Vehicle Safety Design Methods to Comply with Emerging International Standards
Total Page:16
File Type:pdf, Size:1020Kb
University of Windsor Scholarship at UWindsor Electronic Theses and Dissertations Theses, Dissertations, and Major Papers 2012 Vehicle Safety Design Methods to Comply with Emerging International Standards Pingping Gao University of Windsor Follow this and additional works at: https://scholar.uwindsor.ca/etd Recommended Citation Gao, Pingping, "Vehicle Safety Design Methods to Comply with Emerging International Standards" (2012). Electronic Theses and Dissertations. 4806. https://scholar.uwindsor.ca/etd/4806 This online database contains the full-text of PhD dissertations and Masters’ theses of University of Windsor students from 1954 forward. These documents are made available for personal study and research purposes only, in accordance with the Canadian Copyright Act and the Creative Commons license—CC BY-NC-ND (Attribution, Non-Commercial, No Derivative Works). Under this license, works must always be attributed to the copyright holder (original author), cannot be used for any commercial purposes, and may not be altered. Any other use would require the permission of the copyright holder. Students may inquire about withdrawing their dissertation and/or thesis from this database. For additional inquiries, please contact the repository administrator via email ([email protected]) or by telephone at 519-253-3000ext. 3208. Vehicle Safety Design Methods to Comply with Emerging International Standards by Pingping Gao A Thesis Submitted to the Faculty of Graduate Studies through Mechanical, Automotive, and Materials Engineering in Partial Fulfillment of the Requirements for the Degree of Master of Applied Science at the University of Windsor Windsor, Ontario, Canada 2012 © Pingping Gao Vehicle Safety Design Methods to Comply with Emerging International Standards by Pingping Gao APPROVED BY: ______________________________________________ Dr. William Altenhof, Co-Advisor Department of Mechanical, Automotive and Materials Engineering ______________________________________________ Dr. Peter Frise, Co-Advisor Department of Mechanical, Automotive and Materials Engineering ______________________________________________ Dr. Daniel Green Department of Mechanical, Automotive and Materials Engineering ______________________________________________ Dr. Faouzi Ghrib Department of Civil and Environmental Engineering ______________________________________________ Dr. Andrzej Sobiesiak, Chair of Defense DECLARATION OF ORIGINALITY I hereby certify that I am the sole author of this thesis and that no part of this thesis has been published or submitted for publication. I certify that, to the best of my knowledge, my thesis does not infringe upon anyone’s copyright nor violate any proprietary rights and that any ideas, techniques, quotations, or any other material from the work of other people included in my thesis, published or otherwise, are fully acknowledged in accordance with the standard referencing practices. Furthermore, to the extent that I have included copyrighted material that surpasses the bounds of fair dealing within the meaning of the Canada Copyright Act, I certify that I have obtained a written permission from the copyright owner(s) to include such material(s) in my thesis and have included copies of such copyright clearances to my appendix. I declare that this is a true copy of my thesis, including any final revisions, as approved by my thesis committee and the Graduate Studies office, and that this thesis has not been submitted for a higher degree to any other University or Institution. iii ABSTRACT This research focuses on the development of a design methodology for vehicle safety design to comply with the different side impact crash regulations that are used around the world. The main differences of each side impact tests and potential influences on vehicle design were identified. Door intrusion velocity, door trim component stiffness and seat airbag were selected as three design variables. Sled test finite element models based on the Heidelberg buck sled test set-up were developed to investigate the sensitivity of three design factors to the occupant injury in both moving deformable barrier test and oblique pole test load conditions. Occupant injury response variations were assessed at different levels of the design factors. From the simulation results, for moving deformable barrier test, there is a balance between limiting the thorax injury and abdominal injury. For the Oblique pole test, the simulation results show that the padding system development may be more effective than the vehicle structure enhancement. Design guidelines that would enable vehicles to comply with different side impact tests were extracted based on the simulation results. iv DEDICATION To my loving niece Xing Gao v ACKNOWLEDGEMENTS This research would not have been possible without the help of many individuals, who helped me to complete this research. I would like to express my great appreciation and gratitude from the bottom of my heart to everyone who made this thesis possible. I would like to thank Dr. William Altenhof and Dr. Peter Frise of the University of Windsor for their support, guidance, invaluable discussions and encouragement throughout the whole year in Canada. I also wish to express my great respect and gratitude to Dr. Faouzi Ghrib and Dr. Daniel Green for being my thesis committee member, for reviewing this thesis and offering helpful suggestions. I would also like to thank Professor Giovanni Belingardi of Politecnico di Torino, for his encouragement and guidance provided. I am very much grateful to Roberto Puppini from Centro Ricerche Fiat (Fiat research center) for his guidance and invaluable suggestions provided during this year. I’m grateful for the support of Hamid Keshtkar, Dr. Kalu Uduma and Liwu Zhou of the Chrysler Technical Center for providing help from their expertise in crash test simulation, instrumental in guiding me towards the successful completion of this thesis. I would like to express my gratefulness towards Mohammed Malik of the Chrysler ARDC for providing the connection with the industry partner and encouragement in many ways throughout my program. My special thanks to Jeannette Stewart in AUTO 21 for helping me during this year in many ways and revising the manuscript of this thesis. Above all, I am particularly grateful to my parents and my sister, for their endless love and encouragement in everything I do. vi TABLE OF CONTENTS DECLARATION OF ORIGINALITY.............................................................................. iii ABSTRACT....................................................................................................................... iv DEDICATION.....................................................................................................................v ACKNOWLEDGEMENTS............................................................................................... vi LIST OF TABLES............................................................................................................. ix LIST OF FIGURES .............................................................................................................x LIST OF ACRONYMS ................................................................................................... xiv 1. INTRODUCTION 2. LITERATURE REVIEW 2.1 Introduction.....................................................................................3 2.2 Diversity in crash tests....................................................................3 2.2.1 Crash regulations and ratings in North America ................8 2.2.2 Crash regulations and ratings in Europe...........................10 2.2.3 Crash regulations and ratings in China.............................13 2.3 Side impact crashes.......................................................................21 3. SIDE IMPACT TESTS 3.1 Side impact test diversity..............................................................22 3.2 Energy management in side impact..............................................33 3.3 Focus of the research ....................................................................37 4. NUMERICAL MODEL DEVELOPMENT 4.1 Heidelberg buck sled test method.................................................39 4.2 Finite element model development and validation.......................42 5. NUMERICAL MODEL SIMULATION RESULTS 5.1 Simulation of side impact sled tests..............................................53 5.1.1 Baseline condition results.................................................53 5.1.2 The effect of reducing door intrusion velocity .................57 5.1.3 The effect of varying door trim component stiffness .......61 5.1.4 The effect of seat airbags..................................................64 5.2 Simulation of the pole sled test.....................................................68 vii 5.2.1 Baseline condition result...................................................68 5.2.2 The effect of reducing door intrusion velocity .................71 5.2.3 The effect of varying door trim component stiffness .......73 5.2.4 The effect of seat airbags..................................................74 5.3 Proposed solution to comply with regulatory requirement...........77 5.3.1 Summary of the findings from simulation studies............78 5.3.2 Proposed solution..............................................................80 6. SIDE STRUCTURE ENHANCEMENT 6.1 Door intrusion velocity analysis ...................................................86 6.1.1 The effect of different