Assessment of Full Width Deformable Barriertest and CAE simulations for vehicle compatibility

- Development of software to evaluate, animate, interrogate and compareboth test and CAE data -

Prepared by : Dr. Coulton

Dr. Coulton, Jerome Kim, Nam Yong Dr. Shin, Jangho Ebeling, MatthiasHyundai Motor, Europe Hyundai Motor, Europe Hyundai Motor, Company Altair .

ABSTRACTVehicle compatibility is on the Euro-NCAP road map and has been the subject for research by both in Europe (VC-COMPAT) and the USA (NHTSA). This presentation details the development of an automated method to

assess and compare test and CAE data with respect to the proposed Full Width Deformable Barrier test defined by European Enhanced Vehicle Safety Committee Working Group 15 and also the Full Width Rigid Barrier (with

high resolution load cell wall) by NHTSA. The output of the project was a fully interactive HyperWorks plug-in which allows the user to animate, interrogate and compare both test and CAE data.

European HTC 2009 , Ludwigsburg, 2nd – 4th November 2009

Hyundai Motor Europe Technical Center GmbHRüsselsheim

www.hyundai-europe.com

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Hyundai Motor Europe Tech. Center GmbH

• Introduction to Vehicle Compatibility

– Linkage between Occupant and Partner Protection

– Partner Protection Test and Metric Data Set

– Evaluation Metrics for Partner Protection

• Software Development

– Hyundai Barrier Evaluation Tool Requirements

– Input Data

– User Interface

• Output

– Full Width Rigid Barrier

– Full Width Deformable Barrier

– Animation of Forces and Vehicle Simulation

• Software Key Points

• Conclusions

Contents

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Hyundai Motor Europe Tech. Center GmbH

• The first vehicle compatibility agreement has been voluntarily committed to for the North American Market by the Alliance of Automobile Manufacturers in 2003 for implementation in 2009.

• The European Union funded a study into compatibility which completed in 2006. “Improvement of Vehicle Crash Compatibility through the Development of Crash Test Procedures (VC-COMPAT)”

• The protection of occupants in the colliding vehicles (partner protection) is on the Euro-NCAP road map (2014)

Introduction to Vehicle Compatibility

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Hyundai Motor Europe Tech. Center GmbHLinkage between Occupant and Partner Protection

Occupant PartnerU

S N

CAP

IIHS

JN N

CAP

Euro

NC

AP

FWC

B64

OD

B80

OD

B60

PD

B+ LCW+ new barrier+ new speed

+ LCW+ high speed

+ LCW

+ LCW+ new barrier

+ LCW

EEVC

WG

15

NH

TSA

56 Km/h

64 Km/h

56 Km/h

80 Km/h

60 Km/h

Rigid Wall Standard Barrier Load cells New Barrier

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Hyundai Motor Europe Tech. Center GmbHPartner Protection Test and Metric Data Set

Test configuration

FWC

B64

OD

B80

OD

B60

PD

B+ LCW+ new barrier+ new speed

+ LCW+ high speed

+ LCW

+ LCW+ new barrier

+ LCW

NH

TSA

56 Km/h

64 Km/h

56 Km/h

80 Km/h

60 Km/h

Barrier force Fmax (Peak Total Load Cell Wall Force)HoF400 (Height of Force )AHoF400 (Height of Force @ 400 mm displacement)KW400 (Crush work stiffness @ 400 mm displacement)F3 (Σpeak forces in row 3)F4 (Σpeak forces in row 4)F340 (Σpeak forces in row 3, < 40ms)F440, (Σpeak forces in row 4, < 40ms)

Barrier displacement

Barrier force Fmax (Peak Total Load Cell Wall Force)VSI (Area 1) (Vertical structural interaction)VSI (Area 2) (Vertical structural interaction)HSI (Area 1) (Horizontal structural interaction)HSI (Area 1 + outer support) (Horizontal structural interaction)HSI (Area 2) (Horizontal structural interaction)HSI (Area 2 + outer support) (Horizontal structural interaction)

Barrier displacement

Barrier force Fmax (Peak Total Load Cell Wall Force)RHcl (Overall (Cell) relative homogeneity criterion)RHr (Vertical (Row) relative homogeneity criterion)RHc (Horizontal (Column) relative homogeneity criterion)RH0 (Total relative homogeneity criterion)

Barrier displacement

Barrier force Record and monitorBarrier displacement

Barrier force Fmax (Peak Total Load Cell Wall Force)Barrier displacement PPAD (Partner protectionassessment of deformation)

ADoD (Average depth of deformation)AHoD (Average height of Deformation)Dmax (Maximum depth of Deformation)Z(Dmax) (Height of maximum depth of Deformation)Volume (Volume of deformation)Energy (Energy of deformation)

Not defined

TRL V3.0 Mar 2007

NHTSA

PDB V2.3 Feb 2006

TRL V1.6 Feb 2006

Metrics

Obsolete

Ord

er o

f Im

porta

nce

No

Metrics

Software

Exists

No

Metrics

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Hyundai Motor Europe Tech. Center GmbHEvaluation Metrics for Partner Protection

• There are two different types of metrics that could be used for partner protection:– Barrier force– Barrier deformation

• As well as assessing partner protection, occupant protection evaluation is also proposed:– BiW deformation– Occupant injury

• At present there is no standard software for assessing barrier forces for partner protection.

