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Current state-of-the-art vehicles implement pedestrian protection features that rely on pedestrian detection sensors and algorithms to trigger when impacting a pedestrian. During the development phase, the vehicle must “learn” to discriminate pedestrians from the rest of potential impacting objects. Part of the training data used in this process is often obtained in physical tests utilizing legform impactors whose external biofidelity is still to be evaluated. This study uses THUMS as a reference to assess the external biofidelity of the most commonly used impactors (Flex-PLI, PDI-1 and PDI-2). This biofidelity assessment was performed by finite element simulation measuring the bumper beam forces exerted by each surrogate on a sedan and a SUV. The bumper beam was divided in 50 mm sections to capture the force distribution in both vehicles. This study, unlike most of the pedestrian-related literature, examines different impact locations and velocities.

With growing environmental concerns associated with gas-powered vehicles and busier city streets, micro-mobility modes, including traditional bicycles and new technologies, such as electric scooters (e-scooters), are becoming solutions. In 2018, e-scooter usage overtook other shared micro-mobility modes with over 38 million e-scooter trips taken. Concurrently, the societal concern regarding the safety of these devices is also increasing. To examine the types of injuries associated with e-scooters and bicycles, the National Electronic Injury Surveillance System (NEISS), a probability sample of US hospitals that collects information from emergency room (ER) visits related to consumer products, was utilized. Records from September 2017 to December 2018 were extracted, and those associated with powered scooters were identified. Injury distributions by age, sex, race, treatment, diagnosis, and location on the body were explored.

Power steering systems provide significant design challenges. They are detrimental to fuel economy since most require the continuous operation of a hydraulic pump. This generates heat that must be dissipated by fluid lines and heat exchangers. This paper presents a simple one-dimensional transient model for power steering components. The model accounts for the pump power, heat dissipation from fluid lines, the power steering cooler, and the influence of radiation heat from exhaust system components. The paper also shows how to use a transient thermal model of the entire system to simulate the temperatures during cyclic operation of the system. The implications to design, drive cycle simulation, and selection of components are highlighted.

In 1972, the first SAE paper describing the use of computer simulation as a design tool for automotive air conditioning was written by these authors. Since then, many such simulations have been used and new tools such as CFD have been applied to this problem. This paper reviews the work over that past 35 years and presents several of the improvements in the basic component and system models that have occurred. The areas where “empirical” information is required for model support and the value of CFD cabin and external air flow modeling are also discussed.

Recently there has been a greater awareness of the increased risk of certain injuries associated with air bag deployment, especially the risks to small occupants, often women. These injuries include serious eye and upper extremity injuries and even fatalities. This study investigates the interaction of a deploying air bag with cadaveric upper extremities in a typical driving posture; testing concentrates on female occupants. The goals of this investigation are to determine the risk of upper extremity injury caused by primary contact with a deploying air bag and to elucidate the mechanisms of these upper extremity injuries. Five air bags were used that are representative of a wide range of air bag ‘aggressivities’ in the current automobile fleet. This air bag ‘aggressivity’ was quantified using the response of a dummy forearm under air bag deployment.

The poisoning of three way catalysts (TWC) by the phosphorus contained in oil formulations containing zinc dialkyldithiophosphate (ZDDP) is examined. Catalysts were exposed to various types of ZDDP and detergents under conditions that were known to reduce performance through phosphorus poisoning without the blocking of sites by formation of glazing. The presence of phosphorus was detected with energy dispersive x-ray spectroscopy (EDX). In addition to analyzing the surface concentration of the phosphorus on the washcoat, the catalyst was cross cut so phosphorus that diffused into the washcoat could be mapped. The total phosphorus in the catalyst could then be calculated. The amount of total phosphorus detected correlated well with the reduced activity of the catalyst as measured by the temperature of 50% conversion.

This paper evaluates the biofidelity of the Hybrid III 5th percentile female dummy relative to seven small female cadavers tested as out-of-position drivers in static air bag deployment tests. In the out-of-position tests, the chest was positioned against the air bag module in an effort to recreate a worst-case loading environment for the thorax. Two pre-depowered production air bags and a prototype dual-stage air bag were evaluated. Thoracic accelerometers and chestbands were used to compare chest compression, velocity, acceleration, and Viscous Criteria. A statistical comparison of dummy and cadaver results indicate acceptable biofidelity of the Hybrid III dummy with significant differences observed only in the Viscous Criteria.

