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Vehicle Frontal Crash Occupant Safety and CAE
Duration: 2 Days
| April 14-15, 2010 (8:30 a.m. - 4:30 p.m. ) - Troy, Michigan |
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| September 9-10, 2010 (8:30 a.m. - 4:30 p.m. ) - Troy, Michigan |
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Hotel & Travel Information
According to the National Highway Transportation and Safety Administration (NHTSA), a total of 43,200 people lost their lives and 2.7 million people were injured in motor vehicle crashes in 2005. Car companies and suppliers continue to develop new technologies that make vehicles safer. NHTSA is also updating safety regulations based on new research studies, making vehicle safety design more and more complex. The new FMVSS 208, for example, more than tripled the number of test modes, while adding a 5th percentile female dummy and more injury metrics.
Frontal crashes happen more frequently compared with other crash modes such as side and rear crashes. This seminar covers the mechanics of frontal crashes and how vehicle structures, vehicle restraint systems, and vehicle interiors affect occupant safety. It also describes details of how CAE tools work in the simulation of frontal crashes. The goal of the course is to familiarize participants with engineering principles behind vehicle and restraint designs for occupant safety. Accident crash statistics, biomechanics, government regulations and public domain frontal safety tests will be reviewed briefly. Students will also be exposed to Madymo, one of the major occupant CAE tools. The basic inner workings of the tool, such as rigid body dynamics, joints, contact, airbag and seatbelt modeling, and modeling techniques will be shared with the class. The class also offers participants opportunities to do hands-on computer analysis as well as simplified hands-on crash tests, where students can learn first-hand how vehicle pulses and restraint design affect occupant response.
This course has been approved by the Accreditation Commission for Traffic Accident Reconstruction (ACTAR) for 12 Continuing Education Units (CEUs). Upon completion of this seminar, accredited reconstructionists should contact ACTAR, 800-809-3818, to request CEUs. As an ACTAR approved course, the fee for CEUs is reduced to $5.00.
Learning Objectives
By attending this seminar, you will be able to:
- Explain frontal crashes and how vehicle structure and restraint systems affect occupant responses
- Describe how restraint components function in crashes and protect occupants
- Carry out calculations of injury metrics using test or CAE results as input
- Describe the occupant CAE tool, Madymo, and how it works
- Explain assumptions and limitations of CAE models
- Evaluate the relative effect of crash pulse, and restraint system characteristics
- Analyze and evaluate crash pulses
Who Should Attend
This course is designed for engineers who are either new to the field of automotive safety or familiar with only certain aspects of automotive safety. It can help engineers, for example, who design a specific component in a vehicle to understand how it works in vehicle crashes, how its characteristics affect occupant response and how it relates to other components in the vehicle.
Prerequisites
An undergraduate engineering degree or a strong technical background is highly recommended. Participants are expected to have a basic working knowledge of Microsoft Excel.
Topical Outline
DAY ONE
- Vehicle Crash Safety Introduction
- Crash injury and fatality data from the U.S.
