Browse Topic: Side impact crashes

Items (394)

RAMP BRACKET ANGLE OPTIMIZATION COUPLED WITH IMPROVED HEAD ROOM

2024-26-001601/16/2024

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 Airbags

2024-26-001901/16/2024

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

A Study of High Refinement Simulation Prediction on the CAB Development for FMVSS226 Ejection Mitigation Performance

2022-01-092203/29/2022

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

Injury Severity Prediction Algorithm of SUBARU Fleet Model for Advanced Automatic Collison Notification

2022-01-100503/29/2022

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

Structural design of a full-body composite monocoque chassis based on the type of carbon fiber fabrics

2022-01-044403/29/2022

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

Pedestrian Impact Analysis of Side-Swipe and Minor Overlap Conditions

2021-01-088104/06/2021

This paper presents analyses of 21real-world pedestrian versus vehicle collisions that were video recorded from vehicle dash mounted cameras or surveillance cameras. These pedestrian collisions have in common an impact configuration where the pedestrian was at the side of the vehicle, or with a minimal overlap at the front corner of the vehicle (less than one foot overlap). These impacts would not be considered frontal impacts [1], and as a result determining the speed of the vehicle by existing methods that incorporate the pedestrian travel distance post impact, or by assessing vehicle damage, would not be applicable. This research examined the specific interaction of non-frontal, side-impact, and minimal overlap pedestrian impact configurations to assess the relationship between the speed of the vehicle at impact, the motion of the pedestrian before and after impact, and the associated post impact travel distances. The21analyzed events are categorized according to the type of impact

Neale, William T., Danaher, David, Donaldson, Andrew, Smith, Tegan

A Comparative Life Cycle Assessment of Magnesium Front End Autoparts: A Revision to 2010-01-0275

SAE-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

Innovative Active Head Restraint System in a Car: Safety Assessment with Virtual Human Body Model

2020-01-097904/14/2020

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

Methods for quantifying the impact severity of low-speed side impacts at varying angles

2020-01-064104/14/2020

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 examined and readily published for quantifying oblique side impacts. The aim of the current study was to observe the effectiveness of the MER method for predicting the severity of side impacts at varying angles. Data were collected over a sequence of 12 tests with bullet-to-target-vehicle contact angles ranging from approximately 45° to 135° with corresponding impact speeds of approximately 13.7 km/h to 16.4 km/h. Vehicle damage profiles documented after each test allowed for the application of the

Brink, Justin, Swinford, Scott, Furbish, Christopher, Jones, Brian, Welcher, Judson, Anderson, Robert

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

Comparative Responses of the PIPER 6YO Human Body Model and the Q6 ATD for Simulated Frontal and Lateral Impacts

SC18-22-000611/12/2018

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 Analysis

09-06-02-000910/04/2018

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 Decisions

TBMG-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 Rings

2018-01-182309/10/2018

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 Performance

2018-01-501806/18/2018

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 Impacts

2018-01-054404/03/2018

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 Clarity

18AUTP02_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

New HAI-Prevention Cleaning Protocols Reinforce Need for Material Consideration for Medical Device Housings

TBMG-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.

Speedometers and Collision Reconstruction

2017-01-141203/28/2017

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

Crush Energy and Stiffness in Side Impacts

2017-01-141503/28/2017

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.

Accuracy of the Momentum Energy Restitution Method for Offset Inline Minor Rear-End Impacts

2017-01-142503/28/2017

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

A Comprehensive Validation Method with Surface-Surface Comparison for Vehicle Safety Applications

2017-01-022103/28/2017

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

Study on Cycle Time Reduction of Injection Molding Using CAE

2017-01-048903/28/2017

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 Restraint

J3027_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 Behavior

2016-36-012810/25/2016

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 Compartment

J2956_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

Multidisciplinary Optimization under Uncertainty Using Bayesian Network

2016-01-030404/05/2016

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

Alternative Approaches to Occupant Response Evaluation in Frontal Impact Crash Testing

2016-01-154004/05/2016

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

Crashworthiness Design of Automotive Body in White using Topology Optimization

2016-01-153504/05/2016

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 Crash

2016-01-153204/05/2016

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 Components

2016-01-133904/05/2016

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 process

16MEIP03_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 process

16AUTP02_0702/01/2016

Gehm, Ryan

Surface Generation speeds composites throughput with one-shot stamp-forming process

