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One main objective of the EU-Project SENIORS is to provide improved methods to assess thoracic injury risk to elderly occupants. In contribution to this task paired simulations with a THOR dummy model and human body model will be used to develop improved thoracic injury risk functions. The simulation results can provide data for injury criteria development in chest loading conditions that are underrepresented in PMHS test data sets that currently proposed risk functions are based on. To support this approach a new simplified generic but representative sled test fixture and CAE model for testing and simulation were developed. The parameter definition and evaluation of this sled test fixture and model is presented in this paper. The justification and definition of requirements for this test set-up was based on experience from earlier studies. Simple test fixtures like the gold standard sled fixture are easy to build and also to model in CAE, but provide too severe belt-only loading. On the other hand a vehicle buck including production components like airbag and seat is more representative, but difficult to model and to be replicated at a different laboratory. Furthermore some components might not be available for physical tests at later stage. The basis of the SENIORS generic sled test set-up is the gold standard fixture with a cable seat back and foot rest. No knee restraint was used. The seat pan design was modified including a seat ramp. The three-point belt system had a generic adjustable load limiter. A pre-inflated driver airbag assembly was developed for the test fixture. Results of THOR test and simulations in different configurations will be presented. The configurations include different deceleration pulses. Further parameter variations are related to the restraint system including belt geometry and load limiter levels. Additionally different settings of the generic airbag were evaluated. The test set-up was evaluated and optimized in tests with the THOR-M dummy in different test configurations. Belt restraint parameters like D-ring position and load limiter setting were modified to provide moderate chest loading to the occupant. This resulted in dummy readings more representative of the loading in a contemporary vehicle than most available PMHS sled tests reported in the literature. However, to achieve a loading configuration that exposes the occupant to even less severe loading comparable to modern vehicle restraints it might be necessary to further modify the test set-up. The new generic sled test set-up and a corresponding CAE model were developed and applied in tests and simulations with THOR. Within the SENIORS project with this test set-up also volunteer and PMHS as well as HBM simulations are performed, which will be reported in other publications. The test environment can contribute in future studies to the assessment of existing and new frontal impact dummies as well as dummy improvements and related instrumentation. The test set-up and model could also serve as a new standard test environment for PMHS and volunteer tests as well as HBM simulations.
In the EC FP6 Integrated Project Advanced Protection Systems, APROSYS, the first WorldSID small female prototype was developed and evaluated by BASt, FTSS, INRETS, TRL and UPM-INSIA during 2006 and 2007. Results were presented at the ESV 2007 conference (Been et al., 2007). With the prototype dummy scoring a biofidelity rating higher than 6.7 out of 10 according to ISO/TR9790, the results were very promising. Also opportunities for further development were identified by the evaluation group. A revised prototype, Revision1, was subsequently developed in the 2007-2008 period to address comments from the evaluation group. The Revision1 dummy includes changes in the half arms and the suit (anthropometry and arm biomechanics), the thorax and abdomen ribs and sternum (rib durability), the abdomen/lumbar area and the lower legs (mass distribution). Also a two-dimensional chest deflection measurement system was developed to measure deflection in both lateral and anterior-posterior direction to improve oblique thorax loading sensitivity. Two Revision1 prototype dummies have now been evaluated by FTSS, TRL, UPM-INSIA and BASt. The updated prototype dummies were subjected to an extensive matrix of biomechanical tests, such as full body pendulum tests and lateral sled impact tests as specified by Wayne State University, Heidelberg University and Medical College of Wisconsin. The results indicated a significant improvement of dummy biofidelity. The overall dummy biofidelity in the ISO rating system has significantly improved from 6.7 to 7.6 on a scale between 0-10. The small female WorldSID has now obtained the same biofidelity rating as the WorldSID mid size male dummy. Also repeatability improved with respect to the prototype. In conclusion the recommended updates were all executed and all successfully contributed in achieving improved performance of the dummy.
Thoracic injuries are one of the main causes of fatally and severely injured casualties in car crashes. Advances in restraint system technology and airbags may be needed to address this problem; however, the crash test dummies available today for studying these injuries have limitations that prevent them from being able to demonstrate the benefits of such innovations. THORAX-FP7 was a collaborative medium scale project under the European Seventh Framework. It focused on the mitigation and prevention of thoracic injuries through an improved understanding of the thoracic injury mechanisms and the implementation of this understanding in an updated design for the thorax-shoulder complex of the THOR dummy. The updated dummy should enable the design and evaluation of advanced restraint systems for a wide variety (gender, age and size) of car occupants. The hardware development involved five steps: 1) Identification of the dominant thoracic injury types from field data, 2) Specification of biomechanical requirements, 3) Identification of injury parameters and necessary instrumentation, 4) Dummy hardware development and 5) Evaluation of the demonstrator dummy. The activities resulted in the definition of new biofidelity and instrumentation requirements for an updated thorax-shoulder complex. Prototype versions were realised and implemented in three THOR dummies for biomechanical evaluation testing. This paper documents the hardware developments and biomechanical evaluation testing carried out.
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.