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Use of FE Simulations
to Parametrically Evaluate and Compare
Seat Belt Restraint Systems
and Related Injury Risk
in Heavy Truck Frontal Crash Conditions
2015 Traffic Safety Conference
Corpus Christi, Texas
June 09, 2015
Chiara Silvestri Dobrovolny, Ph.D.
Associate Research Scientist, TTI
Nathan Schulz
Graduate Research Assistant, TTI
Order of Presentation
 Background
 Objective
 Methodology
 FE Computer Models (Vehicle, ATD, Passive Restraint Systems)
 FE Computer Frontal Impact Simulations
 Results
 Future Research
Background
 Approximately 340,000 medium/heavy trucks involved in traffic
crashes per year in U.S.
 600 fatalities; 20,000 injuries to truck drivers
 Aggregate cost of crashes to society is $3.1 billion
 No existing standards for truck cab crashworthiness or occupant
protection in heavy truck crashes (although being discussed)
 Need of additional characterization of crash-injury, current heavy
truck crashworthiness, potential benefits of crashworthy structures
in heavy truck cabs
Objectives
TTI and UMTRI proposed jointly effort devoted to collect &
develop required information by:
 analyzing crash & travel datasets available at UMTRI and
TTI;
 identify frequencies & costs of types of heavy truck
crashes;
 estimate benefits of crashworthy structures in heavy trucks
to reduce death, injury, & societal costs of heavy truck
crashes
Methodology
FE Computer Models
Methodology – Big Picture
Heavy Truck ATD Seatbelt Airbag
FE Computer Simulations
 Frontal Impact (Wall)
 Parametric Variation Seatbelt
Properties
 ATD Injury Criteria
+ + +
Simplified Methodology
Crash pulse applied to cab mounts
Frontal Impact (Wall)
ATD Seatbelt Airbag
+ ++
Step 1
Develop Heavy Truck
Cabin Model
Current FE
Computer
Model
?
Computer Model – Heavy Truck
Need for
Occupant
Compartment
Interior
Heavy Truck Cabin Model
FE Model of
Cab-Over-Engine
Cabin*
* Developed by TTI under
project funded by Department
of State
Morphed
Conventional
Cab*
* As of Peterbilt 387
Step 2
Develop Heavy Truck
Interior Compartment
Heavy Truck Interior Compartment
Cloud Point Scans*
* Developed by UMTRI for Peterbilt 387
Heavy Truck Interior Compartment
Models developed
applying mesh
grid over cloud
points
Step 3
Inclusion of ATD
ATD Inclusion and Pre-Positioning
Existing LSTC Hybrid III 50% Male ATD
Step 4
Addition of Passive Restraint
Systems
Seatbelt Model
Original
*Developed by LSTC
for Passenger Car
Modified
*To fit Heavy Truck
Geometry
Original Modified
Seatbelt Model
Modified
*To fit Heavy Truck
Geometry
Airbag Model
Airbag - *Developed by NCAC
Folded Deployed
NCAC Heavy Truck
Step 5
Crash Pulse
Crash Pulse – 35 mph Frontal
Step 6
FE Parametric Simulations of
Frontal Impacts
Frontal Impacts – 35 mph
 Baseline
 No Pretensioner
 4 kN Load Limiter
 8 kN Load Limiter
 Lowered D-Ring
Step 7
ATD Injury Criteria
Evaluation
ATD Modeled Instrumentation
ATD Injury Criteria
Head Injury Criteria (HIC)
Head acceleration recorded during impact event
employed to calculate HIC
representing probability of head injury
ATD Injury Criteria
Comparison to IARV
Body Region Parameter IARV
Injury
Criteria
% of Critical Value
Head HIC 700 104 0.15
Neck Nij 1 0.78 0.78
Neck axial
tension(kN)
4.17 2.8 0.68
Chest Deflection (mm) 63 85 1.36
Lower
Extremity
Femur axial
force(kN)
-10 -4.7 0.47
Tibia Index 1 2.3 2.26
Tibia axial
force(kN)
-8 -9.3 1.16
Injury Assessment Reference Values (IARVs)
Injury event termed “unlikely” if associated injury value does not exceed IARVs
Comparison to IARV
Examples of Computer
Simulations
Frontal Simulations – No Airbag
No Airbag - Baseline No Airbag – No Pretensioner
Frontal Simulations – No Airbag
No Airbag – 4 kN Limit Load No Airbag – Lowered D-Ring
No Airbag – Injury Probability
Head
Chest
Neck
Baseline
When Adding Airbag…
Head Injury Probability
No Airbag Airbag
Neck Injury Probability
No Airbag Airbag
Conclusions
 35 mph w/OUT airbag and 8 kN load limiter produced lowest
injury criteria results for ATD.