16OFHP02_0602/01/2016

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 Tests

2015-22-001211/09/2015

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

A Study on New Approach of Optimization for the Automotive Plastic Interior Parts

2015-01-047604/14/2015

Carmakers have tried to lower the vehicle weight for raising fuel efficiency. This trend involves a trade-off with the vehicle stiffness. In automobile interior parts, the thickness has needed to be decreased for the weight reduction but this makes the stiffness worse. A new approach for improving the stiffness due to the weight reduction is required and various optimization methods at early development stage have been introduced currently. However, it is difficult to apply optimization for the interior parts since many interior parts' structures generally depend on the design. But as studying the structure in detail, we discovered some factors that affect the performance without depending on design. The door trim is selected for optimization item because it has many characteristics of automobile interior parts. In our case study, the factors that improve the performance of door trim without changing design are considered as fastener position and flange rib layout. The optimization

Jo, Hyunkwon, Kim, Youngseung, Lee, Hyunchul, Park, Hyunmin, Song, Suckin

Simulation of Vehicle Lateral Side Impacts with Poles to Estimate Crush and Impact Speed Characteristics

2015-01-142804/14/2015

Current techniques that can be used to evaluate and analyse lateral impact speeds of vehicle crashes with poles/trees are based on measuring the deformation crush and using lateral crash stiffness data to estimate the impact speed. However, in some cases the stiffness data is based on broad object side impacts rather than pole impacts. Some have argued that broad object side impact tests can be used for analysing narrow object impacts; however previous authors have identified the fallacy of this premise. Publicly available side pole crash test data is evaluated in terms of crush depth impact speed and impact energy for six general vehicle types. A range of simulated pole impact tests at various speeds and impact angles were conducted using LS-Dyna and PC-Crash. Publicly available Finite Element Vehicle models of a 1996 Ford Taurus, a 1994 Chevrolet C2500 and a 1997 Geo Metro (Suzuki Swift) were used, providing relationships among impact speeds, crush depths and impact angles.

Richardson, Shane, Moser, Andreas, Orton, Tia Lange, Zou, Roger

Injury Sources for Second Row Occupants in Frontal Crashes Considering Age and Restraint Condition Influence

2015-01-145104/14/2015

The current study examined field data in order to document injury rates, injured body regions, and injury sources for persons seated in the second row of passenger vehicles. It was also intended to identify whether these varied with respect to age and restraint use in vehicles manufactured in recent years. Data from the 2007-2012 National Automotive Sampling System (NASS/CDS) was used to describe occupants seated in the second row of vehicles in frontal crashes. Injury plots, comparison of means and logistic regression analysis were used to seek factors associated with increased risk of injury. Restraint use reduced the risk of AIS ≥ 2 injury from approximately 1.8% to 5.8% overall. Seventy nine percent of the occupants in the weighted data set used either a lap and shoulder belt or child restraint system. The most frequently indicated injury source for persons with a MAIS ≥ 2 was “seat, back support”, across restraint conditions and for all but the youngest occupants. The factors most

Gudlur, Anand Sai, Atkinson, Theresa

Structure Optimization For Installation Position of Side Impact Sensor Using Frequency Response Analysis

2015-01-061804/14/2015

Based on the modal frequency response theory and experiment, the installation layout evaluation and structural optimization method for SIS(side impact sensors) installation position is studied. Establish the finite element model including B-pillar, roof and floor with local constraint. Than study the key parameter's influence on the frequency response analysis results, and the simulation results are correlated by experiment. In view of the installation layout requirements of side impact sensors, the structure optimization method for installation position of side impact sensor is put forward. The optimal scheme is confirmed by the finite element analysis, and a final experimental verification was implemented by a real vehicle test.

