Browse Topic: Operator protective structures

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Overhead Protection for Agricultural Tractors - Test Procedures and Performance RequirementsJ167_202002 (Current)2/20/2020
This SAE Standard applies to an overhead cover installed on a protective frame or enclosure conforming to SAE J2194 or alternately SAE J1194 and the following additional requirement of a drop test to verify the effectiveness of the overhead cover in protecting the operator from falling objects. The test procedures and performance requirements outlined in this document are based on currently available engineering data.
OPTC4, Protective Structures
Personnel Protection - Skid Steer LoadersJ1388_201907 (Current)7/3/2019
This SAE Standard is intended to provide personnel protection guidelines for skid steer loaders. This document is intended as a guide towards standard practice, but may be subject to frequent change to keep pace with experience and technical advances. This should be kept in mind when considering its use. This document provides performance criteria for newly manufactured loaders and it is not intended for in-service machines.
OPTC1, Personnel Protection (General)
Body-in-White Reinforcements for Light-Weight Automobiles2016-01-03994/5/2016
Automotive OEMs are proactively working on vehicle light-weighting, powertrain optimization, alternate/renewable energy sources and combinations of the three to meet challenging corporate average fuel economy (CAFE) standards. Light-weighting of the body-in-white (BIW) is an obvious choice for vehicle light-weighting as this structure contributes to more than 30-35% of the total weight of a car. Changing manufacturing and assembly lines requires substantial investment. As such, OEMs are exploring short-term light-weighting strategies that do not require any major changes to the BIW. Local reinforcement for the BIW are pertinent solutions that does not require any major changes in the existing assembly lines. This paper focuses on the development of BIW reinforcement solutions using engineering thermoplastic materials that can be mounted at appropriate locations on a vehicle’s BIW to achieve significant weight savings without compromising crash performance. Various design and material configurations - including plastic, metal-plastic and composite-plastic structural members - mounted on the BIW are evaluated through CAE studies for various crash scenarios such as high-speed frontal crashes, side impact, pole impact and rollover. The CAE studies, performed using generic vehicle models, quantify the potential weight-savings in a vehicle by either replacing the existing reinforcements using a lighter system or by incorporating additional reinforcements in the BIW by down-gauging the existing BIW. Approaches to correlate the CAE studies using component level testing and validation of generic reinforcements are also investigated. Data from all of this work indicate that the use of BIW reinforcements can achieve significant weight reduction (∼ 1.5%) in a vehicle, while also ensuring no compromise in crash performance.
Munjurulimana, Dinesh, Kulkarni, Amit, Nagwanshi, Dhanendra, Thambi, Joel Luther, Winters, Ruud, Delaney, Matthew
Crashworthiness Design of Automotive Body in White using Topology Optimization2016-01-15354/5/2016
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 process. The results provide a conceptual design which emphasizes the most efficient load paths and could be served as an effective guidance to the next-step BIW detailed design.
Tian, Linli, Gao, Yunkai
Deflection Limiting Volume - Protective Structures Laboratory EvaluationJ397_201503 (Current)3/27/2015
This SAE Standard applies to operator protective structures which may commonly be a part of construction, forestry, mining, and industrial machines.
OPTC4, Protective Structures
Vehicle Roof Strength Test ProcedureJ374_201503 (Current)3/13/2015
This SAE Recommended Practice establishes a uniform laboratory test method to evaluate the strength characteristics of roof systems. The test procedure is intended to provide reliable and repeatable results and to permit numerical comparisons. A test is conducted in which the vehicle roof system is loaded under controlled laboratory conditions. Structural strength measurements are obtained under load application angles chosen to concentrate forces on the forward portions of the roof panel and roof supporting structure.
Impact and Rollover Test Procedures Standards Committee
Multidisciplinary Design Optimization of BEV Body Structure2015-26-02291/14/2015
Blade Electric Vehicle (BEV) with a light body plays an important role in saving the energy and reducing the exhaust emission. However, reducing the body weight need to meet the heterogeneous attributes such as structural, safety and NVH (Noise, Vibration and Harshness) performance. With the rapid development of finite element (FE) analysis technology, simulation analysis is widely used for researching the complex engineering design problem. Multidisciplinary Design Optimization (MDO) of a BEV body is a challenging but meaningful task in the automotive lightweight. In present research, the MDO is introduced to optimize a BEV Body-in-White (BIW). The goal of optimization is to minimize the mass of the BIW while meeting the following requirements: structural performance (the bending and torsion stiffness is increased), NVH performance (the first overall torsion frequency is increased), and safety performance (the roof crush resistance is improved).The sample points were obtained by using Design of Experiment (DOE) with optimal Latin hypercube. The approximation models of mass, bending stiffness, torsion stiffness, modal and safety were established with the polynomial response surface method (RSM). The thicknesses of nine parts of the BIW were selected to be optimized by Muti-island Genetic Algorithm (MGA) method. After the MDO of the BIW, the paper drew the following conclusions: 1.The predictive values of the approximation and the results of FE simulation had a good agreement with an error less than 5.00% and the former met the engineering requirements; 2.The weight of the BIW was reduced by 2.00% and the optimized BIW met all prescribed requirements about structural, NVH and safety performance.
