity18AUTP02_0802/01/2018
Honda's recently introduced Clarity plug-in hybrid sedan is the third variant of this revitalized and electrified nameplate. It joins the Clarity Fuel Cell, which debuted in December 2016 and the Clarity Battery Electric that arrived in the U.S. market in August 2017. The Plug-in Hybrid is the only one that's available in all 50 states and the sole version customers can purchase. The base Plug-in is $33,400 with a more upscale Touring model offering features like leather seats and satellite navigation ringing in at $36,600. Available by lease only, the Fuel Cell is just for California consumption and the Battery Electric version is currently offered only in a couple U.S. West Coast states at present. Honda will also offer the Plug-in in Canada.
Sessions, Ron
Wheel Bearing Brinelling and a Vehicle Curb Impact DOE to Understand Factors Affecting Bearing Loads2017-01-252609/17/2017
As material cleanliness and bearing lubrication have improved, wheel bearings are experiencing less raceway spalling failures from rotating fatigue. Warranty part reviews have shown that two of the larger failure modes for wheel bearings are contaminant ingress and Brinell damage from curb and pothole impacts. Warranty has also shown that larger wheels have higher rates of Brinell warranty. This paper discusses the Brinell failure mode for bearings. It reviews a vehicle test used to evaluate Brinell performance for wheel bearings. The paper also discusses a design of experiments to study the effects of factors such as wheel size, vehicle loading and vehicle position versus the bearing load from a vehicle side impact to the wheel. As the trend in vehicle styling is moving to larger wheels and low profile tires, understanding the impact load can help properly size wheel bearings.
Sutherlin, Robert G.
New HAI-Prevention Cleaning Protocols Reinforce Need for Material Consideration for Medical Device HousingsTBMG-2731508/01/2017
As in any industry, new technologies and material choices present new opportunities and challenges for OEMs looking to build brand equity, bring products to market faster, and meet consumer demand. Medical device manufacturers are faced with multifaceted challenges to meet the highest degrees of performance, efficacy, regulatory compliance, and safety in the service of protecting the health and well-being of patients. From the integration of advanced technologies all the way through to the type of material used, every design decision has lasting real-world consequences.
Application of Lateral Pole Impact Force-Displacement Data to the Reconstruction of Side Impacts with Narrow Objects2017-01-141603/28/2017
Reconstruction of passenger vehicle accidents involving side impacts with narrow objects has traditionally been approached using side stiffness coefficients derived from moveable deformable barrier tests or regression analysis using the maximum crush in available lateral pole impact testing while accounting for vehicle test weight. Current Lateral Impact New Car Assessment Program (LINCAP) testing includes 20 mph oblique lateral pole impacts. This test program often incorporates an instrumented pole so the force between the vehicle and pole at several elevations along the vehicle - pole interface is measured. Force-Displacement (F-D) characteristics of vehicle structures were determined using the measured impact force and calculated vehicle displacement from on-board vehicle instrumentation. The absorbed vehicle energy was calculated from the F-D curves and related to the closing speed between the vehicle and the pole by the vehicle weight. The presented approach resulted in
Ault, B. Nicholas, Toomey, Daniel E.
Side Impact Pressure Sensor Predictions with Computational Gas and Fluid Dynamic Methods2017-01-037903/28/2017
Three computational gas and fluid dynamic methods, CV/UP (Control Volume/Uniform Pressure), CPM (Corpuscular Particle Method), and ALE (Arbitrary Lagrangian and Eulerian), were investigated in this research in an attempt to predict the responses of side crash pressure sensors. Acceleration-based crash sensors have been used extensively in the automotive industry to determine the restraint system firing time in the event of a vehicle crash. The prediction of acceleration-based crash pulses by using computer simulations has been very challenging due to the high frequency and noisy responses obtained from the sensors, especially those installed in crush zones. As a result, the sensor algorithm developments for acceleration-based sensors are largely based on prototype testing. With the latest advancement in the crash sensor technology, side crash pressure sensors have emerged recently and are gradually replacing acceleration-based sensor for side crash applications. Unlike the acceleration
Tyan, Tau, Shaner, Leonard, Niesluchowski, Matt, Kochhar, Nand, Bhalsod, Dilip, Wang, Jason
Crush Energy and Stiffness in Side Impacts2017-01-141503/28/2017
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
Struble, John D., Struble, Donald E.
