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The objectives of this study were to provide insights on how injury risk is influenced by occupant demographics such as sex, age, and size; and to quantify differences within the context of commonly-occurring real-world crashes. The analyses were confined to either single-event collisions or collisions that were judged to be well-defined based on the absence of any significant secondary impacts. These analyses, including both logistic regression and descriptive statistics, were conducted using the Crash Investigation Sampling System for calendar years 2017 to 2021. In the case of occupant sex, the findings agree with those of many recent investigations that have attempted to quantify the circumstances in which females show elevated rates of injury relative to their male counterparts given the same level bodily insult. This study, like others, provides evidence of certain female-specific injuries.

Injury Risk Curves are developed from cadaver data for sternal deflections produced by anterior, distributed chest loads for a 25, 45, 55, 65 and 75 year-old Small Female, Mid-Size Male and Large Male based on the variations of bone strengths with age. These curves show that the risk of AIS ≥ 3 thoracic injury increases with the age of the person. This observation is consistent with NASS data of frontal accidents which shows that older unbelted drivers have a higher risk of AIS ≥ 3 chest injury than younger drivers.

Light duty vehicles in the US are designed to meet and exceed regulatory standards, self-imposed industry agreements and safety rating tests conducted by NHTSA and IIHS. The evolution of side impact regulation in the US from 1973 to 2015 is discussed in the paper along with two key industry agreements in 2003 affecting design of restraint systems and structures for side impact protection. A combination of all the above influences shows that vehicles in the US are being designed to more demanding and comprehensive requirements than in any other region of the world. The crash environment in the US related to side impacts was defined based on data in the nationally representative crash database NASS. Crash environment factors, including the distribution of cars, light trucks and vans (LTV’s), and medium-to-heavy vehicles (MHV’s) in the fleet, and the frequency of their interactions with one another in side impacts, were considered.

The human thermal comfort, which has been a subject of extensive research, is a principal objective of the automotive climate control system. Applying the results of research studies to the practical problems require quantitative information of the thermal environment in the passenger compartment of a vehicle. The exposure to solar radiation is known to alter the thermal environment in the passenger compartment. A photovoltaic-cell based sensor is commonly used in the automotive climate control system to measure the solar radiation exposure of the passenger compartment of a vehicle. The erroneous information from a sensor however can cause thermal discomfort to the occupants. The erroneous measurement can be due to physical or environmental parameters. Shading of a solar sensor due to the opaque vehicle body elements is one such environmental parameter that is known to give incorrect measurement.

The vehicle air-conditioning system has significant impact on fuel economy and range of electric vehicles. Improving the fuel economy of vehicles therefore demand for energy efficient climate control systems. Also the emissions regulations motivate the reduced use of fuel for vehicle's cabin climate control. Solar heat gain of the passenger compartment by greenhouse effect is generally treated as the peak thermal load of the climate control system. Although the use of advanced glazing is considered first to reduce solar heat gain other means such as ventilation of parked car and recirculation of cabin air also have impetus for reducing the climate control loads.

In addition to the thermal comfort of the vehicle occupants, their safety by ensuring adequate visibility is an objective of the automotive climate control system. An integrated dew point and glass temperature sensor is widely used among several other technologies to detect risk of fog formation on the cabin side (or inner) surface of the windshield. The erroneous information from a sensor such as the measurement lag can cause imperfect visibility due to the delayed response of the climate control system. Also the high value, low cost vehicles may not have this sensor due to its high cost. A differential equation based model of the cabin air humidity is proposed to calculate in real-time specific humidity of the passenger compartment air. The specific humidity is used along with the windshield surface temperature to determine relative humidity of air and therefore, the risk of fog formation on the interior surface of a windshield.

A small overlap frontal crash test has been recently introduced by the Insurance Institute for Highway Safety in its frontal rating scheme. Another small overlap frontal crash test is under development by the National Highway Traffic Safety Administration (NHTSA). Whereas the IIHS test is conducted against a fixed rigid barrier, the NHTSA test is conducted with a moving deformable barrier that overlaps 35% of the vehicle being tested and the angle between the longitudinal axis of the barrier and the longitudinal axis of the test vehicle is 15 degrees. The field relevance of the IIHS test has been the subject of a paper by Prasad et al. (2014). The current study is aimed at examining the field relevance of the NHTSA test.

