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A biofidelic flexible pedestrian legform impactor (FlexPLI) has been developed from the year 2000 onwards and evaluated by a technical evaluation group (Flex-TEG) of UN-ECE GRSP. A recently established UN-ECE GRSP Informal Group on GTR9 Phase 2 is aiming at introducing the FlexPLI within world-wide regulations on pedestrian safety (Phase 2 of GTR No. 9 as well as the new UN regulation 127 on pedestrian safety) as a test tool for the assessment of lower extremity injuries in lateral vehicle-to-pedestrian accidents. Besides, the FlexPLI has already been introduced within JNCAP and is on the Euro NCAP roadmap for 2014. Despite of the biofidelic properties in the knee and tibia sections, several open issues related to the FlexPLI, like the estimation of the cost benefit, the feasibility of vehicle compliance with the threshold values, the robustness of the impactor and of the test results, the comparability between prototype and production level and the finalization of certification corridors still needed to be solved. Furthermore, discussions with stakeholders about a harmonized lower legform to bumper test area are still going on. This paper describes several studies carried out by the Federal Highway Research Institute (BASt) regarding the benefit due to the introduction of the FlexPLI within legislation for type approval, the robustness of test results, the establishment of new assembly certification corridors and a proposal for a harmonized legform to bumper test area. Furthermore, a report on vehicle tests that previously had been carried out with three prototype legforms and were now being repeated using legforms with serial production status, is given. Finally, the paper gives a status report on the ongoing simulation and testing activities with respect to the development and evaluation of an improved test procedure with upper body mass for assessing pedestrian femur injuries.
Upcoming test procedures and regulations consider the use of Q-dummies. Especially Q6 and Q10 will be introduced to assess the safety of child occupants in vehicle rear seats. Therefore detailed knowledge of these dummies is important to improve safety. As recent studies have shown, chest deflection measurements of both dummies are influenced by parameters like belt geometry. This could lead to a non optimized design of child restraint systems (CRS) and belt systems. The objective of this study is to obtain a more detailed understanding of the sensitivity of chest measurements to restraint parameters and to investigate the possibilities of chest acceleration as an alternative for the assessment of chest injury risks. A study of frontal impact sled tests was performed with Q6 and Q10 in a generic rear seat environment on a bench. Belt parameters like modified belt attachment locations were varied. For the Q6 dummy, different positioning settings of the CRS (booster with backrest) and of the dummy itself were investigated. The Q10 dummy was seated on a booster cushion. Here the position of the upper belt anchorage point was varied. To simulate the influence of vehicle rotation in the ODB crash configuration, the bench was pre-rotated on the sled in additional tests with the Q10. This configuration was tested with and without pretensioner and load limiter. Chest deflection in Q6 showed a high sensitivity to changes in positioning of the CRS and the dummy itself. A more slouched position of the CRS or dummy resulted in a reduction of measured chest deflection, whereas chest acceleration increased for a more slouched position of the CRS. Chest deflection in Q10 is sensitive to belt geometry as already shown in other studies. In a more outboard position of the shoulder belt anchorage the measured chest deflection is higher. Chest acceleration shows the opposite tendency, which is highest for the rearmost location of the upper belt anchorage. On a pre-rotated bench the highest chest deflection within this test series was observed without load limiter/pretensioner and an outboard belt position. By optimizing the belt location and the use of pretensioner/load limier the chest deflection was significantly reduced. For the Q6 a criterion based on chest acceleration as well as deflection measured at two locations might be the most reliable approach, which requires further research with an additional upper deflection sensor. In the Q10 the measured chest deflection does not always correctly reflect the severity of chest loading. The deflection is depending on initial belt position and restraint parameters as well as test conditions, which result in different directions of belt migration. A3ms chest acceleration might be a better indicator for severity of chest loading independent of different conditions like belt geometries. However, in some cases the benefit of an optimized restraint system could only be shown by deflection. These findings suggest that further research is needed to identify a chest injury assessment method, which could be based on deflection as well as acceleration or other parameters related to belt to occupant interaction.
Real world accident reconstruction with the Total Human Model for Safety (THUMS) in Pam-Crash
(2013)
Further improvement of vehicle safety needs detailed analysis of real world accidents. According to GIDAS (German In-Depth Accident Study) most car to car front accidents occur at mid-crash severity. In this range thoracic injuries already occur. In this study a real world frontal crash with mid-crash severity out of the AARU database was reconstructed. The selected car to car accident was reconstructed by AARU by means of pc-crash software in order to get the initial dynamic accident conditions. These initial conditions were used to reconstruct the complete accident in more detail using FE models for the car structure and the occupants. Occupant simulations were performed with FE HIII-dummy models and the THUMS using Pam-Crash code. An initial THUMS validation was performed in order to verify the model-´s biofidelity by means of table-top test simulations. THUMS bone stiffness values were modified to match the real word occupant age. A comparison between driver and passenger restraint system loading was done, as well as an injury prediction comparison between the HIII-dummy model and THUMS response for both cases. Detailed comparison between the HIII-dummy models and THUMS regarding thoracic loading are discussed.