Zhang, Jibing, Hu, Sanbao, Guo, Xuexun, Zhou, Quan
Evaluation of Different Roof Strength Methods in Quasi-Static and Dynamic Rollover Tests Using Finite Element Analysis of a 2003 Ford Explorer Model2014-01-05324/1/2014
Different roof strength methods are applied on the 2003 Ford Explorer finite element (FE) model to achieve the current Federal Motor Vehicle Safety Standard (FMVSS) 216 requirements. Two different modification approaches are utilized. Additionally, the best design of each approach is tested dynamically, in rollover and side impact simulations. In the first approach, several roll cage designs are integrated in all pillars, roof cross-members, and in the side roof rails. A roll cage design with a strength-to-weight ratio (SWR) of 3.58 and 3.40 for driver and passenger sides, respectively, with a weight penalty of 18.54 kg is selected for dynamic test assessments. The second approach investigates different localized reinforcements to achieve a more reasonable weight penalty. A localized reinforcement of the B-pillar alone with a tube meets the new FMVSS 216 requirements with a weight penalty of 4.52 kg and is selected for dynamic analyses. The two selected reinforcement designs are tested in a dynamic unconstrained rollover crash under different pitch angles while using common rollover initial conditions. Based on the limited dynamic analysis, the localized reinforcement has proved to be an effective approach for front row seat protection. However, passengers in the rear seats are better protected by the roll cage solution. Additionally, side impact analysis is examined for both approaches. Overall, the influence of both reinforcement methods on the side impact is small and therefore deemed acceptable. These methods can be incorporated in vehicle's roof structure or taken into consideration for future vehicle designs.
Albrodt, Simon B., Tahan, Fadi, Digges, Kennerly
Minimum Performance Criteria for Falling Object Guards for ExcavatorsJ1356_201303 (Historical)3/28/2013
This SAE Recommended Practice applies only to excavators, as defined in SAE J/ISO 6165, working above ground, near an excavated or free standing bank or mine face which is higher than the top of the cab, or in demolition applications of free standing buildings or objects higher than the top of the cab.
OPTC4, Protective Structures
A Study on Development of Body Structure Using Hydroforming of a Thin-Walled UHSS Tube2013-01-00353/25/2013
Hydroforming process is an emerging manufacturing technology which allows engineers to use continuous closed section without flange for spot weld in a given package envelope. In this research, Hydroforming is applied to a front pillar and a roof side rail for improvement of obstruction angle, body stiffness and roof crush resistance. In addition, the joints of front / center pillar that were integrated into the hydroforming part and structure of package tray were improved. As a result, front pillar width is reduced by 23%, body torsional stiffness is increased by 45% and roof crush resistance is improved by 35%.
Cha, Munsoo, Kim, Cheol-Ung
Operator Protection for General - Purpose Industrial MachinesJ1042_201206 (Current)6/29/2012
This SAE Standard applies to General-Purpose Industrial Machines described in Category 2 of SAE J1116, but excludes skid steer loaders (covered by SAE J1388). Protection for the operator of an attachment (for example, a backhoe) is excluded from the scope of this document.
OPTC1, Personnel Protection (General)
Finite Element Modeling Comparisons of Rollover Test Devices2011-01-00114/12/2011
Rollover test equipment is of interest in the development of rollover protection system designs. The Controlled Rollover Impact System (CRIS) by Exponent and the Jordan Rollover System (JRS) from the original founder of VIA Systems represent two such systems available. The two systems represent significantly different approaches to the same problem; the CRIS utilizes a structure moving over the ground, while the JRS utilizes a rotating vehicle over a moving ground. Finite Element (FE) modeling of CRIS impacts has been presented previously. In this paper, the ability to model the JRS system is demonstrated. A Finite Element model of the JRS was created and compared with an over-the-ground rollover under the same conditions. An analysis using Finite Element models of a production and roll-caged vehicles and Hybrid III dummies with the CRIS and JRS devices under the same impact conditions then was conducted. The results of the analysis are provided and discussed.
Hutchinson, John, Friedman, Keith, Mihora, Dennis
Light Utility VehiclesJ2258_201012 (Historical)12/8/2010
This SAE Standard defines requirements relating to the elements of design, operation, and maintenance of light utility vehicles. The safety specifications in this document apply to any self-propelled, operator-controlled, off-highway vehicle 1829 mm (72 in) or less in overall width, exclusive of added accessories and attachments, operable on three or more wheels, primarily intended to transport material loads or people, with a gross vehicle weight of 2500 kg (5500 lb) or less, and a maximum design speed less than or equal to 40.23 km/h (25 mph). This document is not intended to cover Go-Karts (ASTM F2007-07a), Fun-Karts (ASTM F2011-02e1), Dune Buggies, and all terrain vehicles (ATVs) complying with ANSI/SVIA 1.
