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Objective: A friction rollover test was conducted as part of a rollover sensing project. This study evaluates vehicle and occupant responses in the test. Methods: A flat dolly carried a Saab 9-3 sedan laterally, passenger-side leading to a release point at 42 km/h (26 mph) onto a high-friction surface. The vehicle was equipped with roll, pitch and yaw gyros near the center of gravity. Accelerometers were placed at the vehicle center tunnel, A-pillar near the roof, B-pillar near the sill, suspension sub-frame and wheels. Five off-board and two on-board cameras recorded kinematics. Hybrid III dummies were instrumented for head and chest acceleration and upper neck force and moment. Belt loads were measured. Results: The vehicle release caused the tires and then wheel rims to skid on the high-friction surface. The trip involved roll angular velocities >300 deg/s at 0.5 s and a far-side impact on the driver’s side roof at 0.94 s. The driver was inverted in the far-side, ground impact.

This work discusses the development of SAE procedure J2747, “Hydraulic Pump Airborne Noise Bench Test”. This is a test procedure describing a standard method for measuring radiated sound power levels from hydraulic pumps of the type typically used in automotive power steering systems, though it can be extended for use with other types of pumps. This standard was developed by a committee of industry representatives from OEM's, suppliers and NVH testing firms familiar with NVH measurement requirements for automotive hydraulic pumps. Details of the test standard are discussed. The hardware configuration of the test bench and the configuration of the test article are described. Test conditions, data acquisition and post-processing specifics are also included. Contextual information regarding the reasoning and priorities applied by the development committee is provided to further explain the strengths, limitations and intended usage of the test procedure.

Computer simulation was used as a complement to crash and injury field data analysis and physical sled and barrier tests to investigate and predict the spinal injuries of a rear impact in an IndyCar. The model was expected to relate the spinal loads to the observed injuries, thereby predicting the probability and location of spinal fractures. The final goal is to help reduce the fracture risk by optimizing the seat and restraint system design and the driver's position using computer modeling and sled testing. MADYMO Full FE Human Body Model (HBM) was selected for use because of its full spinal structural details and its compatibility with the vehicle and restraint system models. However, the IndyCar application imposed unique challenges to the HBM. First, the driver position in a race car is very different from that in a typical passenger car.

The objective of this study was to analyze available anthropomorphic test device (ATD) responses from KARCO rear impact tests and to evaluate an injury predictive model based on crash severity and occupant weight presented by Saczalski et al. (2004). The KARCO tests were carried out with various seat designs. Biomechanical responses were evaluated in speed ranges of 7-12, 13-17, 18-23 and 24-34 mph. For this analysis, all tests with matching yielding and stiff seats and matching occupant size and weight were analyzed for cases without 2nd row occupant interaction. Overall, the test data shows that conventional yielding seats provide a high degree of safety for small to large adult occupants in rear crashes; this data is also consistent with good field performance as found in NASS-CDS. Saczalski et al.'s (2004) predictive model of occupant injury is not correct as there are numerous cases from NASS-CDS that show no or minor injury in the region where serious injury is predicted.

Purpose: A better understanding of rear occupant fatality risks is needed to guide the development of safety improvements for 2nd and 3rd row occupants. This study investigates fatal accidents of 1st, 2nd and 3rd row occupants by principal direction of force (PDOF), irrespective of restraint use. It determined the number of fatalities, exposure and fatality risk. Methods: 1996-2005 FARS was analyzed for occupant fatalities by seating position (1st, 2nd and 3rd row) and principal direction of force (1-12 o'clock PDOF, rollover and other/unknown). Light vehicles were included with model year 1990+. 1996-2005 NASS-CDS was similarly analyzed for occupant exposure. Fatality risk was defined as the number of fatalities in FARS for a given category divided by the exposure from NASS-CDS. Results: Ten percent (9.6%) of fatalities were to 2nd row occupants in FARS. About 2,080 deaths occur to 2nd row occupants annually. 38.4% died in rollovers and 26.8% in frontal crashes.

Some Electronic Throttle Control (ETC) Air Control Valves (ACV) on automotive internal combustion engines are susceptible to icing of the throttle valve. Ice formation can result in an increase in torque required to open or close the valve. Laboratory studies were conducted to improve the understanding of throttle valve icing on electronic throttle control valves with both aluminum and composite (plastic) bodies over various bore sizes (4 cylinder to 8 cylinder engines). Study results indicated that ice compression at the bore and valve gap, not ice adhesion, is the major contributor to the ETC-ACV icing phenomenon. In addition, testing of parts with various bore sizes, orientations and surface cleanliness resulted in further understanding of the icing issue.

