Achieving Robust Sensing Performance for Six-Airbag Systems: Design Approaches and Validation Techniques for Side Sensing

The introduction of GSR 16(E) in India mandates six airbags in passenger vehicles, aiming to enhance occupant safety. In parallel, the new Bharat New Car Assessment Program (BNCAP) outlines performance protocols that demand robust airbag deployment strategies to achieve a five-star safety rating. One of the critical challenges in meeting both regulatory and consumer safety expectations is the optimal packaging of the airbag Electronic Control Unit (ECU) and its associated impact sensors. These must perform reliably across regulatory tests, BNCAP protocols, and real-world accident scenarios. The location of side acceleration ‘g’ side impact sensors—whether mounted on the side sill, B-pillar, C-pillar, or door structures—is pivotal to achieving consistent and timely airbag deployment. These sensors must also demonstrate immunity to false triggers or missed events in both static and dynamic misuse and abuse conditions. Ensuring robust sensor performance under these varied conditions is key to the success of the system. This study focuses on evaluating acceleration-based side impact sensors placed at different locations within the vehicle structure, assessing their sensitivity and correlation with airbag deployment performance. Additionally, for compact vehicles where faster deployment of side airbag is essential, the use of pressure-based sensors was investigated. The findings of this study were instrumental in finalizing the optimal packaging strategy for both acceleration and pressure sensors in six-airbag systems. Keywords: side airbags in passenger vehicles, real world accident scenarios, side impact sensor packaging, and side impact pressure sensors.