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For the assessment of vehicle safety in frontal collisions compatibility (which consists of self and partner protection) between opponents is crucial. Although compatibility has been analysed worldwide for over 10 years, no final assessment approach has been defined to date. Taking into account the European Enhanced Vehicle safety Committee (EEVC) compatibility and the final report to the steering committee on frontal impact [Faerber 2007] and the FP5 VC-COMPAT[Edwards 2007] project activities, two test approaches were identified as the most promising candidates for the assessment of compatibility. Both are composed of an off-set and a full overlap test procedure. In addition another procedure (a test with a moving deformable barrier) is getting more attention in current research programmes. The overall objective of the FIMCAR project is to complete the development of the candidate test procedures and propose a set of test procedures suitable for regulatory application to assess and control a vehicle- frontal impact and compatibility crash safety. In addition an associated cost benefit analysis will be performed. In the FIMCAR Deliverable D 3.1 [Adolph 2013] the development and assessment of criteria and associated performance limits for the full width test procedure were reported. In this Deliverable D3.2 analyses of the test data (full width tests, car-to-car tests and component tests), further development and validation of the full width assessment protocol and development of the load cell and load cell wall specification are reported. The FIMCAR full-width assessment procedure consists of a 50 km/h test against the Full Width Deformable Barrier (FWDB). The Load Cell Wall behind the deformable element assesses whether or not important Energy Absorbing Structures are within the Common Interaction Zone as defined based on the US part 581 zone. The metric evaluates the row forces and requires that the forces directly above and below the centre line of the Common Interaction Zone exceed a minimum threshold. Analysis of the load spreading showed that metrics that rely on sum forces of rows and columns are within acceptable tolerances. Furthermore it was concluded that the Repeatability and Reproducibility of the FWDB test is acceptable. The FWDB test was shown to be capable to detect lower load paths that are beneficial in car-to-car impacts.
Frontal impact is still the most relevant impact direction in terms of injury causation amongst car occupants. Especially for car-to-car frontal impacts the mass ratio between the involved vehicles has a significant impact on the injury risk (the heavier the opponent car the higher the injury risk). In order to address this issue frontal Mobile Deformable Barrier test procedures have been developed world-wide (for example the MPDB procedure that was fully described during the FIMCAR Project). The objective of this study was to investigate how vehicles of different weight classes perform in a mobile barrier test procedure compared to a fixed barrier test procedure (the full width rigid and offset deformable barrier test). Beyond that, the influence of vehicle mass and vehicle deformation on injuries was evaluated based on real world accident data. Five vehicle types were selected and tested in a fixed offset test procedure (ODB), a full width rigid barrier test procedure (FWRB) and a mobile offset test procedure (MPDB). For the accident analyses data from the German In-Depth Accident Study (GIDAS) was evaluated with a focus on MAIS 2+ injured belted front row car (UN-R 94 compliant cars) occupants in frontal impact accidents. Test data indicates higher dummy loadings, in particular for the head acceleration and chest acceleration, in the MPDB test for the vehicles with a mass lighter than the trolley (1,500 kg) compared to the FWRB test. The trend of increased vehicle stiffness (especially illustrated by tests with the MPDB and small cars) shows the need of a further improvement of passive restraint systems to reduce the occupant loading and with it the injury risk. The analyzed GIDAS data confirm the higher injury risk for occupants in cars with an accident weight of less than 1,500 kg compared to those with a crash weight above 1,500 kg in car-to-car and car-to-object or car-to-HGV, respectively. Furthermore the injury risk increases with decreasing mass ratio (i.e., the opponent car is heavier) in car-to-car accidents. Independent from the higher injury risk, the risk for passenger compartment intrusion in frontal impact appears not to be independent on the crash weight of the car.