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From 2009 until present Toyota has had a demonstration program of Prius PHV which is comprised of 600 vehicles throughout Japan, Europe and in the US. The vehicles were given to government agencies, corporations, utility companies and private individuals to use. With these demo units Toyota wanted to understand the market reaction and real world impact of plug-in technology on gasoline displacement with increased use of electricity as a fuel. This presentation shows that approximately 50% of fuel was saved using the PHVs in the US. An experiment in Toyota City shows that if public infrastructure is optimized to be convenient and located where people normally park, there is a potential to achieve an ideal fuel savings of 61%. The demonstration program shows that plug-in technology in fact saves fuel and that the proper infrastructure can optimize the fuel savings of plug-in hybrids. Presenter Avernethy Francisco, Toyota

Plug-in Hybrid Electric Vehicles (PHEVs) are entering the market and bring with them new OBD issues. A key one is how to measure in-use monitor performance ratio and where to set a standard for this, as PHEVs will have varying amounts of engine-on operation depending on customer plug-in and driving behavior. Toyota�s Prius PHEV system is described and customer use data from a US demonstration fleet is examined. Some prior denominator proposals by Toyota and CARB are explained, as background for the current CARB/industry agreement for denominator and ratio. Presenter Morton M. Smith, Toyota

This paper presents the test track scenario design and analysis used to estimate the performances of heavy vehicles equipped with forward collision warning and automatic emergency braking systems in rear-end crash scenarios. The first part of this design and analysis study was to develop parameters for brake inputs in test track scenarios simulating a driver that has insufficiently applied the brakes to avoid a rear-end collision. In the second part of this study, the deceleration limits imposed by heavy vehicles mechanics and brake systems are used to estimate automatic emergency braking performance benefits with respect to minimum stopping distance requirements set by Federal Motor Vehicle Safety Standards. The results of this study were used to complete the test track procedures and show that all heavy vehicles meeting regulatory stopping distance requirements have the braking capacity to demonstrate rear-end crash avoidance improvements in the developed tests.

National concerns over energy consumption and emissions from the transportation sector have prompted regulatory agencies to implement aggressive fuel economy targets for light-duty vehicles through the U.S. National Highway Traffic Safety Administration/Environmental Protection Agency (EPA) Corporate Average Fuel Economy (CAFE) program. Automotive manufacturers have responded by bringing competitive technologies to market that maximize efficiency while meeting or exceeding consumer performance and comfort expectations. In a collaborative effort among Toyota Motor Corporation, Argonne National Laboratory (ANL), and the National Renewable Energy Laboratory (NREL), the real-world savings of one such technology is evaluated. A commercially available Toyota Highlander equipped with two-phase cold storage technology was tested at ANL’s chassis dynamometer testing facility.

The objective of this paper is to describe the general methodology used by NHTSA to perform cost-effectiveness analyses and cost-benefit analyses. This general method will then be directed towards how one could analyze fire countermeasures, providing two analyses as examples. First, for crash related fires, NHTSA's 2003 analysis on fuel tank integrity will be used. Second, for non-crash related fires, NHTSA's 2001 analysis of radiator caps will be used. The paper will describe what data sources were used to determine the target population, the severity of injuries, the costs of burns by injury severity, the cost of the fire countermeasures, etc. While not analyzing any specific fire countermeasure, the methodology will be described in enough detail that others could potentially follow the methodology and make estimates for their own purposes.

In September 2009 the National Highway Traffic Safety Administration (NHTSA) published a report that investigated the incidence of fatalities to belted non-ejected occupants in frontal crashes involving late-model vehicles. The report concluded that after exceedingly severe crashes, the largest number of fatalities occurred in crashes involving poor structural engagement between the vehicle and its collision partner, present in crashes characterized as corner impacts, oblique crashes, impacts with narrow objects, and heavy vehicle underrides. By contrast, few if any of these 122 fatal crashes were full-frontal or offset-frontal impacts with good structural engagement, excepting crashes that were of extreme severity or the occupants that were exceptionally vulnerable. The intent of this research program is to develop a test protocol that replicates real-world injury potential in small overlap impacts (SOI) and oblique offset impacts (Oblique) in motor vehicle crashes.

The purpose of the study was to distinguish the role of vehicle structure in frontal impacts in published coded National Automotive Sampling System (NASS-CDS) data. The criteria used: Collision Deformation Classification (CDC) coding rules, crush profile locator data and the projected location of longitudinal structural members in models of vehicle class sizes used by NASS-CDS. Two classifiers were developed to augment the CDC system. The Coincidence classifier indicates the relationship between the quadrant of the clock face the crash vector originates in and the aspect of the end plane the center of damage is located. It has three values: Linear (12 o'clock impacts) Consistent and Variant ("oblique" Principal Directions of Force or PDOFs). The second classifier indicates the number of longitudinal members engaged: 0, 1 or 2. NASS-CDS data for sample years 2005 to 2009 was filtered for occupants involved in impacts with the highest ranked speed change assigned to the front-end plane.

