Barrier Weight Prediction for Vehicle Compatibility in North America Market using Finite Element Analysis

The proliferation of the electric vehicle (EVs) in the US market led to an increase in the average vehicle weight due to the integration of the larger high-voltage (HV) batteries. To comply with this weight increase and meet stringent US regulations and Consumer Ratings requirements, Vehicle front-end rigidity has substantially increased. This increased stiffness in the larger vehicles (Large EV pickups/SUVs) may have a significant impact during collision with smaller vehicles. To address this issue, it is necessary we consider adopting a vehicle compatibility test like EuroNCAP MPDB in North American market as well. This study examines the influence of mass across vehicle classes and compares the structural variations for each impact class. The EuroNCAP MPDB (Moving Progressive Deformable Barrier) protocol was referenced for this analysis. Our evaluation approach comprises of two sections: the impact of the barrier mass on to the vehicle structure (V2B) and vehicle-to-vehicle impact (V2V) analysis. To predict the correct segment weight representing the barrier weight for the North American market, we benchmarked the year to sales data for North American market to assess the average vehicle weight. We then compared this data with our CAE predictions of the barrier mass (~1500kg- 1600kg). Based on the benchmarked data, the average vehicle mass was found to be approximately ~1500 kg, aligning with our CAE simulations predictions. The study aims to determine the US sales volume and conduct CAE simulations to anticipate the precise weight of the barrier that replicates the lightest vehicle currently available in the North American market, as per this study, a barrier weight of (~1500 -1600) kg can be considered for the future vehicle compatibility for NA market. This predicted vehicle weight aligns with the typical vehicle sales volume for the North American market.