The head impact of pedestrians in the windscreen area shows a high relevance in real-world accidents. Nevertheless, there are neither biomechanical limits nor elaborated testing procedures available. Furthermore, the development of deployable protection systems like pop-up bonnets or external airbags has made faster progress than the corresponding testing methods. New requirements which are currently not considered are taken into account within a research project of BASt and the EC funded APROSYS (Advanced PROtection SYStems) integrated project relating to passive pedestrian protection. Testing procedures for head impact in the windscreen area should address these new boundary conditions. The presented modular procedure combines the advantages of virtual testing, including full-scale multi-body and finite element simulations, as well as hardware testing containing impactor tests based on the existing procedures of EEVC WG 17. To meet the efforts of harmonization in legislation, it refers to the Global Technical Regulation of UNECE (GTR No. 9). The basis for this combined hardware and virtual testing procedure is a robust categorization covering all passenger cars and light commercial vehicles and defining the testing zone including the related kinematics. The virtual testing part supports also the choice of the impact points for the hardware test and determines head impact timing for testing deployable systems. The assessment of the neck rotation angle and sharp edge contact in the rear gap of pop-up bonnets is included. For the demonstration of this procedure, a hardware sedan shaped vehicle was modified by integrating an airbag system. In addition, tests with the Honda Polar-II Dummy were performed for an evaluation of the new testing procedure. Comparing these results, it was concluded that a combination of simulation and updated subsystem tests forms an important step towards enhanced future pedestrian safety systems considering the windscreen area and the deployable systems.
For a number of EU regulatory acts Virtual Testing (VT) is already allowed for type approval (see Commission Regulation No. 371/2010 of 16 April 2010 amending the Framework Directive 2007/46/EC). However, only a very general procedure on how to apply VT for type approval is provided. Technical details for specific regulatory acts are not given yet. The main objective of the European project IMVITER (IMplementation of VIrtual TEsting in Safety Regulations) was to promote the implementation of VT in safety regulations. When proposing VT procedures the new regulation was taken into account, in particular, addressing open issues. Special attention was paid to pedestrian protection as pilot cases. A key aspect for VT implementation is to demonstrate that the employed simulation models are reliable. This paper describes how the Verification and Validation (V&V) method defined by the American Society of Mechanical Engineers was adapted for pedestrian protection VT based assessment. or the certification of headform impactors an extensive study was performed at two laboratories to assess the variability in calibration tests and equivalent results from a set of simulation models. Based on these results a methodology is defined for certification of headform impactor simulation models. A similar study was also performed with one vehicle in the type approval test setup. Its bonnet was highly instrumented and subjected to 45 impacts in five different positions at two laboratories in order to obtain an estimation of the variability in the physical tests. An equivalent study was performed using stochastic simulation with a metamodel fed with observed variability in impact conditions of physical headforms. An estimation of the test method uncertainty was obtained and used in the definition of a validation corridor for simulation models. Validation metric and criteria were defined in cooperation with the ISO TC22 SC10 and SC12 WG4 "Virtual Testing". A complete validation procedure including different test setups, physical magnitudes and evaluation criteria is provided. A detailed procedural flowchart is developed for VT implementation in EC Regulation No 78/2009 based on a so called "Hybrid VT" approach, which combines real hardware based head impact tests and simulations. This detailed flowchart is shown and explained within this paper. Another important point within the virtual testing based procedures is the documentation of relevant information resulting from the verification and validation process of the numerical models used. For this purpose report templates were developed within the project. The proposed procedure fixes minimum V&V requirements for numerical models to be confidently used within the type-approval process. It is not intended to be a thorough guide on how to build such reliable models. Different modeling methodologies are therefore possible, according to particular OEM know-how. These requirements respond to a balance amongst the type-approval stakeholders interests. A cost-benefit analysis, which was also performed within the IMVITER project, supports this approach, showing the conditions in which VT implementation is beneficial. Based on the experience gained in the project and the background of the experts involved an outlook is given as a roadmap of VT implementation, identifying the most important milestones to be reached along the way to a future vehicle type approval procedure supported by VT. The results presented in this paper show an important step addressing open questions and fostering the future acceptance of virtual testing in pedestrian protection type approval procedures.
Recent accident statistics from the German national database state bicyclists being the second endangered group of vulnerable road users besides pedestrians. With 399 fatalities, more than 14.000 seriously injured and more than 61.000 slightly injured persons on german roads in the year 2011, the group of bicyclists is ranked second of all road user groups (Statistisches Bundesamt, 2012). While the overall bicycle helmet usage frequency in Germany is very low, evidence is given that its usage leads to a significant reduction of severe head injuries. After an estimation of the benefit of bicycle helmet usage as well as an appropriate test procedure for bicyclists, this paper describes two different approaches for the improvement of bicyclist safety. While the first one is focusing on the assessment of the vehicle based protection potential for bicyclists, the second one is concentrating on the safety assessment of bicycle helmets. Within the first part of the study the possible revision of the existing pedestrian testing protocols is being examined, using in depth accident data, full scale simulation and hardware testing. Within the second part of the study, the results of tests according to supplemental test procedures for the safety assessment of bicycle helmets developed by the German Federal Highway Research Institute (BASt) are presented. An additional full scale test performed at reduced impact speed proves that measures of active vehicle safety as e.g. braking before the collision event do not necessarily always lead to a reduction of injury severity.