Obesity rates are reaching an epidemic worldwide. In the US, nearly 40 million people are obese. The automotive safety community is starting to question the impact of obesity on occupant protection. This study investigates fatality and serious injury risks for front-seat occupants by Body Mass Index (BMI). NASS-CDS data was analyzed for calendar years 1993-2004. Occupant exposure and injury was divided in seven BMI categories with obese defined as those with BMI ≥ 30 kg/m2. Injuries were studied for drivers and right-front passengers and included analysis of lap-shoulder belted and unbelted occupants. The results show that obese occupants have a higher fatality risk compared to normal BMI occupants; morbidly obese occupants (BMI ≥ 40 kg/m2) have 2.25 times higher fatality risk (1.15% v 0.51%). The fatality risk for belted obese drivers was 0.29%, which was 6.7 times lower than the 1.94% for those unbelted. These rates are similar to other BMI occupants.

Objective: This study analyzes rear sled tests with a 95th% male and 5th% female Hybrid III dummy in various seating positions on ABTS (All Belt to Seat) seats in severe rear impact tests. Dummy interactions with the deforming seatback and upper body extension around the seat frame are considered. Methods: The 1st series involved an open sled fixture with a Sebring ABTS seat at 30 mph rear delta V. A 95th% Hybrid III dummy was placed in four different seating positions: 1) normal, 2) leaning inboard, 3) leaning forward and inboard, and 4) leaning forward and outboard. The 2nd series used a 5th% female Hybrid III dummy in a Grand Voyager body buck at 25 mph rear delta V. The dummy was leaned forward and inboard on a LeSabre ABTS or Voyager seat. The 3rd series used a 5th% female Hybrid III dummy in an Explorer body buck at 26 mph rear delta V. The dummy was leaned forward and inboard on a Sebring ABTS or Explorer seat.

This paper presents the development of a transmission closed loop pressure control system. The objective of this system is to improve transmission pressure control accuracy by employing closed-loop technology. The control system design includes both feed forward and feedback control. The feed forward control algorithm continuously learns solenoid P-I characteristics. The closed loop feedback control has a conventional PID control with multi-level gain selections for each control channel, as well as different operating points. To further improve the system performance, Robust Optimization is carried out to determine the optimal set of control parameters and controller hardware design factors. The optimized design is verified via an L18 experiment on spin dynamometer. The design is also tested on vehicle.

This paper provides an overview of rollover crash safety, including field crash statistics, pre- and rollover dynamics, test procedures and dummy responses as well as a bibliography of pertinent literature. Based on the 2001 Traffic Safety Facts published by NHTSA, rollovers account for 10.5% of the first harmful events in fatal crashes; but, 19.5% of vehicles in fatal crashes had a rollover in the impact sequence. Based on an analysis of the 1993-2001 NASS for non-ejected occupants, 10.5% of occupants are exposed to rollovers, but these occupants experience a high proportion of AIS 3-6 injury (16.1% for belted and 23.9% for unbelted occupants). The head and thorax are the most seriously injured body regions in rollovers. This paper also describes a research program aimed at defining rollover sensing requirements to activate belt pretensioners, roof-rail airbags and convertible pop-up rollbars.

Adaptive Cruise Control (ACC) technology is presently emerging in the automotive market as a convenience function intended to reduce driver workload. It allows the host vehicle to maintain a set speed and distance from preceding vehicles by a forward object detection sensor. The forward object detection sensor is the focal point of the ACC control system, which determines and regulates vehicle acceleration and deceleration through a powertrain torque control system and an automatic brake control system. This paper presents a design of an automatic braking system that utilizes a microprocessor-controlled brake hydraulic modulator. The alternatively qualified automatic braking means is reviewed first. The product level requirements of the performance, robustness, and durability for an automatic brake system are addressed. A brief overview of the presented system architecture is described.

In 2002, NHTSA statistics indicate air bag deployments saved an estimated 1,500 lives; however, reports of occupants having serious or fatal injuries during air bag deployment appear low relative to the number of accidents with air bag deployments. To avoid air bag induced injuries, a variety of occupant sensing technologies are being developed. One of the critical logic deployment challenges faced by these technologies is whether the system can accurately determine if the occupant is in a posture or a position such that air bag deployment may result in an injury. To improve accuracy, it is necessary to understand what postures the occupants are likely to assume during a ride and how often. For this purpose, Delphi Corporation has conducted a survey to solicit opinions on the posture usage rate. With 560 responses, the frequencies for 29 sitting postures for adult passengers and 13 child postures or positions were estimated.

With the requirements for reducing the emissions and improving the fuel economy, the automotive companies are developing hybrid, 42 V and fuel cell vehicles. Power electronics is an enabling technology for the development of environmental friendly vehicles, and to implement the various vehicle electrical architectures to obtain the best performance. In this paper, the requirements of the power semiconductor devices and the criteria for selecting the power devices for various types of low emission vehicles are presented. A comparative study of the most commonly used power devices is presented. A brief review of the future power devices that would enhance the performance of the automotive power conversion systems is also presented.