Dong, Zhihong, Sun, Ying, Zhu, Guitao, Wang, Shihu, Zeng, Jian, Yang, Yuliang

Assessment of Similarity of a Set of Impact Response Time Histories

2015-01-144104/14/2015

Two methods of assessing the similarity of a set of impact test signals have been proposed and used in the literature, which are cumulative variance-based and cross correlation-based. In this study, a normalized formulation unites these two approaches by establishing a relationship between the normalized cumulative variance metric (v), an overall similarity metric, and the normalized magnitude similarity metric (m) and shape similarity metric (s): v=1 − m · s. Each of these ranges between 0 and 1 (for the practical case of signals acquired with the same polarity), and they are independent of the physical unit of measurement. Under generally satisfied conditions, the magnitude similarity m is independent of the relative time shifts among the signals in the set; while the shape similarity s is a function of these. An optimal alignment is defined as the relative shifts corresponding to the minimum of the cumulative variance metric, or equivalently, to the maximum of the shape similarity

Shi, Yibing, Nusholtz, Guy

A Data Mining-Based Strategy for Direct Multidisciplinary Optimization

2015-01-047904/14/2015

One of the major challenges in multiobjective, multidisciplinary design optimization (MDO) is the long computational time required in evaluating the new designs' performances. To shorten the cycle time of product design, a data mining-based strategy is developed to improve the efficiency of heuristic optimization algorithms. Based on the historical information of the optimization process, clustering and classification techniques are employed to identify and eliminate the low quality and repetitive designs before operating the time-consuming design evaluations. The proposed method improves design performances within the same computation budget. Two case studies, one mathematical benchmark problem and one vehicle side impact design problem, are conducted as demonstration.

Xu, Hongyi, Chuang, Ching-Hung, Yang, Ren-Jye

Moving Rigid Barrier Collision Tests

J972_201503 (Current)03/13/2015

Collision tests are conducted on automotive vehicles to obtain information of value in evaluation of structural integrity and in reducing the risk of occupant injuries. The deformation resulting from a moving rigid barrier impact is more severe at a given speed than that produced by using an actual vehicle, but is more readily reproducible than that occurring during vehicle to vehicle impacts. The purpose of this SAE Recommended Practice is to establish sufficient standardization of such moving barriers and moving barrier collision methods so that results of tests conducted at different facilities may be compared.

Impact and Rollover Test Procedures Standards Committee

Interior Trims Design Considerations for Roof Mounted Curtain Airbag

2015-26-015701/14/2015

Curtain airbag design offers protection in side crash and it plays a critical role in safety of the vehicle. Curtain airbag provides protection to the occupant in many impact events like frontal offset, side barrier, and side pole and rollover condition. For a vehicle to be safe for any side impact condition, the curtain airbag should deploy and take its final shape before any injury happens to the occupant. During deployment, it is important that the airbag chooses a path of minimum resistance and does not get entangled in interior trims. In reality, the trims always do obstruct the path of airbag deployment in some way. Hence, special care has to be taken care for designing areas surrounding curtain like providing hinges, deflector components etc. to avoid being caught. There are about ten different factors on this deployment is dependent upon. This paper discusses these factors and the effect of the factors on the trims and airbag development. Proper care needs to be taken while

Hendre, Kedar Madhukar, Purohit, Yogesh

Investigation of Relation between Sub System Level (Quasi-Static) Side Door Intrusion to Side Collision Test

2015-26-017101/14/2015

With the change in the perspective of the Customers towards safer vehicles, most of the Vehicle manufacturers in India are making their vehicles Crash compliant. According to the accidental data collection, Side crashes are second leading cause of death after Frontal crash. Currently sub system level tests are done for evaluating the side impact safety performance of the vehicle. One of such sub system level test is Quasi-static side door intrusion Test. The primary purpose of this testing is to measure the Force-deflection characteristics by intrusion of the impactor into the vehicle. These characteristics are controlled by various door components like door beam, latch & striker, hinge etc. This article studies the relation between Side door intrusion and Side collision, effect of above mentioned components on this relation. A theoretical study is done to study this relationship and it is substantiated with experimental data.

Singh, Niraj, Thakur, Ruhi, Cyriac, Mathew

Integration and Lightweight Design in Automotive Doors

2015-26-024201/14/2015

Future doors require light weight, cost efficient and acoustic optimized solutions. Current steel doors offer only a small range of possibilities in these areas. With the use of aluminum doors the weight will be reduced but production complexity and costs will be increased. A modular door approach supports all of these future demands. Door modules have set milestones for door concepts in the past. Due to technological progress, door modules are more relevant in the current scenario. The use of reinforced plastics allows a high degree of design freedom with high integration of features.[2] In addition to weight reduction of up to 1.5kg per door the complete production process comes leaner with a higher grade of quality. The acoustic performance of a door system can be adjusted for noise reduction and improvement of the sound quality of speakers as illustrated. Functional integration is the key driver of weight and cost reduction

