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This paper compares the results from three human factors studies conducted in a motion-based simulator in 2008, 2014 and 2023, to highlight the trends in driver's response to Forward Collision Warning (FCW). The studies were motivated by the goal to develop an effective HMI (Human-Machine Interface) strategy that enables the required driver's response to FCW while minimizing the level of annoyance of the feature. All three studies evaluated driver response to a baseline-FCW and no-FCW conditions. Additionally, the 2023 study included two modified FCW chime variants: a softer FCW chime and a fading FCW chime. Sixteen (16) participants, balanced for gender and age, were tested for each group in all iterations of the studies. The participants drove in a high-fidelity simulator with a visual distraction task (number reading). After driving 15 minutes in a nighttime rural highway environment, a surprise forward collision threat arose during the distraction task.

Occupant protection in side impacts, in particular for near-side occupants, is a challenge due to the occupant’s close proximity to the impact. Near-side occupants have limited space to ride down the impact. Curtain and side airbags fill the gap between occupant and the side interior. This analysis was conducted to provide insight on the characteristics of side impacts and the relevancy of currently regulated test configurations. For this purpose, 2007-2015 NASS-CDS and 2017-2021 CISS side crash data were analyzed for towed light vehicles. 2008 and newer model year vehicle data was selected to ensure that most vehicles were equipped with side/curtain airbags. The results showed that side impacts accounted for approximately 26.7% of the vehicles involved and 18.9% of the vehicles with at least one seriously injured occupant. Most side impacts involved damage to the front and front-to-center of the vehicle.

Metal cutting/machining is a widely used manufacturing process for producing high-precision parts at a low cost and with high throughput. In the automotive industry, engine components such as cylinder heads or engine blocks are all manufactured using such processes. Despite its cost benefits, manufacturers often face the problem of machining chips and cutting oil residue remaining on the finished surface or falling into the internal cavities after machining operations, and these wastes can be very difficult to clean. While part cleaning/washing equipment suppliers often claim that their washers have superior performance, determining the washing efficiency is challenging without means to visualize the water flow. In this paper, a virtual engineering methodology using particle-based CFD is developed to address the issue of metal chip cleanliness resulting from engine component machining operations. This methodology comprises two simulation methods.

In a recent time, which new vehicle lines comes with a huge number of sensors, control units, embedded technologies, and the complexity of these systems (electronics, electrical and electromechanical parts) increases in an exponential way. Considering these events, the expressive generated data amount grows in the same pace, so, consume, transform, and analyze all these data to better understand the modern customer, their needs and how they use the car features becomes necessary. Through that scenario, connected vehicles developed by Ford Motor Company has been generating opportunities to feature’s improvement and cost reduction based on data analysis. This growing quantity of data might be used to optimize feature systems and help engineering teams to understand how the features have been used and enhance the systems engineering design for new or existing features.

In order to evaluate the THOR-50M as a front impact Anthropomorphic Test Device (ATD) for vehicle safety design, the ATD was compared to the H3-50M in matching vehicle crash tests for 20 unique vehicle models from 2 vehicle manufacturers. For the belted driver condition, a total of fifty-four crash tests were investigated in the 56.3 km/h (35 mph) front rigid barrier impact condition. Four more tests were compared for the unbelted driver and right front passenger at 40.2 km/h (25 mph) in the flat frontal and 30-degree right oblique rigid barrier impact conditions. The two ATDs were also evaluated for their ability to predict injury risk by comparing their fleet average injury risk to Crash Investigation Sampling System (CISS) accident data for similar conditions. The differences in seating position and their effect on ATD responses were also investigated.

A DMS (Driver Monitoring System) is one of the most important safety features that assist in the monitoring functions and alert drivers when distraction or drowsiness is detected. The system is based in a DSMC (Driver Status Monitoring Camera) mounted in the vehicle's dash, which has a predefined set of operational requirements that must be fulfilled to guarantee the correct operation of the system. These conditions represent a trade space analysis challenge for each vehicle since both the DSMC and the underlying vehicle’s requirements must be satisfied. Relying upon the camera’s manufacturer evaluation for every iteration of the vehicle’s design has proven to be time-consuming, resources-intensive, and ineffective from the decision-making standpoint.

Auto industry has faced constant challenges in the economic, technology and global trend in the recent years. This is changing the corporative mindset to find creative and innovative processes and methods to evolve the product development system to adjust and deliver competitive products that satisfy customers expectations. Integrating the work from different teams in an organization has been moving from simple roles and responsibilities definition with effective communication channels to a new vision where teamwork progresses in harmony and embraces change to satisfy customers as part of the process. The path to evolve work in engineering that relies on several computational tools continues. In this article, it is presented an integration of different tools to manage vehicle program changes using model-based systems engineering, the present work improves the reaction capabilities of the teams and enables to adjust to changes in the development of a vehicle.