Objectives. Examination of head injuries in the Pedestrian Crash Data Study (PCDS) indicates that many pedestrian head injuries are induced by a combination of head translation and rotation. The Simulated Injury Monitor (SIMon) is a computer algorithm that calculates both translational and rotational motion parameters relatable head injury. The objective of this study is to examine how effectively HIC and three SIMon correlates predict the presence of either their associated head injury or any serious head injury in pedestrian collisions. Methods. Ten reconstructions of actual pedestrian crashes documented by the PCDS were conducted using a combination of MADYMO simulations and experimental headform impacts. Linear accelerations of the head corresponding to a nine-accelerometer array were calculated within the MADYMO model's head simulation.

The SAE FCV Safety Working Group has been addressing fuel cell vehicle (FCV) safety for over 7 years. The initial document, SAE J2578, was published in 2002. SAE J2578 has been valuable to the FCV development with regard to the identification of hazards and the definition of countermeasures to mitigate these hazards such that FCVs can be operated in the same manner as conventional gasoline IC-powered vehicles. The document is currently being updated to clarify and update requirements so that the document will continue to be relevant and useful in the future. In addition to developing draft revisions to SAE J2578, the working group has updated SAE J1766 and is developing a new recommended practice on vehicular hydrogen systems (SAE J2579). The documents are written from the standpoint of systems-level, performance-based requirements. A risk-based approach was used to identify potential electrical and fuel system hazards and provide criteria for acceptance.

Toyota and BP have performed a collaborative study to understand the impact of fuel composition on the combustion and emissions of a prototype 1.8L lean boosted engine. The fuel matrix was designed to understand better the impact of a range of fuel properties on fundamental combustion characteristics including thermal efficiency, combustion duration, exhaust emissions and extension of lean limit. Most of the fuels in the test matrix were in the RON range of 96 - 102, although ethanol and other high octane components were used in some fuels to increase RON to the range 104 - 108. The oxygen content ranged from 2 - 28%, and constituents included biocomponents, combustion improving additives and novel blend components. Performance and emissions tests were conducted over a range of engine operating conditions. Thermal efficiency was mapped at stoichiometric and lean conditions, and the limit of lean combustion was established for different fuels.

In recent years, engine control systems have become more and more complex because of the growing pressure to develop technical innovations due to social pressures such as global warming and the depletion of fossil fuels. On the other hand, products must be launched on the market in a timely manner and at low cost. For these reasons, calibration processes have become more sophisticated. It is possible to improve the efficiency of calibration by making good use of models, and a calibration process that incorporates models is called model based calibration (MBC). MBC is a valid means of reducing the number of measurement points to some extent by statistical engine modeling and design of experiment (DoE) methodology which places measurement points in order to maximize modeling accuracy. However, it is still necessary to spend much time carrying out boundary detection testing before DoE.

The purpose of the study was to identify all small overlap impacts using published coded NASS-CDS data. Three sets of criteria were used: CDC measurements; crush profiles for frontal impacts; and crush profiles for oblique side impacts to the fender component. All criteria were applied to passenger and non-passenger cars and their different vehicle class sizes. Data were analyzed based on fatalities and different levels of MAIS trauma. The overall data set based on CDC codes for 2005 to 2008 NASS-CDS data had 9,206 MAIS=0; 13,522 MAIS=1-2; 3,600 MAIS=3-6; 1,092 MAIS=7; and 961 fatal cases. For the weighted ensemble, these data were: 5,800,295; 4,324,773; 269,042; 219,481; and 44,906 cases, respectively. However, these cases reduced to 1071, 1468, 364, 82, and 87 raw cases with the application of the CDC criteria for frontal impacts.

This paper focuses on the development of the centralized air flow system S-FLOW (Energy Saving Air Flow Control System). The S-FLOW system directs thermal energy to each seating position in the vehicle based on occupancy, thus prioritizing the energy usage based on the particular scenario. The thermal environment in a vehicle's cabin is non-uniform. If the climate control system is used to direct airflow exclusively to any one region of the cabin, without special considerations, comfort may be adversely impacted. To solve this concern, a non-uniform evaluation method was developed to evaluate comfort at each body region of the occupant using the SET* (Standard new effective temperature) method. SET* is a parameter that combines the effects of temperature, airflow velocity, humidity, and other parameters to quantify thermal comfort. Next, a method was established that correlated each body region's SET* value to the occupant's overall thermal comfort.