Special Purpose Vehicle Committee
Low Speed VehiclesJ2358_201009 (Historical)9/29/2010
This SAE Standard defines the safety and performance requirements for Low Speed Vehicles (“LSV”). The safety specifications in this document apply to any powered vehicle with a minimum of 4-wheels, a maximum level ground speed of more than 32 km/h (20 mph) but not more than 40 km/h (25 mph),), and a maximum gross vehicle weight of 1361 kg (3000 lb), that is intended for operating on designated roadways where permitted by law.
Special Purpose Vehicle Committee
Deflection Limiting Volume—Protective Structures Laboratory EvaluationJ397_200910 (Historical)10/23/2009
This SAE Standard applies to operator protective structures which may commonly be a part of construction, forestry, mining, and industrial machines.
OPTC4, Protective Structures
Computational Methodologies for Vehicles Roof Strength Assessment to Prevent Occupants Injury in Rollover Crashes2009-36-026710/6/2009
Among all types of vehicle crashes, rollover is the most complex and yet least understood. During the last decades, a constant increase in the studies involving rollover crashes and injuries associated with it can be observed. Although the rollover is not the most frequent type of accident, it is of the greatest significance with respect to injury and trauma caused to the vehicle occupants. The existing standards and procedures to test rollover crashworthiness are still not suitable to computer simulation because of the huge computational effort required, and the need of faithful/overly complex representation of the aspects involved in real crashes. The objective of the present work is the development of computational models particularly adapted to simulate different standards and procedures used to evaluate the vehicles' roof strength. The models are compared with other approaches, and their advantages/disadvantages are discussed.
de Lima, Anderson, Marczak, Rogério José
Development of Rollover Protective Structures for Mining Light Vehicles2009-01-08314/20/2009
This paper presents the authors’ work on developing Rollover Protective Structures (ROPS) for light vehicles in mining and resources industries. Various international resource companies have identified rollover crashes of light vehicles (Pickups and SUV’s) as a serious problem for their own and contractor vehicles operating on their sites. The structural rollover protective systems that were used [and continue to be in some cases] were based on inadequate or no specific performance requirement(s) and resulted in a range of occupant protection outcomes. The authors developed and adopted structural requirements for rollover protection based on their; experience, research into rollover crashes, rollover protective systems, defined loading, intrusion and robustness criterion. The design criteria, analysis and testing processes used to develop the rollover protective structural systems are presented.
Richardson, Shane, Rechnitzer, George, Orton, Tia, Shifman, Maxwell, Crocker, Steve, Ramharuk, Avinash, Jones, Chris, Indurjit, Pradeep
Operator Protective Structure Performance Criteria for Certain Forestry EquipmentJ1084_200804 (Current)4/21/2008
This SAE Recommended Practice establishes the test procedures and minimum performance criteria necessary to fulfill the intended purpose and is applicable to Skidders, Grapple Skidders, and Crawlers when used in the harvesting of trees. Structures meeting these performance criteria may not provide complete operator protection under all conceivable circumstances, but they are expected to minimize the possibility of operator injury under reasonable operating situations. The performance requirements and test criteria included in this document are derived from investigations on operator protection that has performed the intended function in a variety of actual operating conditions. Objective This document is intended to establish a consistent, repeatable means of evaluating Operator Protective Structures (OPS) on Skidders, Grapple Skidders, and Crawlers when used in the harvesting of trees. Operator Protective Structures are structures/enclosures whose primary purpose is to minimize the possibility of operator injury from hazards such as whipping saplings, branches, jill-poking (spear-like objects), and snapping winch lines with the least adverse effect on operator visibility, comfort, and protection from other hazards.
MTC4, Forestry and Logging Equipment
Minimum Performance Criteria for Falling Object Guards for ExcavatorsJ1356_200804 (Historical)4/14/2008
This SAE Recommended Practice applies only to excavators, as defined in SAE J/ISO 6165, working above ground, near an excavated or free standing bank or mine face which is higher than the top of the cab, or in demolition applications of free standing buildings or objects higher than the top of the cab. The evaluations are for resistance to penetration of guards to the point of infringement of the Deflection Limiting Volume (DLV, see SAE J397). The performance requirements of a representative specimen (that is, within the manufacturer's specifications), are based on the performance of proven structures under laboratory evaluation procedures. The areas protected include the top of the operator station (Top Guard), for protection from falling objects, and the front of the operator station (Front Guard), for protection from objects which approach the front of the cab. Although falling object guards meeting the following criteria may not give crush protection under all conceivable circumstances in which the machine could be struck from above or the front, it is expected that crush protection will be ensured under at least the loading condition specified in the tests listed in Section 5. This document establishes a consistent, repeatable test procedure and performance requirements for evaluating guards intended to provide excavator operators with reasonable protection from falling objects such as rocks.