• This was the motivation for developing the “Hyundai Barrier Evaluation Tool”.

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Hyundai Motor Europe Tech. Center GmbH

• The automated tool has the following requirements:– Integration within Hyundai CAE/test

environment.

– Read data from different sources• Test (ISO/DIADEM) & CAE (DYNA)

– Compare data

– 2D curve plotting• Load cell wall segments vs. time

– 3D curve plotting• Animated 3D bar chart

– Report

Hyundai Barrier Evaluation Tool Requirements

TEST

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Hyundai Motor Europe Tech. Center GmbHInput Data

• CAE/Test Data from both vehicle and barrier are required:– Vehicle

• Vehicle acceleration.• Identified by node number, ISO

tag “BPIL” or NHTSA tag “BPLR”

– Barrier• LCW forces.• Identified by channel code or

Rigidwall segment number.

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Hyundai Motor Europe Tech. Center GmbHUser Interface

• The GUI is launches from a pull down in HyperGraph/HyperView

Automatic identification of data channels and parameters based on data format type

Restart/reload from configuration file

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Hyundai Motor Europe Tech. Center GmbH

• Following the processing of the data, the software generates a table with the necessary metrics.

• The corresponding 2-D charts to enable their interpretation are also created:– Filtered and unfiltered load cell

wall data– AVS Diagram– Total load cell wall forces– Row 3 and row 4 forces– Height of forces– Crush work Stiffness & energy

Full Width Rigid Barrier (US-NCAP)

Metric Name Limits

AHOF40 406-508mm Ftotal Peak >350 kNF3 Peak >100kN F3(40) >100kN F4 Peak >100kN F4(40) >100kN

Initial Velocity 17.61-18.15m/sAHoF(400) 406-508mm F3(400) >100kN F4(400) >100kN Kw400 1300-1700N/mm

Time Dependent Metrics

Displacement Dependent Metrics15.278 - 15.834 m/S

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Hyundai Motor Europe Tech. Center GmbH

• Following the processing of the data, the software generates a table with the necessary metrics.

• The corresponding 2-D charts to enable their interpretation are also created:– Filtered and unfiltered load cell

wall data– TRL Target row loads– TRL Target cell loads– Peak load cell forces (rows 2

to 5)– Negative deviations (rows 2 to

5)

Full Width Deformable Barrier

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Hyundai Motor Europe Tech. Center GmbH

HyperView Player H3D

Animation of Forces and Vehicle Simulation• The forces can be animated allowing the user to visualize the load

distribution.• The load cell wall forces can be animated and manipulated in 3 dimensions

just like a 3-D CAE model

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Hyundai Motor Europe Tech. Center GmbH

• As the software has been created as a HyperWorks plug-in it will work on multiple platforms.

• The software has been tested under the following conditions:– HyperWorks versions 9 &10– Windows XP (32 & 64 bit)– LINUX (Redhat)

• The use of a configuration file allows the user to reload all necessary data:– location of input files– location of output files– location of results– Evaluation parameters

• All current metrics for FWRD and FWDB are automatically evaluated and exported in a standardized format (.htm file).

Hyundai Barrier Evaluation Software, Key Points

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Hyundai Motor Europe Tech. Center GmbHConclusions

• A new software tool for the evaluation of FWRB and FWDB data was successfully developed (Hyundai Barrier Evaluation Tool).

• Both test and simulation data sets can be read in and compared using a single software tool.

• Through the ability to animate the results in 3 dimensions and review the differences between data sets, the user is able to rapidly identify and understand the root causes for the resultant metricvalues or changes in their values when comparing data sets.

• The Hyundai Barrier Evaluation Tool can help address three majoraspects of vehicle front ends for vehicle compatibility:– Geometry;– Stiffness;– Energy absorbance.

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Hyundai Motor Europe Tech. Center GmbHReferences

1. Public Citizen, Keeping the Safety in SAFETEA: Life-Saving Vehicle Safety Provisions Are Long-Overdue and Feasible, March 2004, retrieved from www.citizen.org

2. European Enhanced Vehicle-safety Committee Working Group 15, Car Crash Compatibility and Frontal Impact - Final Report to Steering Committee, May 2007, retrieved from wg15.eevc.org

3. NHTSA, A Report on Voluntary Industry Effort to Further Enhance Front to Front Vehicle Crash Compatibility (DRAFT), 11-12-08.

4. Van Ratingen, Summary Presentation, APROSYS Final Event, 17/18 February 2009, retrieved from www.aprosys.com

5. KIA joins in voluntary commitment to enhance vehicle safety, 4 December 2003, retrieved from www.kiamedia.com

6. European Transport Safety Council, Assessing risk and setting targets in transport safety programmes, 2003, Brussels, retrieved from www.etsc.eu.

7. European Road Safety Observatory (2006), Vehicle Safety, 10 August 2007, retrieved from www.erso.eu

8. P Mohan & D Smith, Finite element analysis of compatibility metrics in frontal collisions, June 2007, 20th ESV Conference, retrieved from www.nhtsa.dot.gov

9. H Yonezawa et al, Summary of Activities of the Compatibility Working Group in Japan, June 2009, 21st ESV Conference, retrieved from www.nhtsa.dot.gov

10. M Edwards et al., Improvement of Vehicle Crash Compatibility through the Development of Crash Test Procedures, Final Report – VC-COMPAT Project GRD2/2001/50083, retrieved from vc-compat.rtdproject.net