Bücker, Rolf

Sensitivity Analysis of a FE Model for Motorcycle-Car Full-Scale Crash Test

2014-32-002311/11/2014

In the study of new solutions for motorcycle passive safety, FE models of full-scale crash tests play a strategic role. The most important issue in the development process of FE models is their reliability to reproduce real crash tests. To help the engineering in the validation phase, a sensitivity analysis of a FE model for motorcycle-car crash tests is carried-out. The aim of this study is to investigate the model response subjected to variations of specific input parameters. The DOE is performed generating a list of simulations (each one composed by a unique combination of 8 parameters) through Latin Hypercube Sampling. The outputs monitored are the Head Injury Criterion (HIC) and Neck Injury Criteria (Nij). The analysis of the results is performed using scatter plots and linear regression curves to identify the parameters that have major impact on the outputs and to assess the type of dependency (linear or non-linear).

Barbani, Daniele, Baldanzini, Niccolò, Pierini, Marco

The Contribution of Pre-impact Spine Posture on Human Body Model Response in Whole-body Side Impact

2014-22-001411/10/2014

The objective of the study was to analyze independently the contribution of pre-impact spine posture on impact response by subjecting a finite element human body model (HBM) to whole-body, lateral impacts. Seven postured models were created from the original HBM: one matching the standard driving posture and six matching pre-impact posture measured for each of six subjects tested in previously published experiments. The same measurements as those obtained during the experiments were calculated from the simulations, and biofidelity metrics based on signals correlation were established to compare the response of HBM to that of the cadavers. HBM responses showed good correlation with the subject response for the reaction forces, the rib strain (correlation score=0.8) and the overall kinematics. The pre-impact posture was found to greatly alter the reaction forces, deflections and the strain time histories mainly in terms of time delay. By modifying only the posture of HBM, the variability

Poulard, David, Subit, Damien, Donlon, John-Paul, Lessley, David J., Kim, Taewung, Park, Gwansik, Kent, Richard W.

Ambulance Litter Integrity, Retention, and Patient Restraint

J3027_201407 (Historical)07/14/2014

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 or side 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

Modeling of Adaptive Energy Absorbing Steering Columns for Dynamic Impact Simulations

2014-01-080204/01/2014

The objective of this paper focused on the modeling of an adaptive energy absorbing steering column which is the first phase of a study to develop a modeling methodology for an advanced steering wheel and column assembly. Early steering column designs often consisted of a simple long steel rod connecting the steering wheel to the steering gear box. In frontal collisions, a single-piece design steering column would often be displaced toward the driver as a result of front-end crush. Over time, engineers recognized the need to reduce the chance that a steering column would be displaced toward the driver in a frontal crash. As a result, collapsible, detachable, and other energy absorbing steering columns emerged as safer steering column designs. The safety-enhanced construction of the steering columns, whether collapsible, detachable, or other types, absorb rather than transfer frontal impact energy. Recently, more advanced steering column designs with adaptive features, mechanically or

Tyan, Tau, Vinton, Jeff, Beckhold, Eric, Zhang, Xiangtong, Rupp, Jeffrey, Kochhar, Nand, Barbat, Saeed

Validation of Event Data Recorders in Side-Impact Crash Tests

2014-01-050304/01/2014

This study evaluated the accuracy of 75 Event Data Recorders (EDRs) extracted from model year 2010-2012 Chrysler, Ford, General Motors, Honda, Mazda, and Toyota vehicles subjected to side-impact moving deformable barrier crash tests. The test report and vehicle-mounted accelerometers provided reference values to assess the EDR reported change in lateral velocity (delta-v), seatbelt buckle status, and airbag deployment status. Our results show that EDRs underreported the reference lateral delta-v in the vast majority of cases, mimicking the errors and conclusions found in some longitudinal EDR accuracy studies. For maximum lateral delta-v, the average arithmetic error was −3.59 kph (−13.8%) and the average absolute error was 4.05 kph (15.9%). All EDR reports that recorded a seatbelt buckle status data element correctly recorded the buckle status at both the driver and right front passenger locations. For equipped vehicles that reported side torso, side curtain, and frontal airbag

Tsoi, Ada, Johnson, Nicholas, Gabler, H.

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