Test and assessment procedures for passive pedestrian protection based on developments by the European Enhanced Vehicle-safety Committee (EEVC) have been introduced in world-wide regulations and consumer test programmes, with considerable harmonization between these programmes. Nevertheless, latest accident investigations reveal a stagnation of pedestrian fatality numbers on European roads running the risk of not meeting the European Union- goal of halving the number of road fatalities by the year 2020. The branch of external road user safety within the EC-funded research project SENIORS under the HORIZON 2020 framework programme focuses on investigating the benefit of modifications to pedestrian test and assessment procedures and their impactors for vulnerable road users with focus on the elderly. Injury patterns of pedestrians and cyclists derived from the German In-Depth Accident Study (GIDAS) show a trend of AIS 2+ and AIS 3+ injuries getting more relevant for the thorax region in crashes with newer cars (Wisch et al., 2017), while maintaining the relevance for head and lower extremities. Several crash databases from Europe such as GIDAS and the Swedish Traffic Accident Data Acquisition (STRADA) also show that head, thorax and lower extremities are the key affected body regions not only for the average population but in particular for the elderly. Therefore, the SENIORS project is focusing on an improvement of currently available impactors and procedures in terms of biofidelity and injury assessment ability towards a better protection of the affected body regions, incorporating previous results from FP 6 project APROSYS and subsequent studies carried out by BASt. The paper describes the overall methodology to develop revised FE impactor models. Matched human body model and impactor simulations against generic test rigs provide transfer functions that will be used for the derivation of impactor criteria from human injury risk functions for the affected body regions. In a later step, the refined impactors will be validated by simulations against actual vehicle front-ends. Prototyping and adaptation of test and assessment procedures as well as an impact assessment will conclude the work of the project at the final stage. The work will contribute to an improved protection of vulnerable road users focusing on the elderly. The use of advanced human body models to develop applicable assessment criteria for the revised impactors is intended to cope with the paucity of actual biomechanical data focusing on elderly pedestrians. In order to achieve optimized results in the future, the improved test methods need to be implemented within an integrated approach, combining active with passive safety measures. In order to address the developments in road accidents and injury patterns of vulnerable road users, established test and assessment procedures need to be continuously verified and, where needed, to be revised. The demographic change as well as changes in the vehicle fleet, leading to a variation of accident scenarios, injury frequencies and injury patterns of vulnerable road users are addressed by the work provided by the SENIORS project, introducing updated impactors for pedestrian test and assessment procedures.
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.
Test and assessment procedures for passive pedestrian protection of passenger cars are in place for many years within world-wide regulations as well as consumer test programmes. Nevertheless, recent accident investigations show a stagnation of pedestrian fatality numbers on European roads alongside increasing injury severities for older road users. The EU-funded SENIORS (Safety ENhancing Innovations for Older Road userS) project developed and evaluated a thorax injury prediction tool (TIPT) for later incorporation within test and assessment procedures. Accident data indicates an increasing portion of AIS2 and AIS3+ thoracic injuries of older pedestrians and cyclists which are currently not assessed in any test procedure for vulnerable road users. Therefore, SENIORS focused on the development of a test tool predicting the risk of rib fractures of vulnerable road users (VRU). While injury risk functions were reanalyzed, human body model (HBM) simulations against categorized generic vehicle frontends served as input for the definition of test setups and corresponding impact parameters. TIPT component tests against a generic frontend and an actual vehicle were used for the evaluation of the technical feasibility. The TIPT component tests shows the general feasibility of a test procedure for the assessment of thoracic injuries, with good repeatability and reproducibility of kinematics and results. Impact parameters such as the inclination angles of the thorax, angles of the velocity vector and impact speeds well replicate the parameters gained from the HBM simulations. The proposed markup and assessment scheme offers the possibility of a homogeneous evaluation of the protection potential of vehicle frontends while maintaining justifiable testing efforts. During evaluation testing, the proposed requirements were entirely met. The developed prototype of TIPT and launching system offer impact angles and speeds as suggested by HBM simulations. However, since thorax impacts during pedestrian accidents do not occur perpendicularly to the vehicle surface in most cases, the TIPT built-in linear potentiometers do not acquire the true resultant intrusions on the ribcage and thus, TIPT rib deflections do not reflect the actual human injury risk. However; for the impact forward to the bonnet leading edge, the TIPT seems applicable without further modifications. The test and assessment procedures using the TIPT offer for the first time the possibility of replicating the kinematics of a pedestrian thorax with a component test. The developed assessment scheme gives a first indication on how the risk for thoracic injuries could be implemented within the Euro NCAP Box 3 assessment. Future development of the TIPT may focus on implementing a rib cage that can deflect in all axes in a humanlike way.