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Injury to the far side occupant has been demonstrated as a significant portion of the total trauma in side impacts. The objective of the study was to determine the response of PMHS in far side impact configurations, with and without generic countermeasures, and compare responses to the WorldSID and THOR dummies. A far side impact buck was designed for a sled test system that included a center console and three-point belt system. The buck allowed for additional options of generic countermeasures including shoulder or thorax plates or an inboard shoulder belt. The entire buck could be mounted on the sled in either a 90-degree (3-o'clock PDOF) or a 60-degree (2-o'clock PDOF) orientation. A total of 18 tests on six PMHS were done to characterize the far side impact environment at both low (11 km/h) and high (30 km/h) velocities. WorldSID and THOR-NT tests were completed in the same configurations to conduct matched-pair comparisons.

This investigation addresses and evaluates: (1) belted drivers in frontal crashes; (2) crashes divided into low, medium, and high severity; (3) air-bag-equipped passenger vehicles separated into either model years 1985 - 1997 (with airbags) or model years 1998 - 2008; (4) rate of Harm as a function of crash severity and vehicle model year; and (5) injury patterns associated with injured body regions and the involved physical components, by vehicle model year. Comparisons are made between the injury patterns related to drivers seated in vehicles manufactured before 1998 and those manufactured 1998 or later. The purpose of this comparative analysis is to establish how driver injury patterns may have changed as a result of the introduction of more recent safety belt technology, advanced airbags, or structural changes.

The basis for this analysis was NASS/CDS 1997 to 2006. In the NASS database there were 60 cases with major fires in side impact crashes, 37 of which were in passenger vehicles less than 10 years old. These newer vehicles were examined in this study. Cases in NASS were examined to identify crash characteristics associated with major fires in side crashes. The database contained 22 cases with fatalities, eleven of which were coded as fire related. Three of these were associated with fires that did not originate from the crashed vehicle. The fuel tank was coded as the fire origin for 41% of the major fires in vehicles with side damage and for 7 out of the 8 vehicles with fire related fatalities. The most frequent crash characteristic was an impact with a narrow object that produced severe side damage. Lower extent of damage was evident in two fatal cases that involved a rollover following the side impact.

The basis for this analysis was FARS 1979 to 2005 and NASS/CDS 1997 to 2004. For these years, there were 12,493 cases in FARS where fire was coded as the most harmful event. In NASS there were 227 cases with major fires, 87 of which were in frontal crashes. The paper shows the annual trends in FARS with regard to overall fatalities and fatalities with fire as the most harmful event by direction of principal vehicle damage. The NASS/CDS files are used to determine the location of fire origin. The FARS data show that crashes with frontal damage are the most frequent crash types where fire is the most harmful event. In general, the most harmful event fire rates have declined with the overall fatality rates in FARS. However, in recent years the trend in fires with frontal damage has been on the increase. Cases in NASS were examined to identify patterns for major fires in frontal crashes. Engine compartment fires were by far the most frequent.

The National Highway Traffic Safety Administration has sponsored extensive research to improve the frontal protection of motor vehicles. Most of the research was conducted during the 1970's when belt usage rates were less than 10%. At that time, the research objectives did not anticipate the combination of air bags and three point manual belts as the restraint of choice for the 1990's. Consequently, little research was undertaken to extend the performance of this combination. However, the research conducted at that time offers opportunities for significant additional improvements in frontal protection. The purpose of this paper is to summarize some of the relevant research which was sponsored by NHTSA under the direction of the authors. Results will be highlighted which are particularly applicable to current vehicle configurations. Opportunities for further improvement, and required research are discussed.

A PC based interactive program was developed to simulate the unfolding and deploying process of a driver side airbag in the sagittal plane. The airbag was represented by a series of nodes. The maximum allowable stretch was less or equal to one between any two nodes. We assumed that the airbag unfolding was pivoted about folded points. After the completion of the unfolding process the airbag would begin to deploy. During the deploying process, two parameters were used to determine the nodal priority of the inflation. The first parameter was the distance between the instantaneous and final positions of a node. Nodes with longer distances to travel will have to move faster. We also considered the distance between the current nodal position and the gas inlet location. For a node closer to the gas inlet, we assumed that the deploying speed was faster. A graphical procedure was used to calculate the area of the airbag.

A study of air bag deployments has indicated that some occupant injury was “unexpected” and might have been related to loading by the inflating bag. Laboratory studies have found “high” loads on surrogates when they are out of a normal seating position and in the path and against an inflating air bag (out-of-position). The current study evaluated laboratory methods for assessing the significance of deployment loads and the interaction mechanics for the situation of an occupant located near or against a steering wheel mounted air bag. Analysis of the field relevance of the results must consider not only factors relating to the assessment of injury risk, but also exposure frequency. The highest responses for the head, neck, or torso were with that body region aligned with and against the air bag module. The risk of severe injury was low for the head and neck, but high when the torso was against and fully covering the air bag module.

A common injury type among foot and ankle injury is the Lisfranc trauma, or injury to the forefoot. The Lisfranc injury indicates abnormal alignment of the tarsal-metatarsal joints with the loss of their normal spatial relationships. In 2003, Smith completed a laboratory study of this injury mechanism at Wayne State University [1, 2]. He found Lisfranc trauma was correlated with impact force to the forefoot. He proposed a probability of injury function that is based on the applied force to the forefoot. This study examined the instrumentation in the foot of the dummies in the USA New Car Assessment Program (NCAP) and Insurance Institute of Highway Safety (IIHS) frontal crashes. Nineteen different passenger vehicles representing four different vehicle classes were selected based mostly on a large presence in the USA vehicle fleet. Both NCAP and IIHS crashed these nineteen makes and models.