OPTC4, Protective Structures
A Case Study in Structural Optimization of an Automotive Body-In-White Design2008-01-08804/14/2008
A process for simultaneously optimizing the mechanical performance and minimizing the weight of an automotive body-in-white will be developed herein. The process begins with appropriate load path definition though calculation of an optimized topology. Load paths are then converted to sheet metal, and initial critical cross sections are sized and shaped based on packaging, engineering judgment, and stress and stiffness approximations. As a general direction of design, section requirements are based on an overall vehicle “design for stiffness first” philosophy. Design for impact and durability requirements, which generally call for strength rather than stiffness, are then addressed by judicious application of the most recently developed automotive grade advanced high strength steels. Sheet metal gages, including tailored blanks design, are selected via experience and topometry optimization studies. Full-vehicle CAE analysis of the stiffness, durability and impact performance are then used to further refine the sheet metal design. In the next round of iteration, individual components of the body-in-white, such as the shock towers, are optimized using the aforementioned optimization tools and process. In all, using a generic mid-sized SUV body as a test case, it is demonstrated that in using this process, there exists the opportunity to reliably reduce the mass of a body-in-white structure by between 6 and 15 percent while still meeting stiffness, durability and impact goals.
Baskin, Donald M., Reed, David B., Seel, Thomas N., Hunt, Martyn N., Oenkal, Mevluet, Takacs, Zoltan, Vollmer, Axel B.
Theoretical Analysis of a Method of Computing Dynamic Roof Crush During Rollovers2007-01-03664/16/2007
A method of computing dynamic roof crush in rollover accidents has been proposed (Bidez, et al., 2005; Cochran et al., 2005). The method used data obtained from accelerometers mounted to the roof rails of sport utility vehicles, along with other measurements, to compute the instantaneous deformation of the roof rails during dolly rollover crash tests. We examined the feasibility and practicality of this methodology in three ways. First, the theoretical derivation was examined. Errors appeared to have been made in deriving and/or interpreting the equations used to compute instantaneous roof crush. Next, a three-dimensional dynamic rollover simulation program was run to produce ideal acceleration data (Yamaguchi et al., 2006, 2005). Using these data, the equations in original, uncorrected form predicted dynamic roof deformations when none existed. When the equations were corrected, the simulation data yielded proper roof positions and no roof deformations. Finally, a dolly rollover test was conducted to generate real-world accelerometer data. The vehicle was heavily braced internally to avoid producing significant roof crush. Vibrational “noise” present in the real-world accelerometer data caused a large amount of calculational error in the dynamic roof crush calculations. Sensor positioning and angular alignment errors also may have contributed. These results indicate that the method of computing dynamic roof crush from accelerometer data is theoretically feasible when correct equations and ideal data are used, but is impractical using measured real world accelerometer and angular rate sensor data.
Yamaguchi, Gary T., Ashby, Blake M., Luepke, Peter A., Moore, Tara L.A., Bove, Robert T., Corrigan, Catherine Ford
Development of Expanded Polypropylene (EPP) Bumper Systems to Meet Emerging Performance and Safety Standards2007-01-17624/16/2007
This paper describes the development of an Expanded Polypropylene (EPP) bumper system to meet the requirements of the European pedestrian safety legislation. Information regarding the history of pedestrian safety legislation in Europe is presented. The advantages of EPP as an energy absorbing material for bumper systems are discussed. The paper describes the design approach used during the vehicle development process and shows the importance of CAE (computer aided engineering) as a design tool. Examples of the accuracy that can be obtained with CAE are presented.
Doerr, Robert, Huda, Nurul, Newlands, Gavin, Keer, Tim
Axiomatic Design of Automotive Roof Structures2007-01-06854/16/2007
The conceptual design process pertaining to conventional passenger vehicle roof structures is described using axiomatic design principles. Current roof technology and performance, to include passenger vehicles and rally cars, are discussed and analyzed with an emphasis on occupant protection. Functional requirements for optimization are listed. An order of design is deduced from the first axiom to reduce the complexity of the design process. Independent design parameters for improving the crush resistance and rigidity of the structure are clearly linked to functions to record the design intent at each level.
Batzer, Stephen A., Burgess, Robert D., Brown, Christopher A.
Minibaja Frame Design using Topological Optimization and Impact Testing2006-01-09524/3/2006
The search of lighter components and frames in racing competitions is of extreme importance. The usage of a structured design methodology and optimization processes leads to significant weight and design time reductions. In this work the Finite Element Method and optimization tools based on the strain energy approach are used to develop a lightweight Minibaja frame. To assure that the design is also safe, dynamic analysis of a frontal impact against a tree at 25 km/hr and a roll over roof crush test according the FMVSS 216 are carried out. The resultant structure is 9% lighter than its predecessor fulfilling all static and dynamic specifications.
