This paper describes the development of a new component test methodology concept for simulating NHTSA side impact, to evaluate the performance of door subsystems, trim panels and possible safety countermeasures (foam padding, side airbags, etc.). The concept was developed using MADYMO software and the model was validated with a DOT-SID dummy. Moreover, this method is not restricted to NHTSA side impact, but can be also be used for simulating the European procedure, with some modifications. This method uses a combination of HYGE and VIA decelerator to achieve the desired door velocity profile from onset of crash event until door-dummy separation, and also takes into account the various other factors such as the door/B pillar-dummy contact velocity, door compliance, shape of intruding side structure, seat-to-door interaction and initial door-dummy distance. This method is capable of reproducing the characteristic “double-peak” of the door velocity profile and, can be used for side airbag evaluation, by simulating the close-in velocity and distance between the side structure and dummy.
In this approach, the door velocity profile is simulated in four phases: In the first phase, a pre-crushed door mounted on a ‘Door sled’ (at approximately the same distance from the dummy as in a car), is accelerated by the HYGE until it impacts the stationary dummy, to generate the first peak. In the second phase, from the onset of dummy contact, the door sled is decelerated by a honeycomb block (mounted on another ‘Base sled’), simulating the first ride-down of the velocity profile. During this phase, the HYGE is dormant. In the third phase, the HYGE accelerates both the Door and Base sleds together to simulate the second peak. In the fourth phase, the Door and Base sleds are decelerated until door-dummy separation by means of a VIA decelerator system, thus simulating the entire door velocity profile from start of crash event until the door and dummy separate. In conclusion, the MADYMO model demonstrates the feasibility of the concept, pending experimental prove-out on the sled.