An overview NASS study of US frontal crashes was performed to investigate crash involvement, driver injury distributions and rates in airbag equipped vehicles by vehicle class and structural engagement. Frontal crash bins were based on taxonomy of structural engagement, i.e., Full Engagement, Offset, Between Rails and Corner impact crashes. A new classification of Corner impacts included frontal small overlap impacts with side damage as coded by NASS CDS. Belted drivers of two age groups, between 16 and 50 and over 50 years old, were considered. Vehicles were grouped into light and heavy passenger cars and lights trucks, and vans. A method to identify and address overly influential NASS weights was developed based on considerations of weighting factor statistics. The new taxonomy, with an expanded definition of corner impacts, allowed a more comprehensive classification of frontal crash modes.

An evaluation of the four injury risk curves proposed in the NHTSA NCAP for estimating the risk of AIS≻=3 injuries to the head, neck, chest and AIS≻=2 injury to the Knee-Thigh-Hip (KTH) complex has been conducted. The predicted injury risk to the four body regions based on driver dummy responses in over 300 frontal NCAP tests were compared against those to drivers involved in real-world crashes of similar severity as represented in the NASS. The results of the study show that the predicted injury risks to the head and chest were slightly below those in NASS, and the predicted risk for the knee-thigh-hip complex was substantially below that observed in the NASS. The predicted risk for the neck by the Nij curve was greater than the observed risk in NASS by an order of magnitude due to the Nij risk curve predicting a non-zero risk when Nij = 0. An alternative and published Nte risk curve produced a risk estimate consistent with the NASS estimate of neck injury.

By adapting vehicle control systems to the skill level of the driver, the overall vehicle active safety provided to the driver can be further enhanced for the existing active vehicle controls, such as ABS, Traction Control, Vehicle Stability Enhancement Systems. As a follow-up to the feasibility study in [1], this paper provides some recent results on data-driven driving skill characterization. In particular, the paper presents an enhancement of discriminant features, the comparison of three different learning algorithms for recognizer design, and the performance enhancement with decision fusion. The paper concludes with the discussions of the experimental results and some of the future work.

This paper demonstrates the benefit of using simulation and robust optimization for the problem of balancing vehicle noise, vibration, and ride performance over road impacts. The psychophysics associated with perception of vehicle performance on an impact is complex because the occupants encounter both tactile and audible stimuli. Tactile impact vibration has multiple dimensions, such as impact hardness and memory shake. Audible impact sound also affects occupant perception of the vehicle quality. This paper uses multiple approaches to produce the similar, robust, optimized tuning strategies for impact performance. A Design for Six Sigma (DFSS) project was established to help identify a balanced, optimized solution. The CAE simulations were combined with software tools such as iSIGHT and internally developed Kriging software to identify response surfaces and find optimal tuning.

This paper describes the methodology used to design and perform a CFD analysis of a Chevrolet Impala SS Funny Car body. This body was designed for the purpose of making it available for teams to race it in the National Hot Rod Association (NHRA) drag racing series beginning with the 2007 race season. Several challenges were presented in this project: (1) This was the first time a General Motors drag racing body for use in professional classes (Funny Car or otherwise) was ever designed in CAD. (2) The body was originally designed as a 2007 Chevrolet Monte Carlo. After the tooling was completed, changes in Chevrolet’s product lineup required that the body be changed to a 2007 Impala SS. (3) Budget constraints precluded CFD analysis until after the bodies were already being manufactured. There were several teams that raced the new body during the 2007 race season. One of these teams won the Funny Car Driver’s Championship.

The market growth for electric-hybrid passenger vehicles has been very significant and is expected to reach nearly 25% of all vehicles sold in the US by 2015. Hybrid commercial vehicles are also being developed by several OEM's. This paper discusses the progress of Delphi Thermal Systems in developing an integrated electric compressor drive with high cooling capacity (9 kW+), sufficient for large hybrid SUV's and commercial vehicles such as Class 8 tractors with sleeper. An important driver for use of the electric compressor in the hybrid truck application is the reduction of engine idling time while maintaining comfort in the cab or sleeper. Design details of a compact 5 kW SPM motor, its inverter drive, and issues related to its integration into the compressor housing are described. Test results are given confirming excellent performance.

A unified approach to collision warning due to in-lane and neighboring traffic is presented. It is based on the concept of velocity obstacles, and is designed to alert the driver of a potential front collision and against attempting a dangerous lane change maneuver. The velocity obstacle represents the set of the host velocities that would result in collision with the respective static or moving vehicle. Potential collisions are simply determined when the velocity vector of the host vehicle penetrates the velocity obstacle of a neighboring vehicle. The generality of the velocity obstacle and its simplicity make it an attractive alternative to competing warning algorithms, and a powerful tool for generating collision avoidance maneuvers. The velocity obstacle-based warning algorithm was successfully tested in simulations using real sensor data collected during the Automotive Collision Avoidance System Field Operational Test (ACAS FOT) [10].