Fretting fatigue was observed in standard cylindrical fatigue samples at the regions in contact with the grips of the test frames during fatigue testing for AlSi10Mg aluminum alloy produced by laser powder bed fusion process (L-PBF). The failure of the fatigue sample grips occurs much earlier than the failure of the gauge section. This results in a damaged sample and the sample cannot be reused to continue the test. This type of failure is rarely seen in materials produced by traditional manufacturing processes. In this study, X-ray residual stress analysis was performed to understand the cause of failure for L-PBF AlSi10Mg with the as-built surface condition. The result indicates that the fretting fatigue failure was caused by the strong tensile residual stress in the as-built state combining with the fretting wear between the sample and the grip. A few potential solutions to avoid the fretting fatigue failure were investigated.

Driver oblique far-side sled impacts were simulated with three surrogates. The EuroSID side impact dummy with rib extension (ES2re), the WorldSID side impact 50th percentile male dummy (WS50M), and the Global Human Body Modeling Consortium’s 50th percentile male human body (GHBM) models. The versions of the surrogates’ models were 7.0, 7.5.1, and 5.0, respectively. Surrogates were seated in the front left driver seat in a virtual generic crossover sled environment. The Finite Element (FE) based environment consisted of a driver seat, a center console, and a passenger seat. Two restraint systems were considered for each surrogate: belt only (BO) and belt plus a generic seat-mounted far-side impact airbag (BB). Surrogates were restrained using a 3-point belt that has a digressive shoulder force load limiter, and retractor, and anchor pretensioners. The far-side airbag used was a 37-liter in volume and has two chambers.

This study focused on occupant responses in very large pickup trucks in rollovers and was conducted in three phases. Phase 1 - Field data analysis: In a prior study [9], 1998 to 2020 FARS data were analyzed; Pickup truck drivers with fatality were 7.4 kg heavier and 4.6 cm taller than passenger car drivers. Most pickup truck drivers were males. Phase 1 extended the study by focusing on the drivers of very large pickup trucks. The size of 1999-2016 Ford F-250 and F-350 drivers involved in fatal crashes was analyzed by age and sex. More than 90% of drivers were males. The average male driver was 179.5 ± 7.5 cm tall and weighed 89.6 ± 18.4 kg. Phase 2 – Surrogate study: Twenty-nine male surrogates were selected to represent the average size of male drivers of F-250 and F-350s involved in fatal crashes. On average, the volunteers weighed 88.6 ± 5.2 kg and were 180.0 ± 3.2 cm tall with a 95.2 ± 2.2 cm seated height.

In this paper, a novel mixed-integer programming model is developed to optimally assign the die sets to candidate plants to minimize the total costs. The total costs include freight shipping stamped parts to assembly plants, die set movement, outsourcing, and utilization. Therefore, the objective function is weighted multi-criteria and it takes into consideration some of the key constraints in the real-world condition including “must-move die sets”. An optimization tool has been developed that takes several inputs and feeds them as the input to the mathematical model and generates the optimal assignments with the directional costs as the output. The tool has been tested for several plants at Ford and has proved its robustness by saving millions of dollars. The developed tool can easily be applied to other manufacturing systems and original equipment manufacturers (OEMs).

Laser welding of the magnesium-bearing AA5xxx aluminum alloys is often beset by keyhole instability, especially in the lap through joint configuration. This phenomenon is characterized by periodic collapse of the keyhole leaving large voids in the weld zone. In addition, the top surface can exhibit undercut and roughness. In full penetration welds, keyhole instability can also produce a spikey root and severe top surface concavity. These discontinuities could prevent a weld from achieving engineering specification compliance, pose a craftsmanship concern, or reduce the strength and fatigue performance of the weld. In the case of a full penetration weld, a spikey root could compromise part fit-up and corrosion protection, or damage adjacent sheet metal, wiring, interior components, or trim.

This study was conducted to assess the effects of differing rear impact pulse characteristics on restraint performance, front-seat occupant kinematics, biomechanical responses, and seat yielding. Five rear sled tests were conducted at 40.2 km/h using a modern seat. The sled buck was representative of a generic sport utility vehicle. A 50th percentile Hybrid III ATD was used. The peak accelerations, acceleration profiles and durations were varied. Three of the pulses were selected based on published information and two were modeled to assess the effects of peak acceleration occurring early and later within the pulse duration using a front and rear biased trapezoidal characteristic shape. The seatback angle at maximum rearward deformation varied from 46 to 67 degrees. It was lowest in Pulse 1 which simulates an 80 km/h car-to-car rear impact.

Assessment of the physical evidence on a seat belt restraint system provides one source of data for determining an occupant’s seat belt use or non-use during a motor vehicle crash. The evidence typically associated with loading from a restrained occupant has been extensively researched and documented in the literature. However, evidence of loading to the restraint system can also be generated by other means, including the interaction of an unrestrained occupant with a stowed restraint system. The present study evaluates physical evidence on multiple stowed restraint systems generated via interaction with unrestrained occupants during a full-scale dolly rollover crash test of a large multiple passenger van. Unbelted anthropomorphic test devices (ATDs) were positioned in the driver and right front passenger seats and in all designated seating positions in the third, fourth, and fifth rows.

