91 Fahrzeugkonstruktion
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The objective was to develop and validate a crash trolley (reference vehicle) equipped with a compartment and a full restraint system for driver and front seat passenger which can be used in full scale crash testing. Furthermore, the crash trolley should have a suspension to show rotation and nick effects similar to real vehicles. Within the development phase the reference vehicle was build based on a European family car. Special attention was needed to provide appropriate strength to the trolley and its suspension. The reference vehicle is equipped with a restraint system consisting of airbags, pedals, seats, dashboard, and windscreen. On the front of the vehicle different crash barriers can be installed to provide miscellaneous deceleration pulses. For the validation phase a series of low and high speed crash tests with HIII dummies were conducted and compared with full scale tests. For the comparison deceleration pulse, dummy numbers and vehicle movement were analyzed. Validation tests with velocities up to 60 km/h showed promising results. The compartment and the suspension systems stayed stable. Rotation effects were comparable with full scale car crash tests. The airbags and seat belt system worked reasonable. The acceleration pulse compared to an Euro NCAP test had a similar characteristic but was in general slightly lower. After the successful validation the reference vehicle is already in use in different studies in the field of vehicle safety research at BASt.
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.
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.
Die UNECE Regelung R58 regelt die Beschaffenheit und die Installation von Heckunterfahrschutzsystemen an schweren Güterkraftfahrzeugen, deren Ziel die Verbesserung der Kompabilität zwischen Pkw-Frontstrukturen und Lkw-Hecks ist. Dennoch verunglücken laut amtlicher Unfallstatistik allein in Deutschland rund 30 Pkw-Insassen in Heckauffahrunfällen auf Lkw tödlich, da diese Vorrichtungen hinsichtlich Einbauhöhe und Steifigkeit den Anforderungen des realen Unfallgeschehens nicht genügen. Das Ziel dieser Studie ist eine quantitative Abschätzung der möglichen Reduzierung der Verletzungsschwere mit Hilfe eines statistischen Modells, die durch eine Anpassung der geltenden Bestimmungen und die damit verbundenen technischen Veränderungen des bereits vorgeschriebenen Heckunterfahrschutzes zu erreichen wäre. In einer Nutzen-Kosten-Analyse wird die Wirtschaftlichkeit dieser Modifizierungen mit einem idealen Notbremsassistenten verglichen. Die Untersuchung orientiert sich dabei an den aktuell in der UN-ECE WP29/GRSG in Genf diskutierten Vorschlägen zur Anpassung der ECE-R58. Das verwendete ordinale Probit-Modell stellt einen Zusammenhang zwischen der Verletzungsschwere im auffahrenden PKW und erklärenden Größen her, in diesem Fall der kinetischen Energie des unterfahrenden Pkws und der strukturellen lnteraktion zwischen Lkw-Heck und Pkw-Front. Diese Maßnahmen könnten demnach 53 - 78% der Getöteten sowie 27 - 49% der Schwerverletzten bei diesen Unfallkonstellationen reduzieren, was pro Jahr 20 Getöteten und 95 Schwerverletzten entsprechen würde. Somit würde eine Modifikation einer bestehenden passiven Schutzmaßnahme an jährlich 100.000 neuzugelassenen Lkw und Anhängern bereits 20 Getötete adressieren. Im Vergleich dazu müssten jährlich 3 Millionen Pkw mit zusätzlicher Sensorik und Aktuatorik für einen idealen Notbremsassistenten ausgestattet werden, um im Idealfall alle Heckauffahrunfälle von Pkw auf andere Pkw oder Lkw und damit 53 Getötete zu vermeiden. Daher fällt auch das Nutzen-Kosten-Verhältnis deutlich zugunsten des verbesserten Heckunterfahrschutzes aus.
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.
EEVC Working Group 15 (Compatibility Between Passenger Cars) has carried out research for several years thanks to collaborative project funded by the E.C. and also by exchanging results of projects funded by national programmes. The main collaborative activity of the EEVC WG15 for the last four years was a research project partly funded by the European Commission, where the group made the first attempt to investigate compatibility between passenger cars in a comprehensive research program. Accident, crash test, and mathematical modelling data were analysed. The main result was that structural incompatibilities were frequently found and identified as the main source of incompatibility problems but were not easy to quantify. Unfortunately as little vehicle information other than mass is recorded in most accident databases, most analyses have only been able to show the effect of mass or mass ratio. Common ideas to improve compatibility have been reached by this group and from discussion with other research groups. They will be investigated in the next phase, where research work will concentrate on the development of methods to assess compatibility of passenger cars. The main idea is that the prerequisite to improve crash compatibility between cars is to improve structural interaction. The most important issue is that improved compatibility must not compromise a vehicle- self protection. Test methods should lead to vehicles which show good structural interaction in car to car accidents. Test methods to prove good compatibility may be an adaptation of existing regulatory test procedures (offset deformable barrier test or full width test like in the USA) for frontal impact or may be new compatibility tests. Additional criteria, e.g. impact force distribution, and maximum vehicle deceleration or maximum vehicle impact force should result in compatible cars. Attempts will be made to estimate the benefit of a more compatible car fleet for the European Community.