This paper presents the new techniques/methods being used for the rapid vehicle development and system level performance assessment. It consists of two parts: the first part presents the automated multilevel substructuring (AMLS) technique, which greatly reduces the computational demands of larger finite element models with millions of degrees of freedom(DOF) and extends the capabilities to higher frequencies and higher level of accuracy; the second part is on the superelement in conjunction with the Component Mode Synthesis (CMS) and also Automated Component Mode Synthesis (ACMS) techniques. In superelement, a full vehicle model is divided into components such as Body-in-white, Front cradle/chassis, Rear cradle/chassis, Exhaust, Engine, Transmission, Driveline, Front suspension, Rear suspension, Brake, Seats, Instrument panel, Steering system, tires, etc. with each piece represented by reduced stiffness, mass, and damping matrices.

This paper presents the hybrid technique application in identifying the noise transfer paths and the force transmissibility between the interfaces of the different components in the vehicle. It is the stiffness based formulation and is being applied for the low to mid frequency range for the vibration and structure borne noise. The frequency response functions such as dynamic compliance, mobility, inertance, and acoustic sensitivity, employed in the hybrid method, can either be from the test data or finite element solution or both. The Source-Path-Receiver concept is used. The sources can be from the road surface, engine, transmission, transfer case, prop-shaft, differential, rotating components, chain drives, pumps, etc., and the receiver can be driver/passenger ears, steering column, seats, etc.

Neck injury assessment is part of the FMVSS208 requirements. Hardware tests are often conducted to validate whether the vehicle safety system meets the requirements. This paper presents a full vehicle finite element model using LS-DYNA, including structural components, restraint system components, and dummies. In the case of a frontal impact at 30deg angle, in the areas of neck compression, neck extension and neck kinematics, it is demonstrated that a good correlation is achieved between the response of a FE dummy in the model and those of ATDs in the physical hardware tests. It is concluded that the math tool may be applied to comprehend test and design variations that may arise throughout a vehicle development lifecycle and to help develop a vehicle restraint system.

Global R&D is in its infant stages. Senior executives and their organizations need to develop deeper understanding of the opportunities and challenges of off-shoring R&D. While global pressure will continue to mount to deliver more value at ever lower cost, the labor cost arbitrage break in countries such as China or India will not last forever. The fundamental challenge is to use the current low-cost advantage to build rapidly a sustainable technology, product and service advantage. This requires the development of a balanced local growth strategy that is well adapted to the regional strengths while ensuring a seamless global integration of people, organizations, and processes. This paper focuses on the build-up of GM's R&D activities in India with an emphasis on research in one of the key thrust areas in GM R&D - Automotive Electronics, Controls, and Software. Lessons learned apply also to development.

Consumer expectations for automated vehicle operations such as automatic locking, remote ignition control, navigation, and entertainment are primary drivers for the increasing complexity of embedded automotive electronics modules. The prevalent practice for procuring these modules is to develop a written behavioral specification that is then used by an outside supplier to build and test the module. Validation test plans are written separately based on an understanding of the requirements. The challenges posed by the current practice include the inability to completely specify the expected behavior in a timely manner, the need to balance the design between low cost and new features demanded by the customer, and ensuring that the product exactly implements the specified behavior. Moreover, vehicle manufacturers desire the ability to explore sensitivity of specifications by identifying constraints on the system and assessing the product for ease of implementation.

A novel longitudinally sliding overhead video screen monitor was developed to address consumer needs for vehicles equipped with rear seat entertainment and long length sunroofs. Long length sunroof openings in vehicles are causing engineers to mount video screen monitors in locations other than the overhead. Typically, they are mounted on the floor console or on the back of front seat head restraints. Floor console mounted video screen monitors generally do not provide a comfortable viewing distance or angle for second and third row occupants. Head restraint mounted video monitors cause issues with seat shake and two monitors adds to the vehicle cost unnecessarily. The mountable sliding video monitor assembly comprises of a video display screen, brackets for mounting the monitor, a pair of tracks that are movable with respect to each other, a series of ball bearings, and a roof mounting bracket. The inner main track is adapted for mounting the pair of tracks to the vehicle.