 35 mph w/airbag and 4 kN load limiter produced lowest injury
criteria results for ATD.
 Inclusion of airbag resulted in significant reduction in
probability of neck injury
Future Research
 Validation of interior component material modelling (for
accurate deformation response of truck cabin interior)
 Realistic seat characteristics (suspensions)
 Development and analysis of additional restraint systems
 side curtain airbag system
 five point seatbelt
 …
Acknowledgements
 Robert Wunderlich (Associate Director, ATLAS Center, TTI) for
sponsoring the project through ATLAS Center Program.
 DOS for use of COE truck cabin FE model developed by TTI.
 Jingwen Hu (Associate Research Scientist, UMTRI) for seatbelt model and
assistance with FE computer simulations.
 Akram Abu-Odeh (Research Scientist, TTI) and Kimberley Ryan (Former
Graduate Student Worker, TTI) for assistance with TruckSim.
 Abhinav Mohanakrishnan (Former Graduate Student Worker, TTI) for
compilation of injury criteria results.
Questions?
Chiara Silvestri Dobrovolny
E-mail: c-silvestri@ttimail.tamu.edu
Phone: 979-845-8971

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Heavy Truck Seat Belt Restraint FE Simulations

  • 1. Use of FE Simulations to Parametrically Evaluate and Compare Seat Belt Restraint Systems and Related Injury Risk in Heavy Truck Frontal Crash Conditions 2015 Traffic Safety Conference Corpus Christi, Texas June 09, 2015 Chiara Silvestri Dobrovolny, Ph.D. Associate Research Scientist, TTI Nathan Schulz Graduate Research Assistant, TTI
  • 2. Order of Presentation  Background  Objective  Methodology  FE Computer Models (Vehicle, ATD, Passive Restraint Systems)  FE Computer Frontal Impact Simulations  Results  Future Research
  • 3. Background  Approximately 340,000 medium/heavy trucks involved in traffic crashes per year in U.S.  600 fatalities; 20,000 injuries to truck drivers  Aggregate cost of crashes to society is $3.1 billion  No existing standards for truck cab crashworthiness or occupant protection in heavy truck crashes (although being discussed)  Need of additional characterization of crash-injury, current heavy truck crashworthiness, potential benefits of crashworthy structures in heavy truck cabs
  • 4. Objectives TTI and UMTRI proposed jointly effort devoted to collect & develop required information by:  analyzing crash & travel datasets available at UMTRI and TTI;  identify frequencies & costs of types of heavy truck crashes;  estimate benefits of crashworthy structures in heavy trucks to reduce death, injury, & societal costs of heavy truck crashes
  • 6. FE Computer Models Methodology – Big Picture Heavy Truck ATD Seatbelt Airbag FE Computer Simulations  Frontal Impact (Wall)  Parametric Variation Seatbelt Properties  ATD Injury Criteria + + +
  • 7. Simplified Methodology Crash pulse applied to cab mounts Frontal Impact (Wall) ATD Seatbelt Airbag + ++
  • 8. Step 1 Develop Heavy Truck Cabin Model
  • 9. Current FE Computer Model ? Computer Model – Heavy Truck Need for Occupant Compartment Interior
  • 10. Heavy Truck Cabin Model FE Model of Cab-Over-Engine Cabin* * Developed by TTI under project funded by Department of State Morphed Conventional Cab* * As of Peterbilt 387
