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Plug-in electric vehicles are becoming increasingly popular as the U.S. and other nations look for ways to reduce the usage of petroleum fuels and reduce the carbon emission footprint. Though plug-in electric vehicles offer many advantages over conventional vehicles, they also present some unique potential hazards due to the presence of high voltage in the vehicle. Specifically, potential high voltage hazards can occur if the electric vehicle is crashed by another vehicle during its plug-in charging session. High voltage hazards include the possibility of electrical shock and thermal events as a result of electrical arcing that can cause injury or death to persons that operate or work around plug-in electric vehicles. Automotive Safety Integrity Level (ISO 26262), often abbreviated as ASIL, is used by the automotive industry for determining the ranking of safety hazards.

General Motors (GM), OnStar and the University of Michigan International Center for Automotive Medicine (ICAM) have formed a partnership to investigate and analyze real world rollover crashes involving GM vehicles equipped with rollover sensing technology and rollover-capable roof rail airbag systems. Candidates for the study are initially identified by OnStar, who receive notification of a rollover crash through the vehicle's Automatic Crash Response system. If the customer agrees to participate in the study, medical, vehicle and crash scene information are quickly gathered. This information is then reviewed by the medical and GM engineering communities to provide field relevant learning on injury mechanisms and vehicle system performance in rollover events. This paper provides a detailed review of the field case studies collected to date.

This paper reports on a study that examines the effect of shoulder belt load limiters and pretensioners as well as crash and occupant factors that influence upper torso harm in real-world frontal crashes. Cases from the University of Michigan International Center for Automotive Medicine (ICAM) database were analyzed. Additional information was used from other databases including the National Highway Traffic Safety Administration (NHTSA) New Car Assessment Program (NCAP), the Insurance Institute for Highway Safety (IIHS), the National Automotive Sampling System - Crashworthiness Data System (NASS-CDS), and patient data available from the University of Michigan Trauma Center. The ICAM database is comprised of information from real-world crashes in which occupants were seriously injured and required treatment at a Level 1 Trauma Center.

The sensor mounted on the door impact beam plays a major role in side impact events. The accelerations of side impact sensors are processed by sensing algorithms to make a decision on the air bag deployment. The sensing signal criterion for the deployable condition is a well understood process. However, the non-deployment sensing signal for the immunity to abuse conditions is a function of sensor attachment stiffness to the base structure. The base structure can be a door inner panel or door impact beam. In one of the production program, the acceleration based sensor attached to the impact beam showed immunity issues in the abusive door slams/opening to objects. Hence, the computer Aided Engineering (CAE) analysis was used to develop the sensor attachment criterion.

In recent years, there has been a growing interest in driver visibility. This is, in part, due to increasing emphasis placed on design factors influencing visibility such as: aerodynamics, styling, structural stiffness and vehicle packaging. During the development process of a vehicle, it is important to be able to quantify all of these factors. Visibility, however, owing to its sensory nature, has been harder to quantify. As a result, General Motors (GM) has undertaken a study to gain deeper insight into customer perceptions surrounding visibility. Clinics were conducted to help determine the relative importance of different metrics. The paper also explores several new metrics that can help predict customer satisfaction based on vehicle configuration.

This paper reports a study undertaken by the Crash Safety Working Group (CSWG) of the United States Council for Automotive Research (USCAR) to determine generic acceleration pulses for testing and evaluating advanced batteries subjected to inertial loading for application in electric passenger vehicles. These pulses were based on characterizing vehicle acceleration time histories from standard laboratory vehicle crash tests. Crash tested passenger vehicles in the United States vehicle fleet of the model years 2005-2009 were used in this study. Crash test data, in terms of acceleration time histories, were collected from various crash modes conducted by the National Highway Traffic Safety Administration (NHTSA) during their New Car Assessment Program (NCAP) and Federal Motor Vehicle Safety Standards (FMVSS) evaluations, and the Insurance Institute for Highway Safety (IIHS).

General Motors and the Takata Corporation have worked together to bring to production a new, industry first technology called the Front Center Airbag which is being implemented on General Motors' 2013 Midsize Crossover Vehicles. This paper reviews field data, describes the hardware, and presents occupant test data to demonstrate in-position performance in far side impacts. The Front Center Airbag is an airbag that mounts to the inboard side of the driver front seat. It has a tubular cushion structure, and it deploys between the front seating positions in far side impacts, near side impacts and rollovers, with the cushion positioning itself adjacent the driver occupant's head and torso. This paper includes pictures of the technology along with a basic description of the design. In-position occupant performance is also described and illustrated with several examples. Single occupant and two front occupant far side impact test data are included, both with and without the airbag present.

