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We have recently obtained experimental data and used them to develop computational models to quantify occupant impact responses and injury risks for military vehicles during frontal crashes. The number of experimental tests and model runs are however, relatively small due to their high cost. While this is true across the auto industry, it is particularly critical for the Army and other government agencies operating under tight budget constraints. In this study we investigate through statistical simulations how the injury risk varies if a large number of experimental tests were conducted. We show that the injury risk distribution is skewed to the right implying that, although most physical tests result in a small injury risk, there are occasional physical tests for which the injury risk is extremely large. We compute the probabilities of such events and use them to identify optimum design conditions to minimize such probabilities.

The objective of this study was to optimize the occupant restraint systems for a light tactical vehicle in frontal crashes. A combination of sled testing and computational modeling were performed to find the optimal seatbelt and airbag designs for protecting occupants represented by three size of ATDs and two military gear configurations. This study started with 20 sled frontal crash tests to setup the baseline performance of existing seatbelts, which have been presented previously; followed by parametric computational simulations to find the best combinations of seatbelt and airbag designs for different sizes of ATDs and military gear configurations involving both driver and passengers. Then 12 sled tests were conducted with the simulation-recommended restraint designs. The test results were further used to validate the models. Another series of computational simulations and 4 sled tests were performed to fine-tune the optimal restraint design solutions.

In this study, two sled series were conducted with a sled buck representing a compact vehicle. The first series of tests focused on the effects of crash pulse, impact angle, occupant size, and front seat location on rear seat occupant restraint with a generic rear-seat belt system without pre-tensioner or load limiter. The second series of tests focused on investigating the benefit of using advanced features for rear-seat occupant restraint in the most severe crash condition in the first sled series. The first series of tests include 16 test conditions with two impact angles (0° and 15°), two sled pulse (soft and severe), and four ATD sizes (HIII 6YO, HIII 5th female, HIII 95th male, and THOR-NT) with two ATDs in each test. The driver seat was located at the mid position, while the front passenger seat was positioned such that a constant distance between the ATD knee and the front seat is achieved.

This study documented the position and orientation of child restraint systems (CRS) installed in the second rows of vehicles, creating a database of 486 installations. Thirty-one different CRS were evaluated, selected to provide a range of manufacturers, sizes, types, and weight limits. Eleven CRS were rear-facing only, fourteen were convertibles, five were combination restraints, and one was a booster. Ten top-selling vehicles were selected to provide a range of manufacturers and body styles: four sedans, four SUVS, one minivan, and one wagon. CRS were marked with three reference points on each moving component. The contours and landmarks of each CRS were first measured in the laboratory. Vehicle interior contours, belt anchors, and LATCH anchors were measured using a similar process. Then each CRS was installed in a vehicle using LATCH according to manufacturers' directions, and the reference points of each CRS component were measured to document the installed orientation.

The seatbelt system, originally designed for protecting occupants in frontal crashes, has been reported to be inadequate for preventing occupant head-to-roof contact during rollover crashes. To improve the effectiveness of seatbelt systems in rollovers, in this study, we reviewed previous literature and proposed vertical head excursion corridors during static inversion and dynamic rolling tests for human and Hybrid III dummy. Finite element models of a human and a dummy were integrated with restraint system models and validated against the proposed test corridors. Simulations were then conducted to investigate the effects of varying design factors for a three-point seatbelt on vertical head excursions of the occupant during rollovers. It was found that there were two contributing parts of vertical head excursions during dynamic rolling conditions.