The Cummins M-11 high soot diesel engine test is a key tool in evaluating lubricants for the new PC-7 (CH-4) performance category. M-11 rocker arms and crossheads from tests with a wide range of lubricant performance were studied by surface analytical techniques. Abrasive wear by primary soot particles is supported by the predominant appearance of parallel grooves on the worn parts with their widths matching closely the primary soot particle sizes. Soot abrasive action appears to be responsible for removing the protective antiwear film and, thus, abrades against metal parts as well. Subsequent to the removal of the antiwear film, carbide particles, graphite nodules, and other wear debris are abraded, either by soot particles or sliding metal-metal contact, from the crosshead and rocker arm metal surfaces. These particles further accelerate abrasive wear. In addition to abrasive wear, fatigue wear was evident on the engine parts.

During a rollover accident the position of an occupant within a vehicle at the time of vehicle-to-ground contact affects the occupant's injury potential and injury mechanisms. During rollovers, the accelerations developed during the airborne phases cause an occupant to move away from the vehicle's center of mass towards the perimeter of the vehicle. The occupant is already in contact with vehicle structures during upper vehicle structure-to-ground impacts. The location and extent of the occupant-to-vehicle contacts and the times and locations at which the contacts occur depend upon a variety of factors including occupant size, initial position in the vehicle, restraint status, vehicle geometry, and rollover accident parameters. Onboard and offboard video of existing dolly rollover studies, specifically the “Malibu” studies, were examined to quantify the motion of the occupants' heads and determine the timing and locations of head contacts to the vehicle perimeter.

In this study, the occupant containment characteristics of automotive laminated safety glass in side window applications was evaluated through two full-scale, full-vehicle dolly rollover crash tests. The dolly rollover crash tests were performed on sport utility vehicles equipped with heat-strengthened laminated safety glass in the side windows in order to: (1) evaluate the capacity of laminated side window safety glass to contain unrestrained occupants during rollover, (2) analyze the kinematics associated with unrestrained occupants during glazing interaction and ejection, and (3) to identify laminated side window safety glass failure modes. Dolly rollovers were performed on a 1998 Ford Expedition and a 2004 Volvo XC90 at a nominal speed of 43 mph, with unbelted Hybrid II Anthropomorphic Test Devices (ATDs) positioned in the outboard seating positions.

One Dimensional models for front end air flows through the cooling system package are very useful for evaluating the effects of component and front end geometry changes. To solve such models for the air flow requires a robust iterative process that involves a number of non-linear sub-models. The cooling fan (s) constitute a major part of the difficulty, especially when they employ a viscous or “thermal” fan drive. This drive varies the torque coupling between the input and output shafts based on the radiator outlet air temperature. The coupling is achieved by viscous shear between two grooved disks and is regulated by a bimetal strip valve that varies the amount of fluid between the disks. This paper presents a mathematical model by which the input/output speed ratio may be determined as a function of the air temperature and input speed. Coefficients in the model are estimated from standard supplier performance information.

Simple component models are advantageous when simulating vehicle AC systems so that overall model complexity and computation time can be minimized. These models must be robust enough to avoid instability in the iteration method used for determining the AC system operating or “balance” point. Simplicity and stability are especially important when the AC system model is coupled with a vehicle interior model for studies of transient performance because these are more computationally intensive. This paper presents a semi-empirical modeling method for compressors based on dimensionless parameters. Application to some sample compressor data is illustrated. The model equations are simple to employ and will not introduce significant stability problems when used as part of a system simulation.

Properly restraining a child in an automotive seat may require the use of a weight- and size-appropriate Child Restraint System (CRS). Proper installation of the CRS is a critical part of protecting a child during a motor vehicle collision. During a collision, child occupants sometimes exert enough force on the restraint system to generate load marks on the CRS and the vehicle restraint system. These marks are often relied upon by investigators to determine if the child occupant was properly restrained at the time of the collision. This paper is an observational study of the load marks generated from sled testing that was conducted using Hybrid III 3-year-old and 6-year-old Anthropomorphic Test Devices (ATDs). Tests were conducted with various child restraint systems that were installed in accordance with the manufacturer's recommendations as well as installed improperly. Additional tests were conducted with the ATDs without the use of a CRS.