According to the German road traffic regulations children up to the age of 12 or a height below 150 cm have to use approved and appropriate child restraint systems (CRS). CRS must be approved according to UN-ECE Regulation No. 44. The regulation classifies CRS in 5 weight categories. The upper weight group is approved for children from 22 to 36 kg. However, studies show that already today many children weigh more than 36 kg although they have not reached a height of 150 cm. Therefore, no ECE R44 approved CRS is available for these overweight children. In conclusion, today's sizes and weights of children are no longer represented by the current version of the ECE R44. The heaviest used dummy (P10) weighs just 32.6 kg and has a height of 137.9 cm. Statistical data of German children show that already 5% of the children at a height of 137.9 cm have a weight above 45.3 kg. Regarding children at a height of 145 cm, the 95th percentile limit is at a weight of 53.3 kg. Based on these data 4 dummies with different heights and weights were defined and produced. Two of them are overweight. Up to now, there is no experience how current child restraint systems perform in a car crash if they are used by children with a weight above 36 kg and a height smaller than 150 cm. In the future, different child restraint systems will be tested with respect to the ECE R44 regulation using these overweight dummies.
A legform impactor with biofidelic characteristics (FlexPLI) which is being developed by the Japanese Automobile Research Institute (JARI) is being considered as a test tool for legislation within a proposed Global Technical Regulation on pedestrian protection (UNECE, 2006) and therefore being evaluated by the Technical Evaluation Group (TEG) of GRSP. In previous built levels it already showed good test results on real cars as well as under idealised test conditions but also revealed further need for improvement. A research study at the Federal Highway Research Institute (BASt) deals with the question on how leg injury risks of modern car fronts can be revealed, reflected and assessed by the FlexPLI and how the impactor can be used and implemented as a legislative instrument for the type approval of cars according to current and future legislations on pedestrian protection. The latest impactor built level (GTα ) is being evaluated by a general review and assessment of the certification procedure, the knee joint biofidelity and the currently proposed injury criteria. Furthermore, the usability, robustness and durability as a test tool for legislation is examined and an assessment of leg injuries is made by a series of tests with the FlexPLI on real cars with modern car front shapes as well as under idealised test conditions. Finally, a comparison is made between the FlexPLI and the current european legislation tool, the legform impactor according to EEVC WG 17.
To assess occupant safety in a crash test, criteria associating the measurements made with a crash test dummy to injury risk are necessary. To enable better protection of elderly car occupants the objective of this study was to develop improved thoracic injury criteria for the THOR average male dummy. The development of these criteria is usually based on matched dummy and Post Mortem Human Surrogate (PMHS) tests by relating the obtained PMHS injuries to dummy measurements. This approach is limited, since only a few tests in relevant loading conditions are available and any new test series requires high efforts to be performed due to their complexity and costs. To overcome these limitations and to extend the dataset for the development of THOR dummy chest injury risk functions a simulation-based approach was applied within the EC funded project SENIORS (Safety Enhanced Innovations For older Road Users - www.seniors-project.eu). Within this study frontal impact sled simulations with an FE model representing a THOR average male dummy and matched simulations with a human body model (HBM) representing an elderly car occupant were carried out. The HBM used for this study was the THUMS TUC with modified rib cage, which was developed in SENIORS. The modifications included material and geometry changes aiming to represent an elderly car occupant. The rib fracture risk was predicted with a deterministic approach whereby a rib was considered broken when the strain exceeded an age-dependent threshold. Furthermore, a probabilistic method was applied to predict the probability of sustaining a certain number of fractured ribs by comparing local strain values to the distribution of cortical rib ultimate strain. By relating the output from the HBM simulations to a multi-point dummy injury criterion, injury risk curves were calculated by statistical methods. The wide range of loading conditions resulted in the desired range of injuries and THOR ATD output. The number of fractured ribs predicted by the HBM based on the deterministic prediction method was between 0 and 15. Furthermore, the probabilistic risk for the number of rib fractures equal or greater than two, three or four was calculated for each load case. The THOR rib deflection criterion Rmax was between 18 and 56 mm, while the PC Score was in the range of 2.5 to 7.2. Based on these outputs new risk curves for the predicted deterministic (AIS2+/3+) and probabilistic injury risk were calculated. The new curves show reasonable shapes and significance that provide trust in their application. The new risk curves are compared to risk curves obtained by traditional methods. The results were found similar to previous injury risk functions based on physical tests, which gives a high level of confidence in the chosen approach. The simulation-based approach of matched ATD model vs. HBM simulation was successfully applied. Rmax curves show a slightly better quality than the injury criterion PC Score.