EEVC Status report
(2001)
Mit der EU-Verordnung Nummer 661/2009 zur Typgenehmigung und allgemeinen Sicherheit von Kraftfahrzeugen wird von der EU für schwere Nutzfahrzeuge der Einbau von Spurverlassenswarnsystemen und automatischen Notbremssystemen vorgeschrieben. Mit dem obligatorischen Einbau der Systeme wird eine Reduktion der Abkommens- und Auffahrunfälle von Nutzfahrzeugen aus den Klassen M2, M3, N2 und N3, die auf Grund der hohen Masse der Fahrzeuge folgenschwer sind, erwartet. Als Einführungsdaten werden der 1. November 2013 für neue Fahrzeugtypen und der 1. November 2015 für neue Fahrzeuge genannt. Leistungsanforderungen beziehungsweise technische Spezifikationen, denen die Systeme genügen müssen, liegen jedoch noch nicht vor. Diese werden derzeit von einer Expertengruppe auf UN-ECE-Ebene entwickelt. Dabei wird versucht, technologieneutrale Beschreibungen für die Ausgestaltung der Systeme zu erstellen, die gleichzeitig sowohl den gewünschten Nutzen für die Verkehrssicherheit garantieren, sich aber auch an der derzeit vorhandenen und realisierbaren Technologie orientieren. Darüber hinaus müssen die Systemkosten in einem vernünftigen Verhältnis zum Sicherheitsnutzen stehen. Ziel ist es, im Laufe des Jahres 2011 Vorschläge für die Legislative vorzulegen. Es wird über den Stand der Arbeiten, offene Fragestellungen, Herausforderungen bei der Ausgestaltung der technischen Anforderungen sowie sich abzeichnende Ergebnisse berichtet. Dabei sind die Arbeiten in Bezug auf Lane Departure Warning Systems (LDWS) bereits weiter fortgeschritten als zu Advanced Emergency Braking Systems (AEBS).
In the last years there has been a decline in accident figures in Germany especially for four wheeled vehicles. At the same time, accident figures for motorcycles remained nearly constant. About 17 % of road traffic fatalities in the year 2006 were motorcyclists. 33 % of these riders were killed in single vehicle crashes. This leads to the conclusion that improving driving dynamics and driving stability of powered two wheelers would yield considerable safety gains. However, the well-known measures for cars and trucks with their proven effectiveness cannot be transferred easily to motorcycles. Therefore studies were carried out to examine the safety potential of Anti Lock Braking Systems (ABS) and Vehicle Stability Control (VSC) for motorcycles by means of accident analysis, driving tests and economical as well as technical assessment of the systems. With regard to ABS, test persons were assigned braking tasks (straight and in-curve) with five different brake systems with and without ABS. Stopping distances as well as stress and strain on the riders were measured for 9 test riders who completed 105 braking manoeuvres each. Knowing the ability of ABS to avoid falls during braking in advance of a crash and taking into account the system costs, a cost benefit analysis for ABS for motorcycles was carried out for different market penetration of ABS, i.e. equipment rates, and different time horizons. The potential of VSC for motorcycles was estimated in two steps. First the kinds of accidents that could be prevented by such a system at all have been analysed. For these accident configurations, simulations and driving tests were then performed to determine if a VSC was able to detect the critical driving situation and if it was technically possible to implement an actuator which would help to stabilise the critical situation.
For the assessment of vehicle safety in frontal collisions, the crash compatibility between the colliding vehicles is crucial. Compatibility compromises both the self protection and the partner protection properties of vehicles. For the accident data analysis, the CCIS (GB) and GIDAS (DE) in-depth data bases were used. Selection criteria were frontal car accidents with car in compliance with ECE R94. For this study belted adult occupants in the front seats sustaining MAIS 2+ injuries were studied. Following this analysis FIMCAR concluded that the following compatibility issues are relevant: - Poor structural interaction (especially low overlap and over/underriding) - Compartment strength - Frontal force mismatch with lower priority than poor structural interaction In addition injuries arising from the acceleration loading of the occupant are present in a significant portion of frontal crashes. Based on the findings of the accident analysis the aims that shall be addressed by the proposed assessment approach were defined and priorities were allocated to them. The aims and priorities shall help to decide on suitable test procedures and appropriate metrics. In general it is anticipated that a full overlap and off-set test procedure is the most appropriate set of tests to assess a vehicle- frontal impact self and partner protection.