The process of design inherently involves consideration of risk trade offs; intervening to reduce one risk often increases another. In addition to creating a design for the intended function of the product, a rational process of risk management involves prediction of risk through design analysis, statistical evaluation of the history of similar products, and potentially multidisciplinary teams to address diverse causes of risk. As a case study, this paper examines the benefits of using one class of fire retardant to reduce risk of vehicle fire injuries and the countervailing health risk due to increased quantities of fire retardants released in the interior environment. Data sources for fire and health risk were researched and interpreted for use in the analysis. Information needed to reduce the uncertainties in the risk predictions are identified for future refinements to the conclusions.

It is widely accepted that a motorcycle helmet will reduce the risk of a serious brain injury during an accident through energy dissipation. Currently, there is no literature on what happens to a motorcycle helmet after repeated significant impacts or why it cannot be re-used according to the DOT label. It is also unclear experimentally if the foam liner is permanently affected after repeated impacts. In this study, we repetitively dropped one style of DOT-approved motorcycle helmet using a drop tower system in accordance with FMVSS 218. Helmeted Hybrid III and magnesium headforms were dropped onto a flat anvil with contact to the apical region of the helmets. Strips of pressure-indicating film were placed in the mid-sagittal plane between the foam liner and the headform. Headform accelerations and head injury criterion (HIC) for the Hybrid-III headform were calculated for each drop test. There was a trend for maximum headform acceleration to increase with the number of impacts.

Successful product development (PD) includes understanding and delighting customers, anticipating and avoiding failures, and delivering products efficiently. While Design for Six Sigma may be most naturally applied to avoid failures, it has been applied to all three of these areas with varying degrees of success. This paper discusses the advantages and disadvantages of using DFSS to bolster these key elements of PD. Example projects along with successes and shortcomings related to overall PD effectiveness are presented. Whatever form DFSS takes, organizations should make explicit the decision of how to deploy DFSS as part of an overarching quality plan.

The Icing Branch at NASA Glenn Research Center has funded an exploratory effort to identify requirements for developing a flight dispatcher-centered web-based icing training program that would be available for all airspace users. Through research and discussions with personnel at airlines, target areas were identified as influences on the requirements for the training system: 1 Flight dispatchers' icing related judgments and decision-making; 2 Certification, new hire and recurrent flight dispatcher training with respect to icing; 3 Icing related weather sources and the problems that flight dispatchers may have in their interpretation; 4 Pedagogical strategies (such as flight dispatcher-centered scenario-based approaches) for delivering flight dispatcher training content; and 5 Concerns/constraints with respect to web-based training for flight dispatchers.

A biaxial test procedure is used to assess the constitutive properties of polymers in tension. The constitutive constants are derived for high strain rate applications such as those associated with crashworthiness studies. The test procedure is used in conjunction with a time- and strain-dependent quasi-linear viscoelastic constitutive law consisting of a Mooney-Rivlin formulation combined with Maxwell elements. The procedure is demonstrated by describing the stress vs. strain relationship of a rubber specimen subjected to a step-relaxation input. The constitutive equation is transformed from a nonlinear convolution integral to a set of first order differential equations. These equations, with the appropriate boundary conditions, are solved numerically to obtain transient stresses in two principal directions. Material constants for use in the explicit LS-Dyna non-linear finite element code are provided.

Biomechanical data are often assumed to be doubly censored. In this paper, this assumption is evaluated critically for several previously published sets of data. Injury risk functions are compared using simple logistic regression and using survival analysis with 1) the assumption of doubly censored data and 2) the assumption of right-censored (uninjured specimens) and uncensored (injured) data. It is shown that the injury risk functions that result from these differing assumptions are not similar and that some experiments will require a preliminary assessment of data censoring prior to finalizing the experimental design. Some types of data are obviously doubly censored (e.g., chest deflection as a predictor of rib fracture risk), but many types are not left censored since injury is a force-limiting phenomenon (e.g., axial force as a predictor of tibia fracture). Guidelines for determining the censoring for various types of experiment are presented.

This paper presents a technique for developing corridors from individual subject responses contained in experimental biomechanical data sets. Force-deflection response is used as an illustrative example. The technique begins with a method for averaging human subject force-deflection responses in which curve shape characteristics are maintained and discontinuities are avoided. Individual responses sharing a common characteristic shape are averaged based upon normalized deflection values. The normalized average response is then scaled to represent the given data set using the mean peak deflection value associated with the set of experimental data. Finally, a procedure for developing a corridor around the scaled normalized average response is presented using standard deviation calculations for both force and deflection.