National Highway Traffic Safety Administration (NHTSA) has developed an Oblique Offset Moving Deformable Barrier test procedure. For this test procedure to be viable, it must be repeatable within each test facility and it must be reproducible between test facilities. Three tests of a single vehicle model were conducted at three different test facilities, a total of nine tests, to evaluate repeatability and reproducibility. The responses of the vehicle and its occupants were evaluated using three different methodologies to quantify the repeatability within a single test facility and reproducibility among the three test facilities. The first two methods evaluated the time-history of the measured data and the third method only used the peak values. Overall, this test series demonstrated repeatable and reproducible results for the OMDB, vehicle, and driver occupant in the oblique offset test procedure. The method using only the peak values indicates more variability.

The study reports on the results of frontal collisions with 16 cadavers and two Hybrid III dummies with impact velocities of 48 km/h to 55 km/h and a mean sled deceleration of 17 g; mounted to the sled was the front part of a passenger compartment. The cadavers were restrained in the driver position with either 3-point belts (6% and 16 % elongation) and/or air bag with knee bolster and one case was unrestrained. In most cases, both a 12-accelerometer thoracic array and 2 chest bands were employed. In some cases the acceleration at Th6 was measured. The cadavers were autopsied and the injury severity was rated according to the AIS 90. Maximum resultant Th1, Th6, and Th12 accelerations or sternum accelerations in x-direction ranged from 35g to 78g when using 3-point belts and produced injuries ranging from a few rib fractures to unstable chest wall (flail chest).

As greater emphasis is placed on the development of small fuel-efficient cars, there is a growing need to reduce the size of the inverter used in hybrid vehicles (HVs). However, semiconductor devices and other components are generating larger amounts of heat and the parts used to cool these components are becoming thinner. One issue resulting from these trends is perforations that propagate from coolant paths. This development secured corrosion resistance by controlling sacrificial corrosion protection performance, optimizing the use of Mn and Si materials to reduce susceptibility to grain-boundary corrosion, and taking a microstructural approach to the flow of the brazing filler metal. The developed material was applied to the inverter cooler of a small HV released at the end of 2011.

This paper reports the results of one of the tasks addressed in a coordinated NHTSA/MVMA side impact test procedure development program: the identification of specific tests which should be able to discriminate among vehicle designs having a significant effect on side impact injuries. Component and full vehicle crash tests addressing impacts between specific occupant body parts and vehicle regions are recommended for development. Advantages and disadvantages of component vs. full vehicle tests are discussed and areas needing further research to support side impact test development are recommended.

To improve the biofidelity of the currently available Hybrid III 10-year-old (HIII-10C) Anthropomorphic Test Device (ATD), the National Highway Traffic Safety Administration (NHTSA) has developed the Large Omnidirectional Child (LODC) ATD. The LODC head is a redesigned HIII-10C head with mass properties and modified skin material required to match pediatric biomechanical impact response targets from the literature. A dynamic, nonlinear finite element (FE) model of the LODC head has been developed using the mesh generating tool Hypermesh based on the three-dimensional CAD model. The material data, contact definitions, and initial conditions are defined in LS-PrePost and converted to LS-Dyna solver input format. The aluminum head skull is stiff relative to head flesh material and was thus modeled as a rigid material. For the actual LODC, the head flesh is form fit onto the skull and held in place through contact friction.

Testing vision-based advanced driver assistance systems (ADAS) in a Camera-in-the-Loop (CiL) bench setup, where external visual inputs are used to stimulate the system, provides an opportunity to experiment with a wide variety of test scenarios, different types of vehicle actors, vulnerable road users, and weather conditions that may be difficult to replicate in the real world. In addition, once the CiL bench is setup and operating, experiments can be performed in less time when compared to track testing alternatives. In order to better quantify normal operating zones, track testing results were used to identify behavior corridors via a statistical methodology. After determining normal operational variability via track testing of baseline stationary surrogate vehicle and pedestrian scenarios, these operating zones were applied to screen-based testing in a CiL test setup to determine particularly challenging scenarios which might benefit from replication in a track testing environment.

Posterior cruciate ligament (PCL) injuries, although rarely life threatening, affect the quality of life of the person who sustains the injury. The PCL is the primary restraint to posterior tibial translation and can be injured when the tibia moves posteriorly relative to the femur. This type of injury is common in frontal crashes where the tibia may impact the dashboard or steering column. To quantify what happens during dynamic loading of the tibial plateau, isolated cadaveric lower limbs (n = 14) were impacted at dynamic rates with a linear pneumatic ram. During the testing, a static load was applied to the quadriceps tendon to simulate active musculature. Forces as well as the stretch of the PCL were measured. The most common injuries were tibia fractures and PCL tears. The stiffness for the tests at impact velocities of 1.4 and 2.9 m/s were on average 120 N/mm and 141N/mm, respectively. A trend towards increasing femur force with increasing velocity was found.