A Comprehensive Validation Method with Surface-Surface Comparison for Vehicle Safety Applications2017-01-022103/28/2017
Computer Aided Engineering (CAE) models have proven themselves to be efficient surrogates of real-world systems in automotive industries and academia. To successfully integrate the CAE models into analysis process, model validation is necessarily required to assess the models’ predictive capabilities regarding their intended usage. In the context of model validation, quantitative comparison which considers specific measurements in real-world systems and corresponding simulations serves as a principal step in the assessment process. For applications such as side impact analysis, surface deformation is frequently regarded as a critical factor to be measured for the validation of CAE models. However, recent approaches for such application are commonly based on graphical comparison, while researches on the quantitative metric for surface-surface comparison are rarely found. To deal with this problem, a validation metric, which combines the discrepancies measurements in magnitude and shape
Wang, Changsheng, Yang, Junqi, Zhan, Zhenfei, Zheng, Ling, Guo, Gang
Accuracy of the Momentum Energy Restitution Method for Offset Inline Minor Rear-End Impacts2017-01-142503/28/2017
In minor inline rear-end accidents, vehicle damage is the primary tangible indicator of impact severity or vehicle change in velocity (ΔV). A technique for calculating change in velocity based on vehicle damage for collinear impacts involves application of the Momentum Energy Restitution (MER) method. Offset inline minor rear-end impact testing, wherein minimal vehicle bumper or contact surface engagement occurs, has not been readily published to date. Thus, instrumented offset inline rear-end impacts were performed utilizing a 1997 Ford F-150 Pickup, 1996 Kia Sephia, and 1995 Chrysler LeBaron GTC to determine if the MER method can accurately calculate a vehicle’s ΔV when collinear contact does not occur. Vehicle engagement involved 5.1 cm to 76.2 cm of overlap with impact speeds ranging between 0.7 m/s and 4 m/s. Test results indicated that a 15.2 cm or less overlap between vehicle impacting surfaces promoted sideswipe impacts or an incomplete transfer of momentum relative to the
Jones, Brian, Calabro, Michael, Brink, Justin, Swinford, Scott
Speedometers and Collision Reconstruction2017-01-141203/28/2017
Various mechanisms have been used to drive speedometers and other instrument gauges. This paper reviews the mechanisms used; in particular investigates the ability of stepper motors which have become the most common instrument motor in the last decade to freeze at the apparent reading prior to impact. Stepper motors require power to drive the needle to any indicated position, including having to return it to zero. Hence if power to the instrument is lost as a result of a collision, there is no power to move the needle and it should be left at the reading shown at the moment the power was lost. However, not all stepper motor instruments are the same and before accepting the reading, a number of criteria need to be considered to give a level of confidence in the result. As part of recent ITAI (Institute of Traffic Accident Investigators) crash test events in the UK, a number of instrument clusters were installed in vehicles to simulate both frontal and side impacts. Impact speeds were
Goddard, Christopher H., Price, David
Numerical Investigation of the Impact of Nozzle Endwall Clearance Distribution on Variable Nozzle Turbine Performance2017-01-103403/28/2017
As the variable nozzle turbine(VNT) becomes an important element in engine fuel economy and engine performance, improvement of turbine efficiency over wide operation range is the main focus of research efforts for both academia and industry in the past decades. It is well known that in a VNT, the nozzle endwall clearance has a big impact on the turbine efficiency, especially at small nozzle open positions. However, the clearance at hub and shroud wall sides may contribute differently to the turbine efficiency penalty. When the total height of nozzle clearance is fixed, varying distribution of nozzle endwall clearance at the hub and shroud sides may possibly generate different patterns of clearance leakage flow at nozzle exit that has different interaction with and impact on the main flow when it enters the inducer. It is possible that variation of the nozzle endwall clearances between hub side and shroud side, e.g. tiny transverse movement of nozzle vanes along their pivotal shafts
Zhao, Ben, Hu, Liangjun, Engeda, Abraham, Sun, Harold
Study on Cycle Time Reduction of Injection Molding Using CAE2017-01-048903/28/2017
Cost reduction is an important issue in the intense competition automotive industry. Interior parts which are mainly consist of plastic have same issue. The manufacturing main processes of plastic products are injection and assemble and the cost of injection depends on injection cycle time. Therefore many studies for the reduction of injection cycle time have been implemented. However the researches based on engineer's experiences have limits so, nowadays many studies utilize CAE. In this paper, the study for the reduction of cycle time focused on injection molding design. To satisfy appearance quality with the reduction of cycle time, the design of injection molding was optimized by using CAE. The result of CAE showed many causes and effects of problems. The optimization of injection molding design improved the quality with the reduction of cycle time. Finally, the product based on CAE showed good quality and cycle time reduction in comparison with previous products.
