Abteilung Fahrzeugtechnik
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.
Within this paper different European accident data sources were used to investigate the causations and backgrounds of road traffic accidents with pedestrians. Analyses of high level national data and in-depth accident data from Germany and Great Britain was used to confirm and refine preliminary accident scenarios identified from other sources using a literature review. General observations made included that a high proportion of killed or seriously injured pedestrian casualties impacted by cars were in "dark" light conditions. Seven accident scenarios were identified (each divided into "daylight" and "dark" light conditions) which included the majority of the car front-to-pedestrian crash configurations. Test scenarios were developed using the identified accident scenarios and relevant parameters. Hypothetical parameters were derived to describe the performance of pedestrian pre-crash systems based on the assumption that these systems are designed to avoid false positives as a very high priority, i.e. at virtually all costs. As result, three "Base Test Scenarios" were selected to be developed in detail in the AsPeCSS project. However, further Enhanced Test Scenarios may be needed to address environmental factors such as darkness if it is determined that system performance is sensitive to these factors. Finally, weighting factors for the accident scenarios for Europe (EU-27) were developed by averaging and extrapolation of the available data. This paper represents interim results of Work Package 1 within the AsPeCSS project.
In Germany the number of casualties in passenger car to pedestrian crashes has been reduced by a considerable amount of 40% as regards fatalities and 25% with regard to seriously injured pedestrians since the year 2001. Similar trends can be seen in other European countries. The reasons for that positive development are still under investigation. As infrastructural or behavioral changes do in general take a longer time to be effective in real world, explanations related to improved active and passive safety of passenger vehicles can be more relevant in providing answers for this trend. The effect of passive pedestrian protection " specified by the Euro NCAP pedestrian test result " is of particular interest and has already been analyzed by several authors. However, the number of vehicles with some valid Euro NCAP pedestrian score (post 2002 rating) was quite limited in most of those studies. To overcome this problem of small datasets German National Accident Records have been taken to investigate a similar objective but now based on a much bigger dataset. The paper uses German National Accident Records from the years 2009 to 2011. In total 65.140 records of pedestrian to passenger car crashes have been available. Considering crash parameters like accident location (rural / urban areas) etc., 27.143 of those crashes have been classified to be relevant for the analysis of passive pedestrian safety. In those 27.143 records 7.576 Euro NCAP rated vehicles (post 2002 rating) have been identified. In addition it was possible to identify vehicles which comply with pedestrian protection legislation (2003/102/EG) where phase 1 came into force in October 2005. A significant correlation between Euro NCAP pedestrian score and injury outcome in real-life car to pedestrian crashes was found. Comparing a vehicle scoring 5 points and a vehicle scoring 22 points, pedestrians" conditional probability of getting fatally injured is reduced by 35% (from 0.58% to 0.37%) for the later one. At the same time the probability of serious injuries can be reduced by 16% (from 27.4% to 22.9%). No significant injury reducing effect, associated with the introduction of pedestrian protection legislation (phase 1) was detected. Considerable effects have also been identified comparing diesel and gasoline cars. Higher engine displacements are associated with a lower injury risk for pedestrians. The most relevant parameter has been "time of accident", whereas pedestrians face a more than 2 times higher probability to be fatally injured during night and darkness as compared to daytime conditions.
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.