Burke, Allan, Miranda, Jose Carlos
Ultra High Strength FeMn TWIP Steels for Automotive Safety Parts2005-01-13274/11/2005
Energy savings are among the most important goals of steel users. But generally, the increase of Tensile Strength for a given metallurgy is obtained to the detriment of ductility. ARCELOR develops new ultra high strength steel with TWinning Induced Plasticity (TWIP) effect for weight reduction and impact resistance. This product based on a manganese (Mn) alloying metallurgy has a tensile stress higher than 1000 MPa for a total elongation superior to 50%. This text deals with mechanical testing, welding and different design solutions which could be associated with this new steel grade in comparison with conventional UHS steel (HSLA, DP, TRIP, etc.). Tensile and formability properties are presented first by means of basic tests (stretching, bending, etc.) in order to classify the different steels. Then welding parameters and mechanical behavior of spot weld are presented. In addition to this, the crash resistance is investigated by using a dynamic axial compression test and a dynamic three point bending test on structural components with closed and open cross sections. For each steel grade, the estimated weight saving potential is compared with respect to parts manufactured in high drawing ability steel. Fatigue resistance is also investigated on this material and on welding assembly by using cyclic test. The exceptional mechanical characteristics of this product permit to propose innovative steel design solutions for automotive safety component.
Cornette, D., Cugy, P., Hildenbrand, A., Bouzekri, M., Lovato, G.
Practical Problems in Implementing Commercial Vehicle Cab Occupant Protection Standard ECE R-292005-26-0411/19/2005
With ever-increasing concern for the occupant safety, it is desirable that the design of truck cab should meet the safety requirements specified in ECE R-29. The cab must be designed in such a way that, sufficient survival space to be guaranteed in the event of accident for the safety of the driver and co-driver. It was found that there are some areas, which are not covered by the standard or the standard is not very clear. This paper discusses about the practical problems incurred during implementation of the standard in Indian scenario and also suggests possible practical solutions.
Patidar, S. K., Tandon, V., Mahajan, R. S., Raju, S.
Deflection Limiting Volume-Protective Structures Laboratory EvaluationJ397_200405 (Historical)5/18/2004
This SAE Standard applies to operator protective structures which may commonly be a part of construction, forestry, mining, and industrial machines. To establish limits on deflection permissible during laboratory evaluations of certain operator protective structures, such as ROPS, FOPS, OPS, and FOG as defined in other SAE standards.
OPTC4, Protective Structures
Operator Protection for General-Purpose Industrial MachinesJ1042_200303 (Historical)3/12/2003
This SAE Standard applies to General-Purpose Industrial Machines described in Category 2 of SAE J1116, but excludes skid steer loaders (covered by SAE J1388). Protection for the operator of an attachment (for example, a backhoe) is excluded from the scope of this document. Purpose The purpose of this document, with referenced documents, is to establish performance requirements for protective systems that provide operator protection from hazards of machine rollover and/or falling objects.
OPTC1, Personnel Protection (General)
The P2000S Unitized Sport Utility Vehicle Body Structure2003-01-05733/3/2003
The P2000S body structure was designed as part of an advanced research project to determine the feasibility of a high volume, lightweight sport utility vehicle (SUV) that would achieve performance targets of the newly emerging “City SUV” market by developing a unitized (no frame) SUV body structure fabricated principally of aluminum. In order to be viable, this body structure was required to meet all safety, durability, NVH and other functional attributes of a truck while having the ride characteristics of a sedan. This paper describes the P2000S body structure including the structural philosophy, project constraints on the design, manufacturing processes, supporting analyses, assembly processes and unique material and design concepts which resulted in the 50% body structure weight reduction in comparison to similar sized body-on-frame production steel sport utility vehicles.
Cornille, Henry J., Danyo, Michael W., Young, Christopher S.
Operator Protective Structure Performance Criteria for Certain Forestry EquipmentJ1084_200209 (Historical)9/5/2002
This SAE Recommended Practice establishes the test procedures and minimum performance criteria necessary to fulfill the intended purpose and is applicable to Skidders, Grapple Skidders, and Crawlers when used in the harvesting of trees. Structures meeting these performance criteria may not provide complete operator protection under all conceivable circumstances, but they are expected to minimize the possibility of operator injury under reasonable operating situations. The performance requirements and test criteria included in this document are derived from investigations on operator protection that has performed the intended function in a variety of actual operating conditions. Objective This document is intended to establish a consistent, repeatable means of evaluating Operator Protective Structures (OPS) on Skidders, Grapple Skidders, and Crawlers when used in the harvesting of trees. Operator Protective Structures are structures/enclosures whose primary purpose is to minimize the possibility of operator injury from hazards such as whipping saplings, branches, jill-poking (spear-like objects), and snapping winch lines with the least adverse effect on operator visibility, comfort, and protection from other hazards.