  • 11. Step 2 Develop Heavy Truck Interior Compartment
  • 12. Heavy Truck Interior Compartment Cloud Point Scans* * Developed by UMTRI for Peterbilt 387
  • 13. Heavy Truck Interior Compartment Models developed applying mesh grid over cloud points
  • 15. ATD Inclusion and Pre-Positioning Existing LSTC Hybrid III 50% Male ATD
  • 16. Step 4 Addition of Passive Restraint Systems
  • 17. Seatbelt Model Original *Developed by LSTC for Passenger Car Modified *To fit Heavy Truck Geometry Original Modified
  • 18. Seatbelt Model Modified *To fit Heavy Truck Geometry
  • 19. Airbag Model Airbag - *Developed by NCAC Folded Deployed NCAC Heavy Truck
  • 21. Crash Pulse – 35 mph Frontal
  • 22. Step 6 FE Parametric Simulations of Frontal Impacts
  • 23. Frontal Impacts – 35 mph  Baseline  No Pretensioner  4 kN Load Limiter  8 kN Load Limiter  Lowered D-Ring
  • 24. Step 7 ATD Injury Criteria Evaluation
  • 26. ATD Injury Criteria Head Injury Criteria (HIC) Head acceleration recorded during impact event employed to calculate HIC representing probability of head injury
  • 28. Comparison to IARV Body Region Parameter IARV Injury Criteria % of Critical Value Head HIC 700 104 0.15 Neck Nij 1 0.78 0.78 Neck axial tension(kN) 4.17 2.8 0.68 Chest Deflection (mm) 63 85 1.36 Lower Extremity Femur axial force(kN) -10 -4.7 0.47 Tibia Index 1 2.3 2.26 Tibia axial force(kN) -8 -9.3 1.16 Injury Assessment Reference Values (IARVs) Injury event termed “unlikely” if associated injury value does not exceed IARVs
  • 31. Frontal Simulations – No Airbag No Airbag - Baseline No Airbag – No Pretensioner
  • 32. Frontal Simulations – No Airbag No Airbag – 4 kN Limit Load No Airbag – Lowered D-Ring
  • 33. No Airbag – Injury Probability Head Chest Neck
  • 35. Head Injury Probability No Airbag Airbag
  • 36. Neck Injury Probability No Airbag Airbag
  • 37. Conclusions  35 mph w/OUT airbag and 8 kN load limiter produced lowest injury criteria results for ATD.  35 mph w/airbag and 4 kN load limiter produced lowest injury criteria results for ATD.  Inclusion of airbag resulted in significant reduction in probability of neck injury
  • 38. Future Research  Validation of interior component material modelling (for accurate deformation response of truck cabin interior)  Realistic seat characteristics (suspensions)  Development and analysis of additional restraint systems  side curtain airbag system  five point seatbelt  …
  • 39. Acknowledgements  Robert Wunderlich (Associate Director, ATLAS Center, TTI) for sponsoring the project through ATLAS Center Program.  DOS for use of COE truck cabin FE model developed by TTI.  Jingwen Hu (Associate Research Scientist, UMTRI) for seatbelt model and assistance with FE computer simulations.  Akram Abu-Odeh (Research Scientist, TTI) and Kimberley Ryan (Former Graduate Student Worker, TTI) for assistance with TruckSim.  Abhinav Mohanakrishnan (Former Graduate Student Worker, TTI) for compilation of injury criteria results.
  • 40. Questions? Chiara Silvestri Dobrovolny E-mail: c-silvestri@ttimail.tamu.edu Phone: 979-845-8971