This report (including any attachments) is a confidential ... · This report (including any...
Transcript of This report (including any attachments) is a confidential ... · This report (including any...
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
2
Background
(a) (b)
Oblique Moving
Deformable Barrier THOR (Test Device for Human
Occupant Restraint)
Driver Occupant : THOR Metric
Front Passenger : THOR Metric
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
• Objective
• Vehicle Tests
• MADYMO model development
• Sled Tests
• Observations
3
Contents
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
4
Issue
Current sled methodology is mostly dedicated to full frontal crash study
• Hyge sled
• Hydraulic sled
Some sled methodology is also available for side impacts
Short term goals
Study crash test data and develop MADYMO model
System level correlation
MADYMO model methodology development
Mid term goals
Sled model development
Sled level Correlation
Sled test methodology development
Goal
Post project, using the sled methodology and simulation methodology for development of
countermeasures
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
5
Vehicle Spec
Test Mode
Vehicle : Sedan Dummy (Driver & front Passenger)
Vehicle 1 (V1) Vehicle 2 (V2) THOR THOR
RMDB ● ● ●
RMDB ● ● ●
Small Overlap ● ●
Small Overlap ● ●
• Hyundai performed several oblique crash test prior to RFC from NHTSA
Vehicle Test Matrix
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
Injury Comparison
NHTSA Oblique
IIHS Small Overlap
NHTSA Oblique
Head strike thru’
NHTSA Oblique Impact
Obliqueness and severity of the event
Significantly high chest deflection for chest upper and lower
right potentiometer; Anchor PT, IP intrusion contributes in
overall high deflection
High intrusions in upper dash area contributes to femur and
tibia loading
Floor and toe pan intrusions dominate ankle injury
Outboard
seat movement
Head visor
contact
UL
LL
UR
LR
Impact mode
comparison
6
%IA
RV
valu
es
* Provisional IARV values per Saunders and Parent (2013)
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
7
Injury Comparison
V1
V2
NHTSA oblique impact: Driver
Head injuries are similar for baseline and
modified vehicle
Higher chest deflection for baseline vehicle
due to higher cowl X-bar intrusion
NHTSA oblique impact: Passenger
Similar injury pattern is seen for baseline
and modified vehicle
High HIC value for baseline due to head
strike thru’
Small overlap countermeasures are
mainly concentrated in side sill area
These countermeasures reduce
intrusions in A-pillar area, in door frame
and IP beam area and in sill area. The
reduced intrusions are not sufficient
though and do not help in reducing
injury values
V1 vs V2
%IA
RV
valu
es
7 * Provisional IARV values per Saunders and Parent (2013)
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
8
Logic Flow
Full vehicle testing
Full vehicle CAE
modeling and correlation
Sled model development /
parametric study
Sled test baseline
development
Sled test parametric
study
CAE Analysis Sled Testing
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
MADYMO Input parameters
Occupant kinematics
• Vehicle Acceleration in X and Y direction (Vx and Vy)
• Vehicle pitching, yaw and rotation
• Rate of rotation
Occupant Injuries
• Head Injury
BrIC
HIC
• Chest Deflection
MADYMO model
development
Intrusion
Acceleration pulse
Restraint Interaction
Interior interaction
9
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
Vehicle MADYMO Model Development
MADYMO model using version R7.5
MADYMO THOR dummy: R7.5 Beta version
Correlated front NCAP model was used as starting
point
Displacement based MADYMO model
Vehicle X and Y acceleration pulse is used to derive
X and Y vehicle displacements
Additional joints and planes were created to account
for vehicle intrusions
Vehicle intrusion are incorporated to steering column,
IP, toe pan, A-pillar in the model
Rate of intrusion are based on video analysis and
peak injury timing
CAB, Door structure, knee bolsters and other vehicle
interior were incorporated to account for occupant
kinematics and injury
MADYMO model
development
10
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
Vehicle MADYMO Model Development
Front NCAP model
Oblique model floor
Floor Intrusions
Door trim and roof rail
Interior set up and CAB support
MADYMO model
development
11
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
MADYMO input parameters
Vehicle motion
• X and Y displacement extracted from vehicle acceleration
• Displacement based model was seen to be more effective than acceleration based model
Vehicle Intrusions
• Dynamic Intrusion Floor, Steering column intrusion, IP and toe pan
• Rate of Intrusion was determined by video analysis and peak injury timings
MADYMO model
development
12
CONFIDENTIAL
Video
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
Vehicle MADYMO Model Correlation
Model correlation focus
o Dummy kinematics
40 ms 60 ms 80 ms 100 ms 120 ms
CAE
Test
MADYMO model
correlation
13
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
Correlation: Head Injury
Correlation: Chest Injury CAE
TEST
MADYMO model
correlation
14
Head Resultant Acceleration
Chest Resultant Acceleration Chest Deflection
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
Correlation: Femur Injury
Correlation: Pelvis Injury CAE
TEST
MADYMO model
correlation
Correlation: Belt load
15
Femur Force
Video
Resultant Acceleration Belt Load
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
16
Logic Flow
Full vehicle testing
Full vehicle CAE
modeling and correlation
Sled model development /
parametric study
Sled test baseline
development
Sled test parametric
study
CAE Analysis Sled Testing
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
Sled MADYMO Model Development
R
Displacement based MADYMO model
Model rotation based on head free body trajectory from
vehicle (22°)
Resultant displacement is used
Static steering column and IP intrusions
Sled model
development
Vehicle test driver head trajectory 22°
MADYMO R7.5 ATD- THOR Beta Version
17
CONFIDENTIAL Resultant displacement
