In spite of today's highly sophisticated crash test procedures like the different NCAP programs running world-wide, bad real world crash performance of cars is still an issue. There are crash situations which are not sufficiently represented by actual test configurations. This is especially true for car to car, as well as for car to object impacts. The paper describes reasons for this bad performance. The reasons are in principal bad structural interaction between the car and its impact partners (geometric incompatibility), unadjusted front end stiffness (stiffness incompatibility) and collapse of passenger compartments. To show the efficiency of improving cars' structural behaviour in accidents with different impact partners an accident data analysis has been taken out by members of European Project VC-COMPAT. Accident data analysis has shown that in Germany between 15,000 and 20,000 of the now severely injured car occupants might get less injured and between 600 and 900 car occupant fatalities might be saved. Similar results arise for the UK.
Today, Euro NCAP is a well established rating system for passive car safety. The significance of the ratings must however be evaluated by comparison with national accident data. For this purpose accidents with involvement of two passenger cars have been taken from the German National Road Accident Register (record years 1998 to 2004) to evaluate the results of the NCAP frontal impact test configuration. Injury data from both drivers involved in frontal car to car collisions have been sampled and have been compared, using a "Bradley Terry Model" which is well established in the area of paired comparisons. Confounders " like mass ratio of the cars involved, gender of the driver, etc. " have been accounted for in the statistical model. Applying the Bradley Terry Model to the national accident data the safety ranking from Euro NCAP has been validated (safety level: 1star <2 star <3 star <4 star). Significant safety differences are found between cars of the 1 and 2 star category as compared to cars of the 3 and 4 star category. The impact of the mass ratio was highly significant and most influential. Changing the mass ratio by an amount of 10% will raise the chance for the driver of the heavier car to get better off by about 18%. The impact of driver gender was again highly significant, showing a nearly 2 times lower injury risk for male drivers. With regard to the NCAP rating drivers of a high rated car are more than 2 times more probable (70% chance) to get off less injured in a frontal collision as compared to the driver of a low rated car.