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Implementation, Improvement and Statistical Validation of Scoring by Milling Process on an Instrument Panel with In-Mold Grain Lamination

Ford Motor Company-Caio V. Bertolini, Fábio Koki, Renato Veiga, Leandro Quinelato
  • Technical Paper
  • 2019-36-0155
Published 2020-01-13 by SAE International in United States
This paper starts describing the in-mold grain lamination and bilaminated film cover when applied to instrument panels with seamless passenger air bag doors. It then offers a comparison between two different PAB door weakening processes, the laser scoring and the scoring by milling. It further discuss the scoring by milling process and analyses its implementation on a real case instrument panel. In the implementation case, the scoring pattern is checked against a pre-defined engineering specification and correlated to the results of a drop tower test, which shows the force necessary to break the PAB door. Three iterations are performed until the results for scoring pattern and breaking force are achieved. The breaking force results are then statistically validated against the specification and capability analysis.
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Injury Reduction in Vehicle to Pedestrian Collision Using Deployable Pedestrian Protection System in Vehicles

International Centre for Automotive Technology-Jitendra Singh Gaur
  • Technical Paper
  • 2019-28-2551
Published 2019-11-21 by SAE International in United States
Head injuries are the main source of road fatalities when a pedestrian or other vulnerable road user (VRU) such as cyclist or motorcyclist is involved in an accident with the approaching high speed vehicle. The frontal part of a car such as engine hood (bonnet), lower-windshield area and A-pillars are the possible location of head impact in these accidents. The head impact with hard points located in these areas may result in the fatal head injuries. The effect of impact can be reduced by using the deployable pedestrian protection systems (DPPS) such as pop-up hoods and windshield airbag in the vehicle. The study indicates how these systems are effective in reducing the fatalities in pedestrian accidents and how to evaluate the performance of these deployable systems. The pedestrian & VRU road fatalities contribute to more than 33percent of total road fatalities in India. Worldwide regulations for pedestrian protection include the evaluation of head injuries at a relative speed of 35kmph. However, the actual impact can occur at higher speeds many times which results in high…
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Recommended Practice for Optimizing Automobile Damageability and Repairability

Motor Vehicle Council
  • Ground Vehicle Standard
  • J1555_201910
  • Current
Published 2019-10-24 by SAE International in United States
This SAE Recommended Practice applies to all portions of the vehicle, but design efforts should focus on components and systems with the highest contribution to the overall average repair cost (see 3.7). The costs to be minimized include not only insurance premiums, but also out-of-pocket costs incurred by the owner. Damageability, repairability, serviceability and diagnostics are inter-related. Some repairability, serviceability and diagnostics operations may be required for collision or comprehensive loss-related causes only. Some operations may be for non-collision-related causes only (warranty, scheduled maintenance, non-scheduled maintenance, etc.). Some may be required for both causes. The scope of this document deals with only those operations that involve collision and comprehensive insurance loss repairs.
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The Effects of Front-Mounted Accessories on Air Bag Sensors and Crashworthiness

Motor Vehicle Council
  • Ground Vehicle Standard
  • J2431_201910
  • Current
Published 2019-10-09 by SAE International in United States
Almost all light trucks now are being manufactured with at least a driver side air bag and all will have dual air bags by 1998. The driving forces behind this feature are occupant safety, federal regulations, and competition in the industry. Along with the booming popularity of pickups and SUVs, they are commonly accessorized with a wide variety of products. Many accessories for four-wheel drives in particular are mounted on the front of the vehicle. These products include grille/brush guards, winches, snow plows, replacement bumpers, bicycle carriers, etc. Concerns have arisen over the compatibility of these accessories with the vehicle’s air bag system. The vehicle manufacturers are concerned because of their huge investment in design and crash test verification of the complete vehicle system and keen awareness of the federal regulations. The crushability of the front bumper and supporting structure are key elements in the system, so alterations to that area become logical concerns. The accessory manufacturers, dealers, and installers are concerned because the very core of their business could be at risk. The unknowns…
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Honda ready with new injury-reducing airbag

Automotive Engineering: October 2019

Bill Visnic
  • Magazine Article
  • 19AUTP10_08
Published 2019-10-01 by SAE International in United States

Starting next year, Honda will begin fitting vehicles with a new, advanced-design passenger-side front airbag that its engineers said is designed to mitigate brain and neck injuries by cradling the head like a baseball in a catcher's mitt. The design is particularly effective, Honda said, for angled impacts or when an occupant is not in optimal position when the crash occurs, reducing rotational acceleration of the head that can traumatize the brain.

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Latest mass-reducing innovations honored by Altair

Automotive Engineering: September 2019

Ryan Gehm
  • Magazine Article
  • 19AUTP09_09
Published 2019-09-01 by SAE International in United States

The fourth-generation Jeep Wrangler, which eliminated 92 kg (203 lb) compared to the previous-generation vehicle, and Ferrari's Portofino, which is 80 kg (176 lb) lighter yet 35% stiffer than the outgoing California T it replaces, were the Full Vehicle category winners of the 7th annual Altair Enlighten Awards, the widely-anticipated lightweighting competition sponsored by Altair and presented at the Center for Automotive Research (CAR) 2019 Management Briefing Seminars (MBS) conference in Traverse City, Mich.