A flexible pedestrian legform impactor (FlexPLI) has been evaluated by a Technical Evaluation Group (Flex-TEG) of the Working Party on Passive Safety (GRSP) of the United Nations Economic Commission for Europe (UN-ECE). It will be implemented within phase 2 of the global technical regulation (GTR 9) as well as within a new ECE regulation on pedestrian safety as a test tool for the assessment of lower extremity injuries in lateral vehicle-to-pedestrian accidents (UN-ECE 2010-1, 2010-2 and 2010-3). Due to its biofidelic properties in the knee and tibia section, the FlexPLI is found to having an improved knee and tibia injury assessment ability when being compared to the current legislative test tool, the lower legform impactor developed by the Pedestrian Safety Working Group of the European Enhanced Vehicle-safety Committee (EEVC WG 17). However, due to a lack of biofidelity in terms of kinematics and loadings in the femur part of the FlexPLI, an appropriate assessment of femur injuries is still outstanding. The study described in this paper is aimed to close this gap. Impactor tests with the FlexPLI at different impact heights on three vehicle frontends with Sedan, SUV and FFV shape are performed and compared to tests with a modified FlexPLI with upper body mass. Full scale validation tests using a modified crash test dummy with attached FlexPLI that are carried out for the first time prove the more humanlike responses of the femur section with applied upper body mass. Apart from that they also show that the impact conditions described in the current technical provisions for tests with the FlexPLI don"t necessarily compensate the missing torso mass in terms of knee and tibia loadings either. Therefore it can be concluded that an applied upper body mass will contribute to a more biofidelic overall behavior of the legform and subsequently an improved injury assessment ability of all lower extremity injuries addressed by the FlexPLI. Nevertheless, the validity of the original as well as the modified legform for tests against vehicles with extraordinary high bumpers as well as flat front vehicles still needs to be evaluated in detail. A first clue is given by the application of an additional accelerometer to the legform.
Thoracic injury is one of the predominant types of severe injuries in frontal accidents. The assessment of the injury risk to the thorax in the current frontal impact test procedures is based on the uni-axial chest deflection measured in the dummy Hybrid III. Several studies have shown that criteria based on the linear chest potentiometer are not sensitive enough to distinguish between different restraint systems, and cannot indicate asymmetric chest loading, which has been shown to correlate to increased injury risk. Furthermore, the measurement is sensitive to belt position on the dummy chest. The objective of this study was to evaluate the optical multipoint chest deflection measurement system "RibEye" in frontal impact sled tests. Therefore the sensitivity of the RibEyesystem to different restraint system parameters was investigated. Furthermore, the issue of signal drop out at the 6 th rib was investigated in this study.A series of sled tests were conducted with the RibEye system in the Hybrid III 50%. The sled environment consisted of a rigid seat and a standard production three-point seat belt system. Rib deflections were recorded with the RibEye system and additionally with the standard chest potentiometer. The tests were carried out at crash pulses of two different velocities (30 km/h and 64 km/h). The tests were conducted with different belt routing to investigate the sensitivity of chest deflection measurements to belt position on the dummy chest. Furthermore, different restraint system parameters were investigated (force limiter level, with or without pretensioning) to evaluate if the RibEye measurements provide additional information to distinguish between restraint system configurations . The results showed that with the RibEye system it was possible to identify the effect of belt routing in more detail. The chest deflections measured with the standard chest potentiometer as well as the maximum deflection measured by RibEye allowed the distinction to be made between different force limiter levels. The RibEye system was also able to clearly show the asymmetric deflection of the rib cage due to belt loading. In some configurations, differences of more than 15 mm were observed between the left and side areas of the chest. Furthermore, the abdomen insert was identified as source of the problem of signal drop out at the 6th rib. Possible solutions are discussed. In conclusion, the RibEye system provided valuable additional information regarding the assessment of restraint systems. It has the potential to enable the evaluation of thoracic injury risk due to asymmetric loading. Further investigations with the RibEye should be extended to tests in a vehicle environment, which include a vehicle seat and other restraint system components such as an airbag.
Evaluation of the performance of competitive headforms as test tools for interior headform testing
(2009)
The European Research Project APROSYS has evaluated the interior headform test procedure developed by EEVC WG 13, representing the head contact in the car during a lateral impact. One important aspect within this test procedure was the selection of an appropriate impactor. The WG13 procedure currently uses the Free Motion Headform as used within the FMVSS 201. The ACEA 3.5 kg headform used in Phase 1 of the European Directive and the future European Regulation on Pedestrian Protection is still discussed as a possible alternative. This paper reports work performed by the Federal Highway Research Institute (BASt) as a part of the APROSYS Task 1.1.3. The study compares the two headform impactors according to FMVSS and ACEA, in a series of basic tests in order to evaluate their sensitivity towards different impact angles, impact accuracy, the effect of differences to impactors of the same type and the effects of the repeatability and reproducibility of the test results. The test surface consisted of a steel tube covered with PU foam and PVC, representing the car interior to be tested. Despite of the higher mass of the FMH the HIC values of this impactor were generally lower than those of the ACEA headform. The FMH showed a higher repeatability of test results but a high sensitivity on the angle of roll, the spherical ACEA impactor performed better with regards to the reproducibility. In case of the ACEA impactor-, the angle of roll had no influence.