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This study deals with passenger side restraint system design for frontal impact and four impact modes are considered in optimization. The objective is to minimize the Relative Risk Score (RRS), defined by the National Highway Traffic Safety Administration (NTHSA)'s New Car Assessment Program (NCAP). At the same time, the design should satisfy various injury criteria including HIC, chest deflection/acceleration, neck tension/compression, etc., which ensures the vehicle meeting or exceeding all Federal Motor Vehicle Safety Standard (FMVSS) No. 208 requirements. The design variables include airbag firing time, airbag vent size, inflator power level, retractor force level. Some of the restraint feature options (e.g., some specific features on/off) are also considered as discrete design variables. Considering the local variability of input variables such as manufacturing tolerances, the robustness and reliability of nominal designs were also taken into account in optimization process.

The National Highway Traffic Safety Administration (NHTSA) recently published a Request for Comments regarding a potential upgrade to the US New Car Assessment Program (US NCAP) - a star-rating program pertaining to vehicle crashworthiness. Therein, NHTSA (a) cited two metrics for assessing head risk: Head Injury Criterion (HIC15) and Brain Injury Criterion (BrIC), and (b) proposed to conduct risk assessment via its risk curves for those metrics, but did not prescribe a specific method for applying them. Recent studies, however, have indicated that the NHTSA risk curves for BrIC significantly overstate field-based head injury rates. Therefore, in the present three-part study, a new set of BrIC-based risk curves was derived, an overarching head risk equation involving risk curves for both BrIC and HIC15 was assessed, and some additional candidate-predictor-variable assessments were conducted. Part 1 pertained to the derivation.

A provisional, age-dependent thoracic risk equation (or, “risk curve”) was derived to estimate moderate-to-fatal injury potential (AIS2+), pertaining to men with responses gaged by the advanced mid-sized male test dummy (THOR50). The derivation involved two distinct data sources: cases from real-world crashes (e.g., the National Automotive Sampling System, NASS) and cases involving post-mortem human subjects (PMHS). The derivation was therefore more comprehensive, as NASS datasets generally skew towards younger occupants, and PMHS datasets generally skew towards older occupants. However, known deficiencies had to be addressed (e.g., the NASS cases had unknown stimuli, and the PMHS tests required transformation of known stimuli into THOR50 stimuli).

With the increasing demands of developing vehicles for global markets, different regulations and public domain tests need to be considered simultaneously for side impact. Various side impact countermeasures, such as side airbags, door trim, energy absorbing foams etc., are employed to meet multiple side impact performance requirements. However, it is quite a challenging task to design a balanced side impact restraint system that can meet all side impact requirements for multiple crash modes. This paper presents an integrated multi-objective optimal design and robustness assessment framework for vehicle side impact restraint system design.