Jo, Hyunkwon, Kim, Jongsoo, Park, Jaemin, Yang, Heeseung, Park, Hyunmin
Ambulance Litter Integrity, Retention, and Patient RestraintJ3027_201611 (Historical)11/01/2016
This SAE Recommended Practice describes the testing procedures required to evaluate the integrity of a ground ambulance-based patient litter, litter retention system, and patient restraint when exposed to a frontal, side or rear impact. Its purpose is to provide litter manufacturers, ambulance builders, and end-users with testing procedures and, where appropriate, acceptance criteria that, to a great extent ensures the patient litter, litter retention system, and patient restraint utilizes a similar dynamic performance test methodology to that which is applied to other vehicle seating and occupant restraint systems. Descriptions of the test set-up, test instrumentation, photographic/video coverage, test fixture, and performance metrics are included.
Truck Crashworthiness Committee
Full Instrumentation of Side Impact Pole and In-Depth Analysis of Vehicle Structural Behavior2016-36-012810/25/2016
In order to obtain more information from the side impact tests, a pole was fully instrumented with triaxle load cells. Also, a sled modification was carried out providing a sub-frame view of the vehicle during the entire test and making possible to compare the structure and element deformations with the obtained data. An in-depth analysis of vehicle structural behavior focused on the forces received by the vehicle during the pole side impact test was made. A crash test was set to validate the acquisition system of the instrumented pole. The obtained data like the forces and the deformations were analyzed in depth and used for a structural study of the vehicle. The data acquired by the acquisition system was used to obtain a force diagram from the pole and a comparison was made with the vehicle absorption mechanisms and structural elements involved. Moreover, the force data was compared with the sub-frame view and with the structural element’s deformation. With the results, it was
Sanchez, Jacob, Malivern, Melcior, Parera, Núria, Fornells, Alba
Occupant Restraint and Equipment Mounting Integrity – Side Impact Ambulance Patient CompartmentJ2956_201608 (Historical)08/23/2016
This SAE Recommended Practice describes the test procedures for conducting side impact occupant restraint and equipment mounting integrity tests for ambulance patient compartment applications. Its purpose is to describe crash pulse characteristics and establish recommended test procedures that will standardize restraint system and equipment mounting testing for ambulances. Descriptions of the test set-up, test instrumentation, photographic/video coverage, and the test fixtures are included.
Truck Crashworthiness Committee
Alternative Approaches to Occupant Response Evaluation in Frontal Impact Crash Testing2016-01-154004/05/2016
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
Keon, Timothy
Multidisciplinary Optimization under Uncertainty Using Bayesian Network2016-01-030404/05/2016
This paper proposes a novel probabilistic approach for multidisciplinary design optimization (MDO) under uncertainty, especially for systems with feedback coupled analyses with multiple coupling variables. The proposed approach consists of four components: multidisciplinary analysis, Bayesian network, copula-based sampling, and design optimization. The Bayesian network represents the joint distribution of multiple variables through marginal distributions and conditional probabilities, and updates the distributions based on new data. In this methodology, the Bayesian network is pursued in two directions: (1) probabilistic surrogate modeling to estimate the output uncertainty given values of the design variables, and (2) probabilistic multidisciplinary analysis (MDA) to infer the distributions of the coupling and output variables that satisfy interdisciplinary compatibility conditions. A copula-based sampling technique is employed for efficient sampling from the joint and conditional
Liang, Chen, Mahadevan, Sankaran
Body-in-White Reinforcements for Light-Weight Automobiles2016-01-039904/05/2016
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
Munjurulimana, Dinesh, Kulkarni, Amit, Nagwanshi, Dhanendra, Thambi, Joel Luther, Winters, Ruud, Delaney, Matthew
Crashworthiness Design of Automotive Body in White using Topology Optimization2016-01-153504/05/2016
Based on equivalent static loads method (ESL), a nonlinear dynamic topology optimization is carried out to optimize an automotive body in white (BIW) subjected to representative legislative crash loads, including frontal impact, side barrier impact, roof crush and rear impact. To meet the crashworthiness performances, two evaluation indexes are defined to convert the practical engineering problems into mathematic optimization problems. The strain energy is treated as the stiffness evaluation index of the BIW and the relative displacement is employed as the compliance index of the components and parts. The optimization problem could be changed into maximizing structural stiffness of the design space while constraining the relative displacements of the passenger cabin lower than a certain value to guarantee the stiffness of passenger cabin, constraining the relative displacements of the front and rear cabin greater than a certain value to increase the energy absorption during the crash
Tian, Linli, Gao, Yunkai
A Research on the Prediction of Door Opening by the Inertia Effect during a Side Impact Crash2016-01-153204/05/2016
The purpose of this study is to develop a dynamic model that can accurately predict the motion of the door handle and counterweight during side impact crash tests. The door locking system, mainly composed of the door outside handle and door latch, is theoretically modeled, and it is assumed that the door outer panel can rotate and translate in all three directions during a side impact crash. Additionally, the numerical results are compared with real crash video footage, and satisfactory qualitative agreement is found. Finally, the simplified test rig that efficiently reflects the real crash test is introduced, and its operation is analyzed.
