Developing a dynamic test protocol for the updated IIHS deformable barrier

The Insurance Institute for Highway Safety (IIHS) introduced its updated side-impact ratings test in 2020 to address the nearly 5,000 fatalities occurring annually on U.S. roads in side crashes. Research for the updated test indicated the most promising avenue to address the remaining real-world injuries was a higher severity vehicle-to-vehicle test using a striking barrier that represents a sport utility vehicle. A multi-stiffness aluminum honeycomb barrier was developed to match these conditions. The complexity of a multi-stiffness barrier design warranted research into developing a new dynamic certification procedure. A dynamic test procedure was created to ensure product consistency. The current study outlines the process to develop a dynamic barrier certification protocol. The final configuration includes a rigid inverted T-shaped fixture mounted to a load cell wall. This fixture is impacted by the updated IIHS moving deformable barrier at 30 km/h. The fixture represents the stiff sections of a typical vehicle’s side structure and creates deformation patterns on the deformable barrier that are similar to the baseline results established during the development of the updated IIHS side crashworthiness test. Three different barrier manufacturers submitted 3–4 samples each for evaluation. These barriers were tested to determine performance and quality across manufacturers. Load cell wall data was used to establish force-displacement corridors for the center and left/right sections of the deformable barrier. The corridors will be used as part of a periodic certification process that barrier manufacturers can use to prove their finished products and manufacturing processes meet IIHS requirements.