VEHICLECRASHWORTHINESSAND

OCCUPANTPROTECTION
Contents Contents
MotorVehicleSafetyy
TheAutomobileStructure
Materials
Crashworthiness
CrashworthinessGoals
CrashworthinessRequirements
AchievingCrashworthiness
C h hi Crashworthinesstests
CrashworthinessModelRequirements
Motor Vehicle Safety
Contents
MotorVehicleSafety
The first motor vehicle fatality occurred in 1889 in New y
York City.
An early period of safety from the turn of the century to
1935 period of genesis, growth, and development to
understanding the extremely complex process of vehicle
collisions. collisions.
The second period from 1936 to 1965 intermediate safety
period with crash avoidance devices.
The third period starts in 1966 the creation of the National
Highway Traffic Safety Administration (NHTSA).
The Automobile Structure
Contents
TheAutomobileStructure
Currentcarbodystructuresandlighttrucks y g
bodyoverframestructure
unitbodystructure(includingspaceframe)
V hi l b d Vehiclebody
External to minimize drag
Interiors for adequate space to comfortably Interiors for adequate space to comfortably
accommodate its occupants
Vehicle body with the suspension to minimize road
vibrations and aerodynamic noise transfer vibrations and aerodynamic noise transfer
Vehiclestructuretomaintainitsintegrityandprovide
adequateprotectioninsurvivablecrashes
The Automobile Structure
Contents
TheAutomobileStructure
BodyonFrame
BodyinwhiteofaUnibody
construction construction
Materials
Contents
Materials
The majority of massproduced vehicle bodies over the The majority of mass produced vehicle bodies over the
last six decades were manufactured from stamped
steel components.
Until the 1920s, automakers built vehicle bodies from
a composite of wood panels joined with steel brackets.
As metallurgists improved the formability of sheet steel
and toolmakers built durable dies capable of stamping
millions of parts and spot weld technology allowed for millions of parts and spot weld technology allowed for
joining large body shells.
Dodge built an allsteel vehicle body in 1924 Dodge built an all steel vehicle body in 1924.
Crashworthiness
Contents
Crashworthiness
Crashworthinessmeasure of the ability of a structure Crashworthiness measure of the ability of a structure
and any of its components to protect the occupants in
survivable crashes. (aerospace industry)
Crashworthiness connotes a measure of the vehicles
structural ability to plastically deform and yet maintain
ffi i t i l f it t i h a sufficient survival space for its occupants in crashes
involving reasonable deceleration loads.
Restraint systems and occupant packaging provide Restraint systems and occupant packaging provide
additional protection to reduce severe injuries and
fatalities.
Crashworthiness Goals
Contents
CrashworthinessGoals
The body structures include progressive crush zones to The body structures include progressive crush zones to
absorb part of the crash kinetic energy.
Vehicles maintain integrity of the passenger Vehicles maintain integrity of the passenger
compartment and simultaneously control the crash
deceleration pulse. p
Accident reconstruction and analysis of vehicle crashes
provide information regarding the safety performance. p g g y p
Currently, vehicle crashworthiness is evaluated in four
distinct modes: frontal, side, rear and rollover crashes. , ,
Crashworthiness Requirements 1/2
Contents
CrashworthinessRequirements1/2
Sufficiently stiff in bending and torsion for Sufficientlystiffinbendingandtorsionfor
properrideandhandling.
Minimize high frequency fore aft vibrations Minimizehighfrequencyforeaftvibrations
thatgiverisetoharshness.
A d f f i Accommodateforarangeofoccupantsizes,
ages,andcrashspeedsforbothgenders.
Crashworthiness Requirements 2/2
Contents
CrashworthinessRequirements2/2
Characteristics:
Deformable,yetstiff,frontstructurewithcrumple
zonestoabsorbthecrashkineticenergy.
Deformable rear structure to maintain integrity Deformablerearstructuretomaintainintegrity.
Properlydesignedsidestructuresanddoorsto
minimizeintrusion.
Strongroofstructureforrolloverprotection.
Properlydesignedrestraintsystemsthatworkin
harmonywiththevehiclestructure. y
Accommodatevariouschassisdesignsfordifferent
powertrainlocationsanddriveconfigurations
Achieving Crashworthiness 1/2
Contents
AchievingCrashworthiness1/2
Uniqueworkofautomotivestructural U que o o auto ot e st uctu a
crashworthinessengineer:
must meet all service load requirement and it must
deform plastically in a short period of time
(milliseconds) to absorb the crash energy in a
controllable manner.
must be light and be economically massproduced.
The structural stiffness must be tuned for ride and
h dl d b bl h h handling, NVH and must be compatible with other
vehicles on the road, so it is not too soft or too
aggressive. gg
Achieving Crashworthiness 2/2
Contents
AchievingCrashworthiness2/2
Automotive Safety engineer: AutomotiveSafetyengineer:
packagingtheoccupantsfor decelerations
transmittedtotheoccupantsaremanageableby
theinteriorrestraintstofallwithintherangeof
humantolerance.
The ultimate goal of the safety engineer is to Theultimategoalofthesafetyengineeristo
reduceoccupantharm.
Typically designers accomplish this goal using a Typically,designersaccomplishthisgoalusinga
combinationofcrashavoidanceand
crashworthinessmeasures.
Crashworthiness Tests 1/4
Contents
CrashworthinessTests1/4
In spite of the tremendous progress achieved In spite of the tremendous progress achieved
in crashworthiness simulations, vehicle
certification relies on laboratory tests certification relies on laboratory tests.
Three categories of tests:
C t t t Componenttests
Sledtests
ll l b Fullscalebarrierimpacts
Crashworthiness Tests 2/4
Contents
CrashworthinessTests2/4
Component Tests: Component Tests:
Dynamicand/orquasistaticresponsetoloading
of an isolated component ofanisolatedcomponent.
Crucialinidentifying
Crush mode Crushmode
Energyabsorptioncapacity
Understanding performance is essential to the Understandingperformanceisessentialtothe
developmentofmathematicalmodelsand
prototypes prototypes.
Crashworthiness Tests 3/4
Contents
CrashworthinessTests3/4
Sled test : Sledtest :
Vehiclebuck passengercompartment
h hi d i d Anthropomorphictestdevicesorcadavers
driversorpassenger.
Dynamicloadvehicledecelerationtimepulse
Primaryobjective toevaluaterestraints y j
Sensorsondummy,highspeedphotography
for data fordata.
Crashworthiness Tests 4/4
Contents
CrashworthinessTests4/4
Fullscalebarriertest:
Collisionofaguidedvehicle,propelledintoa
barrieratapredeterminedinitialvelocityand
angle angle.
Abarriertestusesacompletevehicle.
ex Regulations FMVSS 208 ex.Regulations FMVSS208
Frontalimpactwithbarrierzero, 30
Unrestraineddummiesinthedriverandrightfront
passenger
NCAP higherspeedimpactwithrestrained
dummy dummy
CrashworthinessModels
Contents
Requirements
Accuracy themodelshouldbeabletoyieldreasonably y y y
accuratepredictionsoftheessentialfeaturesbeingsought
Speed themodelshouldbeexecutablewithareasonable
turnaroundtime,nottoexceed12hoursregardlessofits
size,toallowforiterationsandparameterstudies.
Robustness small variations in model parameters should Robustness smallvariationsinmodelparametersshould
notyieldlargemodelresponses.
Developmenttime themodelcouldbebuiltina
reasonablyshortperiodoftime,nottoexceedtwoweeks