MTC4, Forestry and Logging Equipment
Minimum Performance Criteria for Falling Object Guards for ExcavatorsJ1356_200208 (Historical)8/23/2002
This SAE Recommended Practice applies only to excavators, as defined in SAE J/ISO 6165, working above ground, near an excavated or free standing bank or mine face which is higher than the top of the cab, or in demolition applications of free standing buildings or objects higher than the top of the cab. The evaluations are for resistance to penetration of guards to the point of infringement of the Deflection Limiting Volume (DLV, see SAE J397). The performance requirements of a representative specimen (that is, within the manufacturer's specifications), are based on the performance of proven structures under laboratory evaluation procedures. The areas protected include the top of the operator station (Top Guard), for protection from falling objects, and the front of the operator station (Front Guard), for protection from objects which approach the front of the cab. Although falling object guards meeting the following criteria may not give crush protection under all conceivable circumstances in which the machine could be struck from above or the front, it is expected that crush protection will be ensured under at least the loading condition specified in the tests listed in Section 5. This document establishes a consistent, repeatable test procedure and performance requirements for evaluating guards intended to provide excavator operators with reasonable protection from falling objects such as rocks.
OPTC4, Protective Structures
Application of CAE Simulation in 2002 Jeep Liberty Vehicle Development2001-01-304910/16/2001
Extensive Computer Aided Engineering (CAE) Analysis was done at DaimlerChrysler in developing the all-new 2002 Jeep Liberty body structure. Vehicle Simulations were performed during the development cycle to continuously improve the design for various disciplines such as NVH (Noise, Vibration and Harshness), Impact and Durability. This paper discusses the methodology adopted for CAE analysis and the benefits seen in the final product due to the use of CAE tools.
Dhulipudi, R., Drobot, S., Nayak, S., Pol, A., Gogate, S., Potty, K.
Labeling of ROPS and FOPS and OPSJ1164_200002 (Current)2/8/2000
This SAE Standard establishes the specifications and content for labeling of ROPS, FOPS, and OPS, which may commonly be a part of construction, forestry, mining, and industrial machines. The label content herein shall be applied to a ROPS and/or FOPS and/or OPS on any of these machines.
OPTC4, Protective Structures
Tire Guards for Operator Protection--Earthmoving Haulage MachinesJ321_199905 (Historical)5/24/1999
This SAE Standard establishes a criteria for a minimum zone of protection for the operator of the machine and establishes certain structural requirements for guards on pneumatic-tired earthmoving haulage machines capable of speeds in excess of 25 km/h. Earthmoving machines covered by this document are dumpers and tractor-scrapers as identified in SAE J/ISO 6165.
OPTC1, Personnel Protection (General)
The P2000 Body Structure9824059/29/1998
The objective of the P2000 body structure design was to provide a body structure with 50% of the mass of current mid-size production vehicles while maintaining all the safety, durability, NVH and other functional attributes. In addition, the design was to be consistent with the PNGV affordability objectives and high volume production by 2005. This paper describes the P2000 body structure including the structural philosophy, project constraints on the design, manufacturing processes, supporting analyses, assembly processes and unique material and design concepts which resulted in the 50% weight reduction from comparable production vehicles.
Cornille, Henry J., Weishaar, Joseph C., Young, Christopher S.
ADVANCED DESIGNS FOR SIDE IMPACT AND ROLLOVER PROTECTION9861725/31/1998
Every year in the U.S., about 8,000 fatalities occur in side impacts, and about 9,500 fatalities occur in vehicle rollovers. Severe head trauma and spinal cord injuries are the prevalent traumatic injuries that are directly related to the extent of inward crushing or intrusion into the occupant's “survival space” and to the rigidity and shape of interior edges and surfaces. Based on accident evaluations and assessment of available technologies, there are feasible and practical advanced design features for vehicle bodies and interiors that can concurrently enhance both side-impact protection and rollover roof-integrity protection: Strengthened vehicle body by the use of rigid-foam-filled tubular members that strengthen and stiffen the vehicle body, by tripling resistance to bending and compression. Strengthened doors with full-perimeter overlap and multiple latches. Multi-layer laminated floorpans, cross-panels, and roofs of composite materials. Roof tubular members in an interconnected design, with full-length internal stiffeners and/or rigidfoam-filled. Wrap-around stronger seats with taller headrests, and integral seatbelts and belt pre-tensioners that activate in side impacts and when rollovers are initiated. Energy-absorbent closed-cell padding of interior surfaces, some with a metal-air-gap underlayer. Side airbags for torso and head protection. Side window glass-plastic glazing and perimeter bonding, to cushion head impacts and prevent occupant ejection from the vehicle. The main objects of these safety upgrades are to (A) encourage deflection of the striking vehicle and struck vehicle away from each other, (B) minimize intrusion into the occupant's “survival space”, (C) reduce the velocity differential between the struck vehicle and the occupant kinematic movements, (D) restrain and cushion the occupant's head and torso, or allow contact with energy-absorbing materials to maximize distribution of contact forces.