The ASSESS project is a collaborative project that develops test procedures for pre-crash safety systems like Automatic Emergency Braking (AEB). One key criterion for the effectiveness of e.g. AEB is reduction in collision speed compared to baseline scenarios without AEB. The speed reduction for a given system can only be determined in real world tests that will end with a collision. Soft targets that are crashable up to velocities of 80 km/h are state of the art for these assessments, but ordinary balloon cars are usually stationary targets. The ASSESS project goes one step further and defines scenarios with moving targets. These scenarios define vehicle speeds of up to 100 km/h, different collision scenarios and relative collision speeds of up to 80km/h. This paper describes the development of a propulsion system for a soft target that aims to be used with these demanding scenario specifications. The Federal Highway Research Institute- (BASt-) approach to move the target is a self-driving small cart. The cart is controlled either by a driver (open-loop control via remote-control) or by a computer (closed-loop control). Its weight is limited to achieve a good crashability without damages to the test vehicle. To the extent of our knowledge BASt- approach is unique in this field (other carts cannot move at such high velocities or are not crashable). This paper describes in detail the challenges and solutions that were found both for the mechanical construction and the implementation of the control and safety system. One example for the mechanical challenges is e.g. the position of the vehicle- center of gravity (CG). An optimum compromise had to be found between a low CG oriented to the front of the vehicle (good for driveability) and a high CG oriented to the rear of the vehicle (good for crashability). The soft target itself which is also developed within the ASSESS project will not be covered in detail as this is work of a project partner. Publications on this will follow. The paper also shows first test results, describes current limitations and gives an outlook. It is expected that the presented test tools for AEB and other pre-crash safety systems is introduced in the future into consumer testing (NCAP) as well as regulatory testing.
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.
The objectives of the FIMCAR (Frontal Impact and Compatibility Assessment Research) project are to answer the remaining open questions identified in earlier projects (such as understanding of the advantages and disadvantages of force based metrics and barrier deformation based metrics, confirmation of specific compatibility issues such as structural interaction, investigation of force matching) and to finalise the frontal impact test procedures required to assess compatibility. Research strategies and priorities were based on earlier research programs and the FIMCAR accident data analysis. The identified real world safety issues were used to develop a list of compatibility characteristics which were then prioritised within the consortium. This list was the basis for evaluating the different test candidates. This analysis resulted in the combination of the Full Width Deformable Barrier test (FWDB) with compatibility metrics and the existing Offset Deformable Barrier (ODB) as described in UN-ECE Regulation 94 with additional cabin integrity requirement as being proposed as the FIMCAR assessment approach. The proposed frontal impact assessment approach addresses many of the issues identified by the FIMCAR consortium but not all frontal impact and compatibility issues could be addressed.
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.
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 frontal impact working group (WG15) and the FP5 VC-COMPAT project activities, two test approaches have been 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 should be performed. The objectives of the work reported in this deliverable were to review existing full-width test procedures and their discussed compatibility metrics, to report recent activities and findings with respect to full-width assessment procedures and to assess test procedures and metrics. Starting with a review of previous work, candidate metrics and associated performance limits to assess a vehicle- structural interaction potential, in particular its structural alignment, have been developed for both the Full Width Deformable Barrier (FWDB) and Full Width Rigid Barrier (FWRB) tests. Initial work was performed to develop a concept to assess a vehicle- frontal force matching. However, based on the accident analyses performed within FIMCAR frontal force matching was not evaluated as a first priority and thus in line with FIMCAR strategy the focus was put on the development of metrics for the assessment of structural interaction which was evaluated as a first priority.
Cost benefit analysis
(2014)
Although the number of road accident casualties in Europe is falling the problem still remains substantial. In 2011 there were still over 30,000 road accident fatalities [EC 2012]. Approximately half of these were car occupants and about 60 percent of these occurred in frontal impacts. The next stage to improve a car- safety performance in frontal impacts is to improve its compatibility for car-to-car impacts and for collisions against objects and HGVs. Compatibility consists of improving both a car- self and partner protection in a manner such that there is good interaction with the collision partner and the impact energy is absorbed in the car- frontal structures in a controlled way which results in a reduction of injuries. Over the last ten years much research has been performed which has found that there are four main factors related to a car- compatibility [Edwards 2003, Edwards 2007]. These are structural interaction potential, frontal force matching, compartment strength and the compartment deceleration pulse and related restraint system performance. The objective of the FIMCAR FP7 EC-project was to develop an assessment approach suitable for regulatory application to control a car- frontal impact and compatibility crash performance and perform an associated cost benefit analysis for its implementation.