Regulatory and market pressures continue to challenge the automotive industry to develop technologies focused on reducing exhaust emissions and improving fuel economy. This paper introduces a practical model, which evaluates the economic value of various technologies based on their ability to reduce fuel consumption, improve emissions or provide consumer benefits such as improved performance. By evaluating the individual elements of economic value as viewed by the OEM manufacturer, while keeping the end consumer in mind, technology selection decisions can be made. These elements include annual fuel usage, vehicle performance, mass reduction and emissions, among others. The following technologies are discussed and evaluated: gasoline direct injection, variable valvetrain technologies, common-rail diesel and hybrid vehicles.

The industry strategy for automotive safety systems has been evolving over the last 20 years. Systems, such as frontal and side airbags, are available today on the worldwide market that provide proven safety benefits. Interest in advanced safety systems for occupant protection and accident avoidance, is focused on making further reductions in road fatalities and injuries. Interior occupant sensing systems for advanced restraint systems, trapped occupant sensing, and driver monitoring are today under intense development as part of the industry's safety vision. In this paper, we will discuss the need for and requirements of interior occupant sensing systems, as well as applicable technologies

This paper presents a methodology to predict component and system reliability and durability. The methodology is illustrated with an electronic diesel fuel injector case study that integrates customer usage data, component failure distribution, system failure criteria, manufacturing variation, and variation in customer severity. Extension to the vehicle system level enables correlation between component and system requirements. Further, this analysis provides the basis to establish a knowledge-based test option for a success test validation program to demonstrate reliability.

Purpose: This study presents cases of fracture-dislocation of the thoracic spine in extension during severe rear impacts. The mechanism of injury was investigated. Methods: Four crashes were investigated where a lap-shoulder-belted, front-seat occupant experienced fracture-dislocation of the thoracic spine and paraplegia in a severe rear impact. Police, investigator and medical records were reviewed, the vehicle was inspected and the seat detrimmed. Vehicle dynamics, occupant kinematics and injury mechanisms were determined in this case study. Results: Each case involved a lap-shoulder-belted occupant in a high retention seat with ≻1,700 Nm moment or ≻5.5 kN strength for rearward loading. The crashes were offset rear impacts with 40-56 km/h delta V involving under-ride or override by the impacting vehicle and yaw of the struck vehicle. In each case, the occupant's pelvis was restrained on the seat by the open perimeter frame of the seatback and lap belt.

Electro-hydraulic actuation has been used widely in automatic transmission designs. With greater demand for premium shift quality of automatic transmissions, higher pressure control accuracy of the transmission electro-hydraulic control system has become one of the main factors for meeting this growing demand. This demand has been the driving force for the development of closed loop pressure controls technology. This paper presents the further research done based upon a previously developed closed loop system. The focus for this research is on the system requirements, such as solenoid driver selection and system latency handling. Both spin-stand and test vehicle setups are discussed in detail. Test results for various configurations are given.

Objective: This is a descriptive study of the incidence of spinal injury by crash type using NASS-CDS. It provides an understanding of impacts to the undercarriage of the vehicle and injuries to the lumbar spine by reviewing electronic cases in NASS-CDS to determine crash circumstances for fractures of the lumbar spine with undercarriage impacts. Methods: 1997-2015 NASS-CDS was evaluated for serious injury (MAIS 3 + F) to front-seat occupants by seatbelt use and crash type in 1994+ MY vehicles. Undercarriage impacts were defined by GAD1 = U without a rollover. Serious injury was defined as MAIS 3 + F. Spinal injuries AIS 3+ were separated into cervical, thoracic and lumbar regions. Weighted data was determined using ratio weight. NASS-CDS electronic cases were downloaded from NHTSA with AIS 3+ lumbar spine injuries in undercarriage impacts. Results: There were 2,160 MAIS 3 + F injured occupants in undercarriage impacts. This was 0.23% of all serious injury.

Objective: This study investigated the incidence of abdominal injuries in frontal crashes by occupant age and seating position. It determined the risk for abdominal injury (AIS 2+) by organ and injury source. Methods: 1997-2015 NASS-CDS was analyzed to estimate the occurrence of abdominal injuries in non-ejected, belted occupants involved in frontal crashes. Vehicles were included with 1997+ model year (MY). The annual incidence and rate for different types of abdominal injury were estimated with standard errors. The sources for abdominal injury were determined. Results: 77.8% of occupants were drivers, 16.7% were right-front passengers and 5.4% were rear passengers. Rear passengers accounted for 77.1% of 8-11 year old (yo) and 17.2% of 12-17 yo group. The risk for moderate abdominal injury (MAIS 2 + abdo) was 0.30% ± 0.053% in drivers, 0.32% ± 0.086% in right-front passengers and 0.38% ± 0.063% in rear occupants.