Bloch, Byron
Injury Causation in Rollover Accidents and the Biofidelity of Hybrid III Data in Rollover Tests9803622/23/1998
There is a continuing debate in the scientific literature and among policy making bodies regarding the role of roof crush in the causation of rollover accident injuries. A question arising from field studies is whether the correlation between roof crush and injuries occurs because roof crush causes injuries or because roof crush is associated with accident severity, which is related to injury potential. Recent literature is reviewed to address this question. The Malibu rollover tests have been criticized for the level of “potentially injurious impacts” measured in the Hybrid III dummies used in these studies. Additionally, it has been asserted that the Hybrid III neck is excessively stiff in compression and that experimental testing with the Hybrid III produces results that are not representative of human occupant responses. A careful review of the literature reveals that the Hybrid III and cadavers have similar neck stiffnesses in some loading modes when subjected to the same boundary conditions. The time history of neck forces developed in a drop test using a Hybrid III dummy was compared to the time history of neck forces found in recently published cadaver drop tests and found to be similar. A published computational model proposing a causal relationship between roof stiffness and injury was found to be inaccurate and non-representative of human occupant kinematics. Research to date has found that roof crush is not causally related to injuries in typical rollover accidents.
Piziali, Robert, Hopper, Robert, Girvan, Daniel, Merala, Raymond
Structural Design of Aluminum Space Frame with Battery Tray9605242/1/1996
An aluminum space frame is the main structure of our recently developed electric vehicle. The frame consists of extruded members. As each extrusion has the same cross section, it is possible to accomplish an optimal design of the whole space frame by setting up design variables for each extruded member. Size optimization was completed to minimize the weight of the space frame at the desired overall stiffnesses, service loads, and desired natural frequencies. A tray structure was proposed for the batteries of the electric vehicle, and as a result, the overall stiffness was improved. In addtion, it became easier to install the batteries. A method to reduce the weight of tray was tried within the design constraints. Special reinforcements were used for weak parts between each member. The space frame was modeled as shell elements for the numerical analysis. The structural design of the space frame compensated for the increased weight by batteries making the lightweight, 4-seat, electric vehicle a reality.
Chung, Tae-Eun, Lee, Yong-Rae, Kim, Chang-Soo
Development of Roof Crush Analysis Technique Using Simple Model with Plastic Hinge Concept9605222/1/1996
A computational technique for predicting roof crush resistance in the early design stage of vehicle development is presented in this paper. This technique developed a simple nonlinear finite element beam model with several nonlinear spring elements which represent plastic hinge behaviors after bending collapse. In general, these plastic hinge behaviors are apt to occur al each weak area of vehicle body structure. By idealizing actual sections as equivalent simple sections, maximum bending moments are calculated for all weak areas. Predicted results of roof crush resistance arc correlated well with test results.
Chun, Byung-Kwan, Choi, Jae-Hwan, Kang, Sung-Jong
Deflection Limiting Volume-Protective Structures Laboratory EvaluationJ397_199510 (Historical)10/1/1995
This SAE Standard applies to operator protective structures which may commonly be a part of construction, forestry, mining, and industrial machines. To establish limits on deflection permissible during laboratory evaluations of certain operator protective structures, such as ROPS, FOPS, OPS, and FOG as defined in other SAE standards.
OPTC4, Protective Structures
Operator Protection for General-Purpose Industrial MachinesJ1042_199306 (Historical)6/1/1993
This SAE Standard applies to general-purpose industrial machines described in Category 2 of SAE J1116, but excludes skid steer loaders (covered by SAE J1388). Protection for the operator of an attachment (for example, a backhoe) is excluded from the scope of this document. The purpose of this document, with referenced documents, is to establish performance requirements for protective systems that provide operator protection from hazards of machine rollover and/or falling objects.
OPTC1, Personnel Protection (General)
Empirical and Pictorial Results of Vehicle Tip-Over Impact Tests9306643/1/1993
A combination of metal roof passenger vehicles, an open top convertible passenger vehicle and enclosed multiple purpose utility vehicles were subjected to tip-over-the-front-end type pitch-over tests. The resulting roof crush and occupant compartment intrusion are presented in empirical and pictorial format. The tip-over roof crush performance is discussed relative to other recent side-over type rollover literature and to the FMVSS 216 on Roof Crush Resistance for Passenger Cars.
Robinette, Ric D., Fay, Richard J.
Small Agricultural Tractor ROPS - New Operator Protective Zone9117829/1/1991
The Equipment Manufacturers Institute (EMI) sponsored a literature search conducted by Triodyne, Inc. which attempted to identify all “Operator Protective Zones” ever utilized in the world. This effort was intended to determine whether published information existed to define a more compact Operator Protective Zone than those of current SAE (ASAE) standards for possible utilization in developing a new standard for a more compact design of Rollover Protective Structures (ROPS) for small agricultural tractors. The research has led Triodyne to conclude that the Operator Protective Zones upon which the current SAE (ASAE) ROPS standards are based are the only substantiated zones available for possible application to small agricultural tractors.
Fritz, Edward A., Case, J.I., Switalski, William G.
Two Piece Composite Truck Cab9003062/1/1990
This report is a comprehensive investigation into the use of resin transfer molded glass fiber reinforced plastics in a structural application. A pickup truck cab structure is an ideal application for plastic composites. The cab is designed to fit a production Ranger pickup truck and uses carryover frame and front end structure. The cab concept consists primarily of two molded pieces. This design demonstrates extensive parts integration and allows for low-cost tooling, along with automated assembly.