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
18
Parametric study to determine physical test setup
Sled rotation angle: 16 – 28° (2° Δ)
Simulate ATD rotation
ATD seating height Z: 0 – 75 mm (15 mm Δ)
Simulate vehicle pitching
Steering column
intrusion X: 0 – 60 mm (10 mm Δ)
Y: 0 – 50 mm (10 mm Δ)
Simulate Column intrusion
Knee bolster intrusion X: 0 – 50 mm (10 mm Δ)
Simulate IP intrusion
Final Sled Setup 22°
Steering column
stroking X: 0 – 70mm
Sled model
development
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
Sled model
development
Sled Angle variation study
Vehicle Vy Trend
• Vy ↑ α off centered head contact
• DAB interaction α ωz ↑
Steering column stroke study
• Sled buck angle 22°; 3 column stroke variations: No stroke, 50% stroke and 100% stroke
100% column stroke = 70 mm
• Reduction in BrIC is observed with increase in sled angle
reduced DAB interaction
* BrIC calculation 2013 Stapp Takhouts et al. (2013) 19
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
20
• BrIC has no effect with knee bolster intrusions
• BrIC increases with increase in steering column intrusions due to
restricted dummy kinematics
Sled model
development
Knee bolster intrusion study
Steering column intrusion study
* Provisional IARV values per Saunders and Parent (2013)
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
21
Driver chest deflection found to be insensitive to static
intrusions in sled environment
* Provisional IARV values per Saunders and Parent (2013)
Sled model
development
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
22
Logic Flow
Full vehicle testing
Full vehicle CAE
modeling and correlation
Sled model development /
parametric study
Sled test baseline
development
Sled test parametric
study
CAE Analysis Sled Testing
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
23
Resultant accel
eration
θ
Sled buck • Sled buck at 22°based on head trajectory angle
• Vehicle resultant X and Y acceleration provided in
global X direction
• Static intrusions based on CAE analysis
Resultant acceleration pulse
Sled Setup
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
24
Sled Setup
Sled setup input parameters
Based on CAE studies and sled parametric studies the following setup parameters were established
• Buck angle was finalized to 22 deg
• Steering column static intrusion was set to 25mm in X direction
• No knee bolster intrusion
• Steering column stroking was removed
• Dummy height H-point raised by 25mm to account for pitching and the airbag contact point
220
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
25
Sled vs. Vehicle
Driver Head shows good correlation to vehicle test
Head accel [g] and disp [mm] Vehicle test
Sled Test Head ang vel [deg/s]
Vehicle test
Sled Test
* BrIC calculation 2013 Stapp Takhouts et al. (2013)
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
26
Sled test correlation: Driver Head
26
< Standard Shoulder > < SD3 Shoulder >
70 ms
90 ms
110 ms
Vehicle test
Sled Test
Vehicle test Sled Test
Vehicle test Sled Test
Vehicle test Sled Test
Sled test has longer coupling of Driver
shoulder to seatbelt
Sled vs. Vehicle
* BrIC calculation 2013 Stapp Takhouts et al. (2013)
CONFIDENTIAL Information
CONFIDENTIAL Information
CONFIDENTIAL Information
CONFIDENTIAL Information
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
27
Driver Chest shows good correlation to vehicle test
Chest accl [g] & belt load [N] Vehicle test
Sled Test
Chest deflection Vehicle test
Sled Test
Sled vs. Vehicle
* BrIC calculation 2013 Stapp Takhouts et al. (2013)
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
28
Vehicle test
Sled Test Head accel [g] and disp [mm] Head ang vel [deg/s]
Vehicle test
Sled Test
Passenger head shows good correlation to vehicle test
• Head strike in vehicle - same logic as shown for driver
Sled vs. Vehicle
* BrIC calculation 2013 Stapp Takhouts et al. (2013)
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
29
Sled 90 ms
110 ms
130 ms
29
< Standard Shoulder > < SD3 Shoulder >
Sled test has longer coupling of
Passenger shoulder to seatbelt
Vehicle test Sled Test
Vehicle test Sled Test
Vehicle test Sled Test
Sled vs. Vehicle
* BrIC calculation 2013 Stapp Takhouts et al. (2013)
CONFIDENTIAL Information
CONFIDENTIAL Information
CONFIDENTIAL Information
CONFIDENTIAL Information
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
30
Passenger chest shows good correlation to vehicle test
Chest accl [g] & belt load [N] Vehicle test
Sled Test
Chest deflection Vehicle test
Sled Test
Sled vs. Vehicle
* BrIC calculation 2013 Stapp Takhouts et al. (2013)
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
31
Sled vs. Vehicle
Passenger repeatability study (n=3)
* BrIC calculation 2013 Stapp Takhouts et al. (2013)
Head ang vel [deg/s]
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
MADYMO Observations:
• MADYMO proved to be an effective tool in order to set up Sled buck
• Model was able to replicate dummy kinematics from vehicle which was translated in the sled
• Injury trends in MADYMO sensitivity study and Sled sensitivity study matched well
• Driver BrIC is sensitive to early interaction with curtain airbag
• MADYMO sled injury results did not capture peak injuries from vehicle
Sled test Observations:
• Sled test showed good correlation to the vehicle test
• Sensitivity study was used to correlate sled to vehicle test
• Sled buck angle was finalized to 22° based on head trajectory angle and sensitivity study
• Driver BrIC is sensitive to early interaction with curtain airbag
• Driver and Passenger chest deflection found to be insensitive to static intrusions in sled environment
• Repeatability
– Passenger study showed good repeatability for BrIC and ATD head kinematics (n=3)
• Injury trends shown can be used in further countermeasure development
32
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
This report (including any attachments) is a confidential and classified document. The publication or distribution of this report or
the information contained herein must not be disclosed without the written approval of the author.
33
Questions?