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Parametric Analysis and Optimization of Variables Affecting the Brain Injury Criterion (BrIC) in Various Crash Scenarios

SAE International Journal of Transportation Safety

Bowhead (Systems and Technology Group), United States-Vikas Hasija
National Highway Traffic Safety Administration, United States-Erik G. Takhounts, Matthew J. Craig
  • Journal Article
  • 09-07-01-0005
Published 2019-08-19 by SAE International in United States
Incompressibility of the brain makes it susceptible to damage from shear strains. Head rotational motion can easily produce high shear strains causing brain injury. Since head injury criterion (HIC) does not account for rotational motion, a brain injury criterion (BrIC) was developed. To design potential countermeasures for reducing BrIC, it is important to investigate the parameters that influence BrIC. This article focuses on parametric analysis to examine the sensitivity of BrIC to vehicle design and crash-related parameters, and identifying important parameters which can be controlled in developing countermeasures for reducing BrIC. Global Human Body Models Consortium (GHBMC) 50th percentile male simplified human finite element (FE) model was used in this study. Four different analyses were conducted: a Design of Experiments (DOE) study to investigate sensitivity of BrIC to impact direction and crash pulse severity b DOE studies, with fixed crash severity, for frontal, far side oblique, and near side oblique crash modes to identify important vehicle design parameters influencing BrIC c Optimization for frontal, far side oblique, and near side oblique crash modes to minimize…
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Stapp Car Crash Journal Vol. 62, 2018

  • Book
  • B-STAPP2018
Published 2019-04-30 by The Stapp Association in United States
This title includes the technical papers developed for the 2018 Stapp Car Crash Conference, the premier forum for the presentation of research in impact biomechanics, human injury tolerance, and related fields, advancing the knowledge of land-vehicle crash injury protection. The conference provides an opportunity to participate in open discussion about the causes and mechanisms of injury, experimental methods and tools for use in impact biomechanics research, and the development of new concepts for reducing injuries and fatalities in automobile crashes. The topics covered this year include: • Effect of restraints on chest deflection • Thoracic response in dynamic front loading • Side impact assessments and comparisons • Front airbag deployment rates and implications • Reanalysis of experimental brain strain data • Modeling pedestrian impacts • Short communications o New data on the biomechanics of injury and human tolerance, new methods and tools to study the biomechanics of injury, new developments in occupant protection systems, and new concepts on the biomechanics of injury based on experimental and analytical studies.
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Innovative Knee Airbag (KAB) Concept for Small Overlap and Oblique Frontal Impacts

Detroit Engineered Products (DEP) Inc.-Rahul Makwana
Ford Motor Co., Ltd.-Pardeep Jindal
Published 2019-04-02 by SAE International in United States
Considerable research has been conducted in terms of attempting to reduce lower leg injury risk in full frontal impacts, in some cases by the use of a knee airbag (KAB). However, there has been limited research into the performance of KAB systems during a crash test with increased oblique loading, such as the IIHS small overlap frontal test, an oblique moving deformable barrier test (OI) being researched by NHTSA, and a mobile progressive deformable barrier test (MPDB) that is expected to be implemented by Euro NCAP in the next few years. The objective of the current numerical study was concentrated on the evaluation of an innovative KAB concept design intended to reduce ATD right inboard lower leg/foot responses under small overlap and oblique loading conditions. A novel appendage KAB concept design was developed with the help of morphing and computational studies which were performed with different ATD sizes. In the study, one of the lower leg/foot responses was monitored and compared over a conventional KAB design. Cases investigated in the study showed that the novel…
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Performance of Event Data Recorders Found in Toyota Airbag Control Modules in High Severity Frontal Oblique Offset Crash Tests

Kineticorp, LLC.-William Bortles
University of Tulsa-Ryan Hostetler
Published 2019-04-02 by SAE International in United States
This paper presents an in-depth analysis of the performance of Event Data Recorders (EDRs) found in the Airbag Control Modules (ACMs), as tested in support of the National Highway Traffic Safety Administration’s Frontal Oblique Offset Program. Previous studies have examined EDR performance in high severity full-frontal barrier crash tests and moving deformable barrier side impact tests. This paper presents data from a high severity oblique frontal impact test in which the vehicle was struck by a moving deformable barrier. This paper examines the results of EDR data downloaded from two 2015 model year Toyota Highlanders, and the results of EDR reported change in velocity (delta-v), to vehicle mounted accelerometers and reference instrumentation. This paper will analyze EDR performance in reporting: Seatbelt buckle status,Occupant Size Classification, Front Passenger,Airbag and seatbelt pretensioner deployment time(s),Longitudinal delta-v, andLateral acceleration/crash pulse.
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