Kwak, Kyoungtaek, Seo, Seungwoo, Potekin, Randi, Blanchard, Antoine, Vakakis, Alexander, McFarland, Donald, Bergman, Lawrence
Impact of Light-Weight Design on Manufacturing Cost - A Review of BMW i3 and Toyota Corolla Body Components2016-01-133904/05/2016
OEMs are investigating opportunities to reduce vehicle mass, driven by a need to meet upcoming CAFE targets, increase the range and reduce battery size of EVs. A number of lightweight materials including high strength steels, aluminum alloys, plastics and composites are now in production. To facilitate development of corporate R&D and commercialization plans for new materials, it is beneficial to understand the current manufacturing costs for production components, and their impact on piece price at different volumes. This paper investigates design and cost impact of light-weighting with respect to front door and floor assembly of Toyota Corolla and BMW i3. Toyota Corolla has a traditional steel body and is sold in high volumes while BMW i3 has relatively low annual sales and is primarily made of composite, aluminum and plastic parts. This study identifies good practices by BMW for both light-weighting and low / medium volume production where reduction in tooling costs become
Bubna, Piyush, Wiseman, Marc
Surface Generation speeds composites throughput with one-shot stamp-forming process16MEIP03_2103/01/2016
Surface Generation is working with research group WMG, an academic department of the University of Warwick, and AGC AeroComposites to develop new composite press-forming processes for automotive and aerospace manufacturers. Surface Generation, a U.K.-based provider of advanced carbon-fiber processing technologies, is developing new press-forming mold faces that incorporate its patented PtFS (Production to Functional Specifications) technology for the production of high-performance thermoplastic composite components. By integrating Surface Generation's active thermal management technologies into the mold face itself, WMG and AGC are able to continuously adapt heating and cooling levels for each mold area and process stage in real time. The companies believe that this enhanced capability will improve both the quality and throughput of compression molding applications.
Gehm, Ryan
Surface Generation speeds composites throughput with one-shot stamp-forming process16AUTP02_0702/01/2016
Surface Generation is working with research group WMG, an academic department of the University of Warwick, and AGC AeroComposites to develop new composite press-forming processes for automotive and aerospace manufacturers. Surface Generation, a U.K.-based provider of advanced carbon-fiber processing technologies, is developing new press-forming mold faces that incorporate its patented PtFS (Production to Functional Specifications) technology for the production of high-performance thermoplastic composite components. By integrating Surface Generation's active thermal management technologies into the mold face itself, WMG and AGC are able to continuously adapt heating and cooling levels for each mold area and process stage in real time. The companies believe that this enhanced capability will improve both the quality and throughput of compression molding applications.
Gehm, Ryan
Surface Generation speeds composites throughput with one-shot stamp-forming process16OFHP02_0602/01/2016
Surface Generation is working with research group WMG, an academic department of the University of Warwick, and AGC AeroComposites to develop new composite press-forming processes for automotive and aerospace manufacturers. Surface Generation, a U.K.-based provider of advanced carbon-fiber processing technologies, is developing new press-forming mold faces that incorporate its patented PtFS (Production to Functional Specifications) technology for the production of high-performance thermoplastic composite components. By integrating Surface Generation's active thermal management technologies into the mold face itself, WMG and AGC are able to continuously adapt heating and cooling levels for each mold area and process stage in real time. The companies believe that this enhanced capability will improve both the quality and throughput of compression molding applications.
Gehm, Ryan
Responses of the Q6/Q6s ATD Positioned in Booster Seats in the Far-Side Seat Location of Side Impact Passenger Car and Sled Tests2015-22-001211/09/2015
Passenger car side impact crash tests and sled tests were conducted to investigate the influence of booster seats, near-side occupant characteristics and vehicle interiors on the responses of the Q6/Q6s child ATD positioned in the rear, far-side seating location. Data from nine side impact sled tests simulating a EuroNCAP AEMD barrier test were analyzed with data obtained from 44 side impact crash tests. The crash tests included: FMVSS 214 and IIHS MDB, moving car-to-stationary car and moving car-to-moving car. A Q6 or prototype Q6s ATD was seated on the far-side, using a variety of low and high back booster seats. Head and chest responses were recorded and ATD motions were tracked with high-speed videos. The vehicle lateral accelerations resulting from MDB tests were characterized by a much earlier and more rapid rise to peak than in tests where the bullet was another car. The near-side seating position was occupied by a Hybrid III 10-year-old ATD in the sled tests, and a rear or
Tylko, Suzanne, Bohman, Katarina, Bussières, Alain
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