Bonnett, R. E., Carpenter, R. A., Gallagher, S. W.
Deflection Limiting Volume--Protective Structures Laboratory EvaluationJ397_198804 (Historical)4/1/1988
This SAE Standard applies to operator protective structures which may commonly be a part of construction, forestry, mining, and industrial machines. To establish limits on deflection permissible during laboratory evaluations of certain operator protective structures, such as ROPS, FOPS, OPS, and FOG as defined in other SAE standards.
OPTC4, Protective Structures
Performance Criteria for Falling Object Guards for ExcavatorsJ1356_198802 (Historical)2/1/1988
This SAE Recommended Practice applies only to excavators, as defined in SAE J/ISO 6165, working above ground, near an excavated or free standing bank or mine face which is higher than the top of the cab, or in demolition applications of free standing buildings or objects higher than the top of the cab. The evaluations are for resistance to penetration of guards to the point of infringement of the Deflection Limiting Volume (DLV, see SAE J397). The performance requirements of a representative specimen (that is, within the manufacturer's specifications), are based on the performance of proven structures under laboratory evaluation procedures. The areas protected include the top of the operator station (Top Guard), for protection from falling objects, and the front of the operator station (Front Guard), for protection from objects which approach the front of the cab. Although falling object guards meeting the following criteria may not give crush protection under all conceivable circumstances in which the machine could be struck from above or the front, it is expected that crush protection will be ensured under at least the loading condition specified in the tests listed in Section 5. This document establishes a consistent, repeatable test procedure and performance requirements for evaluating guards intended to provide excavator operators with reasonable protection from falling objects such as rocks.
OPTC4, Protective Structures
Occupant Protection for All-Terrain Vehicles87192010/1/1987
The last few years have witnessed a steadily increasing growth in the sales and use of three and four wheel all-terrain recreational vehicles (ATVs). These vehicles are promoted for off-road use and are operated in widely varied environments ranging from dry desert surfaces to wet hilly wooded areas of the country. The design of the ATV and its intended purpose make it an attractive vehicle for a large cross-section of the general public. The general appearance of the vehicle suggests a relatively simple and safe means of transportation, even in environments which have heretofore had limited accessibility. However, it appears that the design and operational characteristics of these vehicles require more of a driver than he may initially assume as evidenced by the number of injuries and deaths that have occurred. How can the number of deaths be reduced and the severity of injuries be lessened? The intent of this paper la to address these questions by focusing on occupant protection for the driver by means of a rollover protective structure (ROPS) and a seat restraint system. These questions are addressed by: analyzing accidents which have occurred to understand how ATV injuries and deaths occur, applying existing technology and knowledge of HOPS and restraint systems on other vehicles, using creative engineering in the application of this knowledge, and determining the safety tradeoffs, if any. A ROPS and a seat restraint system (patent pending) were developed for a four-wheeled ATV without any apparent degradation of the ATV stability and maneuverability. The addition of the seat restraint system by itself appears to greatly enhance the ability to ride the vehicle by providing body support for various operating positions. However, from a safety standpoint a ROPS must accompany the incorporation of the seat restraint system.
Dahle, John L.
Deflection Limiting Volume--Protective Structures Laboratory EvaluationJ397_198602 (Historical)2/1/1986
This SAE Standard applies to operator protective structures which may commonly be a part of construction, forestry, mining, and industrial machines. To establish limits on deflection permissible during laboratory evaluations of certain operator protective structures, such as ROPS, FOPS, OPS, and FOG as defined in other SAE standards.
OPTC4, Protective Structures
Operator Protection for General - Purpose Industrial MachinesJ1042_198602 (Historical)2/1/1986
This SAE Standard applies to General-Purpose Industrial Machines described in Category 2 of SAE J1116, but excludes skid steer loaders (covered by SAE J1388). Protection for the operator of an attachment (for example, a backhoe) is excluded from the scope of this document. Purpose The purpose of this document, with referenced documents, is to establish performance requirements for protective systems that provide operator protection from hazards of machine rollover and/or falling objects.
OPTC1, Personnel Protection (General)
Nonlinear Analysis of the Terex Scraper Rollover Protective Cab8507884/1/1985
A rollover test of the Terex Rollover Protective Cab was conducted by Engineering Methods, Inc. using finite element analysis. The analysis follows SAE procedure J1040C for testing the performance of rollover protective structures (ROPS). The MSC/NASTRAN version 61B finite element program was used in the analysis, which includes the geometric stiffening and nonlinear material property options. The analysis predicts the extent of permanent deformation of the protective cab, and the energy absorbed during rollover. Computer graphic software developed by Engineering Methods, Inc. was used for geometry plotting and post-processing of the displacements and stress levels throughout the structure. A simplified stick model of the protective cab was used for displacement plots at various stages of the analysis. Translucent color stress plots of the full model were also prepared at maximum horizontal and maximum vertical load cases.
Hunckler, Charles J., Purdy, Robert J., Austin, Randy D.
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