- Distribution of different crash types
- Active safety and passive safety
- Vehicle Frontal Crash Modes
- Frontal rigid barrier
- Frontal offset deformable barrier
- Frontal angular
- Out of position tests, driver and passenger
- HYGE and Servo sled tests
- Component tests
- Biomechanics
- Human anatomy
- AIS injury scale
- Brief Overview of Frontal Test Dummies and Injury Metrics
- 50th, 5th, 95th
- 3yr, 6yr, 1 yr
- Frontal dummy metrics
- Frontal Crash Mechanics
- Crash pulse, front loaded, rear loaded
- Project using Excel:
- Calculate vehicle velocity and crush from pulse
- Get maximum crush, time to zero velocity
- Pulse comparison, front-loaded and rear loaded pulses
- Intrusions
- Occupant to restraint gaps and restraint characteristics
- Belted vs. unbelted occupant
- Project: Given pulse, restraint characteristics, occupant mass, find occupant responses
- Airbag quickness and stiffness
- Belt slack, pretension, EMR
- Project: Given pulse, occupant mass, restraint boundaries, find best restraint characteristics
- Driver vs. passenger
- Typical crash event
- Project: Given restraint characteristics, occupant mass, find optimal pulse shape
- 5th percentile female submarining
- Crash Sensor
- Airbag & pretensioner firing & non-firing conditions
- Sensor crash tests
DAY TWO
- Brief Review of Regulations
- U.S. Regulations - FMVSS 208, FMVSS 201, FMVSS 301
- U.S. Public Domain Tests - NCAP, IIHS frontal offset
- European Regulations - ECE 94, ECE 16
- European Public Domain Tests - Euro-NCAP
- Numerical Data Processing
- Filtering and SAE J211 guidelines
- HIC, Nij, Cumdur, V*C calculations
- Numerical integration, differentiation, occupant relative travel
- Vehicle Crash Computer Modeling (CAE)
- Vehicle structure CAE, finite element method
- Finite element method
- Explicit and implicit solvers
- Unibody and body on frame vehicles
- Occupant CAE, rigid body dynamics
- Madymo, occupant CAE tool
- Rigid bodies
- Mechanical joints
- Joint stiffness
- Ellipsoids and rigid FE mesh
- Planes
- Elliptical cylinders
- Contacts
- Acceleration fields
- Prescribed motion
- Airbag models
- Seatbelt modeling, seat integrated belt system
- Vehicle interior, IP, knee bolster, steering wheel, steering column, floor, dash, seat
- Vehicle pitch and yaw
- Madymo and LsDyna coupling
- Out of position modeling, CFD
- CAE assumptions and limitations
- DABLIT - an example of component test for driver airbag
- DOE and Optimization
- DOE used in component test, HYGE sled and CAE
- Optimization in CAE
- Robust design using CAE
- Restraint System
- Airbag, inflator, single & dual stage
- Closed tank test, 10 ms rise rate, peak pressure
- Drawbacks of tank tests
- Airbag shape, fabric, tether, venting
- Airbag module cover design
- Crash sensor, Restraint Control Module (RCM)
- Seatbelt, D-rings
- Retractors, torsion bars
- Buckle pretensioner
- Retractor pretensioner
- Steering column stroke
- Steering wheel lower and upper rims
- Knee bolster
- Real World Crashes - safety for the aging population, crash severity distribution
- Summary
Instructor(s): Stephen Kang
Dr. Stephen Kang is currently a Technical Specialist in the Safety Core and Strategy Department of Ford Motor Company where he is responsible for developing safety methods such as component test methods, CAE methods and best practices. He was responsible for developing a truck program from beginning to production launch, and for meeting the new FMVSS safety regulations that were effective in 2006, as well as other requirements. This included initial concept modeling, component development, sled and barrier test, design optimization, system CAE modeling and final test verification. Dr. Kang has been conducting occupant safety and CAE training internally at Ford Motor Company for the past eight years. He has designed and conducted extensive dynamic component tests that significantly improved crash modeling, established several Ford internal component design requirements and is responsible for the establishment of an Occupant CAE database at Ford. Dr. Kang is the recipient of the Henry Ford Technology Award in 2005. He serves as an Advisory Board Member for TNO North America and is a certified six-sigma Black Belt. Dr. Kang has a B.S. in Mechanical Engineering from Tianjin University, a M.S. in Mechanical Engineering from Wayne State University and a Ph.D. in Biomechanics from Wayne State University.
Fees: $1,195
; SAE Members: $1,075
1.3 CEUs
Testimonial
"The course and the instructor were magnificent. Absolutely indispensable training for any accident reconstructionist wanting an understanding of vehicle safety systems."
Sal Fariello
Accident Reconstructionist
Eastern Forensic Science Group
"Excellent seminar with a lot of interaction and hands-on practice."
Juan Carlos Tapia de Hoyas
Validation Engineer
Takata Corporation
To register, click Register button at the top of this page and submit the online form, or contact SAE Customer Service at 1-877-606-7323 (724/776-4970 outside the U.S. and Canada) or at CustomerService@sae.org.
For a quote on bringing this course to your company site, fill out a Corporate Learning Solutions Request Form
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