The FlexRay serial data protocol is being considered in automotive vehicle architectures as an enabler for active safety, time critical systems due to the advantages it provides for time-determinism, increased data bandwidth, and multiple data channels to support fault tolerance strategies. To improve the robustness/availability of the electrical/physical layer when used for these critical applications, a FlexRay Active Star device is available. The Active Star is part of the physical layer and facilitates the creation of robust, fault tolerant network systems by partitioning the network into individual branches connected to one or more ECUs. This partitioning allows fault confinements and isolation activities to be performed at individual branches with minimal disruption to network communication. This paper describes the investigation of Active Star capabilities and some complexities related to their network integration.

The introduction of new safety critical features using software-intensive systems presents a growing challenge to hazard analysis and requirements development. These systems are rich in feature content and can interact with other vehicle systems in complex ways, making the early development of proper requirements critical. Catching potential problems as early as possible is essential because the cost increases exponentially the longer problems remain undetected. However, in practice these problems are often subtle and can remain undetected until integration, testing, production, or even later, when the cost of fixing them is the highest. In this paper, a new technique is demonstrated to perform a hazard analysis in parallel with system and requirements development. The proposed model-based technique begins during early development when design uncertainty is highest and is refined iteratively as development progresses to drive the requirements and necessary design features.

Internal organ injuries of the chest are one of the leading causes of deaths in motor vehicle crashes. The issue of initial presence and dynamic formation of voids around the heart and aorta is addressed to improve kinematics, force interaction and injury risk assessment of these organs of the Global Human Body Model. Steps to fill the voids are presented.

This paper reports a 2010 study undertaken to determine generic acceleration pulses for testing and evaluating advanced batteries for application in electric passenger vehicles. These were based on characterizing vehicle acceleration time histories from standard laboratory vehicle crash tests. Crash tested passenger vehicles in the United States vehicle fleet of the model years 2005-2009 were used. The crash test data were gathered from the following test modes and sources: 1 Frontal rigid flat barrier test at 35 mph (NHTSA NCAP) 2 Frontal 40% offset deformable barrier test at 40 mph (IIHS) 3 Side moving deformable barrier test at 38 mph (NHTSA side NCAP) 4 Side oblique pole test at 20 mph (US FMVSS 214/NHTSA side NCAP) 5 Rear 70% offset moving deformable barrier impact at 50 mph (US FMVSS 301). The accelerometers used were from locations in the vehicle where deformation is minor or non-existent, so that the acceleration represents the “rigid-body” motion of the vehicle.

General Motors conducted a series of subsystem rigid fixture sled rollover tests to evaluate the effects of various safety belt pyrotechnic pretensioners on Anthropomorphic Test Device (ATD) head motion. Twelve tests were conducted using a rigid fixture comprised of a modified compact sport utility vehicle (SUV) body encased in a rigid exoskeleton. The testing simulated the pre-trip/trip, free flight and first roof to ground impact phases of a field representative curb trip initiation rollover crash test with a roof to ground impact angle of approximately 180 degrees. Various combinations of safety belt lap anchor, buckle and retractor pretensioners were tested and film analysis was used to measure trailing side ATD head motion relative to the vehicle. Additionally, a new analysis technique of measuring the reduction of lap webbing length during the crash event was developed for evaluating the ability of a restraint system to reduce ATD head motion during the rollover tests.

Insulation coordination requirements for electrical equipment applications are defined in various standards. The standards are defined for application to stationary mains connected equipment, like IT, power supply or industrial equipment. Protection from an electric shock is considered the primary hazard in these standards. These standards have also been used in the design of various automotive components. IEC 60664-1 is an example of the standard. Automobiles are used across the world, in various environments and in varied usage by the customers. Automobiles need to consider possible additional hazards including electric shock. This paper will provide an overview of how to adapt these standards for automotive application in the design of High Voltage (HV) automotive components, including High Voltage batteries and other HV components connected to the battery. The basic definitions from the standards and the principles are applied for usage in automotive applications.