Prior to developing or modifying the protocol of a performance evaluation test, it is important to identify field relevant conditions. The objective of this study was to assess the distribution of selected crash variables from rear crash field collisions involving modern vehicles. The number of exposed and serious-to-fatally injured non-ejected occupants was determined in 2008+ model year (MY) vehicles using the NASS-CDS and CISS databases. Selected crash variables were assessed for rear crashes, including severity (delta V), impact location, struck vehicle type, and striking objects. In addition, 15 EDRs were collected from 2017 to 2019 CISS cases involving 2008+ MY light vehicles with a rear delta V ranging from 32 to 48 km/h. Ten rear crash tests were also investigated to identify pulse characteristics in rear crashes. The tests included five vehicle-to-vehicle crash tests and five FMVSS 301R barrier tests matching the struck vehicle.

The automotive industry is passing for a big transformation, due to technologies advance. The electrical technologies are also on a good rising curve, calling the attention of the Original Equipment Manufacturer (OEMs). This scenario generates the demand for a faster method to train their new hired engineers, when compared with usual on the job training. Model in the Loop (MiL) consists in one of the real-time embedded systems test phases, which is developed in a computational environment, performing a mathematical modeling of the system, presenting an interface that allows the visualization of its dynamics and the signals involved. Two powerful software in industry that apply MiL are the Matlab and Simulink. A project involving these applications was proposed for a team of new hired engineers, developing models of several vehicle Electronic Control Units (ECUs), with some scope reduction as an example the functional requirements reduction.

The average body weight of the US population has increased over time. This study investigates the effect of increasing weight on seat and occupant responses in 15-18 km/h and 42 km/h rear sled tests. The effect of initial occupant posture is also discussed. Seven tests were conducted with lap-shoulder belted ATDs (anthropometric test device) placed on older and modern driver seats. Four tests were conducted with a 50th percentile male Hybrid III, two with 95th percentile male Hybrid III and one with a BioRID. The ATDs were ballasted to represent a Class I or II obese occupant in three tests. The tests were matched by seat model and sled velocity. The effect of occupant weight was assessed in three matches. The results indicated an increase in seatback deflection with increasing occupant weight.

Occupant protection in rear crashes is complex. While seatbelts and head restraints are effective in rear impacts, seatbacks offer the primary restraint component to front-seat occupants in rear impacts. Seatback deflection due to occupant loading can occur in a previous rear crash and/or in multiple-rear event crashes. Seatback deflection will in-turn affect the plastic seatback deformation and energy absorption capabilities of the seat. This study was conducted to provide information on seatback deflection and seat energy consumption in low and high-speed rear impacts. The results can be used to examine seatback deflection and energy consumed in a previous rear impact, or in collisions with multiple rear impacts. Prior seatback deflection and energy absorption can affect the total remaining energy absorption and seat performance for a subsequent rear impact.

Interest in rear-seat occupant safety has increased in recent years. Information relevant to rear-seat occupant interior space and kinematics are needed to evaluate injury risks in real-world accidents. This study was conducted to first assess the effect of size and restraint conditions, including belt misuse, on second-row occupant kinematics and to then document key clearance measurements for an Anthropomorphic Test Device (ATD) seated in the second row in modern vehicles from model years 2015-2020. Twenty-two tests were performed with non-instrumented ATDs; three with a 5th percentile female Hybrid III, 10 tests with a 10-year-old Hybrid III, and 9 tests with a 6-year-old Hybrid III. Test conditions included two sled bucks (mid-size car and sport utility vehicle (SUV)), two test speeds (56 and 64 km/h), and various restraint configurations (properly restrained and improperly restrained configurations). Head and knee trajectories were assessed.

Blunt impacts to the back of the torso can occur in vehicle crashes due to interaction with unrestrained occupants, or cargo in frontal crashes, or intrusion in rear crashes, for example. Six pendulum tests were conducted on the back of an instrumented 50th percentile male Hybrid III ATD (Anthropomorphic Test Device) to determine kinematic and biomechanical responses. The impact locations were centered with the top of a 15-cm diameter impactor at the T1 or at T6 level of the thoracic spine. The impact speed varied from 16 to 24 km/h. Two 24 km/h tests were conducted at the T1 level and showed repeatability of setup and ATD responses. The 16 and 24 km/h tests at T1 and T6 were compared. Results indicated greater head rotation, neck extension moments and neck shear forces at T1 level impacts. For example, lower neck extension was 2.6 times and 3.8 times greater at T1 versus T6 impacts at 16 and 24 km/h, respectively.