The research reported in this paper is a follow-on to a five year research program conducted by General Motors in accordance with an administrative Settlement Agreement reached with the US Department of Transportation. This paper is the fourth in a series of technical papers intended to disseminate the results of the ongoing research [Digges 2004, 2005, 2006]. This paper summarizes progress in several of the projects to better understand the crash factors that are associated with crash induced fires. Part I of the paper presents the distribution of fire cases in NASS/CDS by damage severity and injury severity. It also examines the distributions by crash mode, fire origin, and fuel leakage location. The distributions of cases with fires and entrapment are also examined. Part II of the paper provides summaries of recent projects performed by MVFRI contractors. Technologies to reduce fuel leakage from siphoning and rollover are documented.

This study identified the mechanical properties of ten cadaveric lumbar spines and two Hybrid III lumbar spines. Eight tests were performed on each specimen: tension, compression, anterior shear, posterior shear, left lateral shear, flexion, extension and left lateral bending. Each test was run at a displacement rate of 100 mm/sec. The maximum displacements were selected to approximate the loading range of a 50 km/h Hybrid III dummy sled test and to be non-destructive to the specimens. Load, linear displacement and angular displacement data were collected. Bending moment was calculated from force data. Each mode of loading demonstrated consistent characteristics. The load-displacement curves of the Hybrid III lumbar spine demonstrated an initial region of high stiffness followed by a region of constant stiffness.

A three-dimensional finite element model of a human neck has been developed in an effort to study the mechanics of cervical spine while subjected to impacts. The neck geometry was obtained from MRI scans of a 50th percentile male volunteer. This model, consisting of the vertebrae from C1 through T1 including the intervertebral discs and posterior elements, was constructed primarily of 8-node brick elements. The vertebrae were modeled using linear elastic-plastic materials, while the intervertebral discs were modeled using linear viscoelastic materials. Sliding interfaces were defined to simulate the motion of synovial facet joints. Anterior and posterior longitudinal ligaments, facet joint capsular ligaments, alar ligaments, transverse ligaments, and anterior and posterior atlanto-occipital membranes were modeled as nonlinear bar elements or as tension-only membrane elements. A previously developed head and brain model was also incorporated.

This study assessed the primary involved physical components attributed to the head and face injuries of child occupants seated directly adjacent to the stuck side of a vehicle in a side impact collision. The findings presented in this study were based upon analysis of the National Automotive Sampling System/Crashworthiness Data System (NASS/CDS) for the years 1993–2007. Injury analysis was conducted for those nearside child occupants aged between 1–12 years-old. The involved children were classified as toddler-type, booster-type, or belted-type occupants. These classifications were based upon the recommended restraint system for the occupant. Injury mechanisms were assessed for the child occupants in each of the three groups. A detailed study of NASS/CDS cases was conducted to provide a greater understanding of the associated injury mechanisms.

Nitro Fuel Funny cars have 7-8,000 hp and travel 330 mph in a quarter mile. These cars experience extreme forces in normal operation. One phenomenon familiar to drag racers is tire shake. Mild cases can cause loss of traction and vision. Extreme cases can cause injury or death. In March of 2007, a study and subsequent revision of the passenger compartment in a Fuel Funny car was performed after a fatal accident due to extreme tire shake. Tire shake on a drag race car normally occurs when the force on the rear tire causes the tire to roll over itself causing a loss of traction and side-to-side vibration. In other cases, if the tire fails at high speed, the tire may partially separate, causing an extreme vibration in the cockpit of the car. The vibration may set up a harmonic in the chassis, which is transferred to the driver since the rear end is bolted directly to the chassis with no suspension to absorb the energy.

The research reported in this paper is a follow-on to a five year research program conducted by General Motors in accordance with an administrative Settlement Agreement reached with the US Department of Transportation. In a subsequent Judicial Settlement, GM agreed fund more than $4.1 million in fire related research over the period 2001-2004. The purpose of this paper is to provide a public update report on the projects that have been funded under this latter research program, along with results to date. An analysis of FARS and State accident data has been completed. Results indicate that fire rates have been significantly reduced over the past 20 years. Fire rates for passenger cars and LTVs have approached similar levels. Fire rates by crash mode indicate that rear impact fires have been significantly reduced; however, fires in rollover crashes have seen considerably less reduction. The highest percentages of fires are subsequent to frontal impacts.

Real world crashes in NASS/CDS 1997 to 2000 were examined individually in order to find patterns in single vehicle rollover crashes. Typical maneuver induced rollovers of SUV's were reconstructed using the HVE model. From HVE and roll event reconstructions, the values of longitudinal, lateral, and vertical displacement, and roll, pitch, and yaw angle, for the pre-roll and rollover event were calculated. These values were used as inputs to a MADYMO model for simulated vehicle motion to predict occupant kinematics. Both near-side and far-side rollovers were simulated. The MADYMO model provided estimates of head velocity for the various rollover scenarios for a belted driver. In both near-side and far-side rollovers of the type reconstructed, the lateral component of head velocity was the greatest. Maximum head velocities of 5.3 m/s were predicted. The simulations were for two complete rollovers. The highest head velocity occurred during the first three quarter turns.

This paper presents an analysis of the National Automotive Sampling System (NASS) and the Fatal Accident Reporting Systems (FARS) data for the combined years 1988–97 with respect to side impacts. Accident variables, vehicle variables, occupant variables and their interactions have been considered, with special emphasis on occupant injury patterns. The crash modes considered are car-to-car, car-to-LTV (light trucks and vans) and car to narrow object, with special emphasis on the latter two. This study was undertaken to obtain a better understanding of injury patterns in lateral impacts, their associated causation factors, and to obtain information that will assist in prioritizing crash injury research problems in near side impacts. Of particular interest is the increase in the population of light trucks and vans and their influence on side impact priorities. Conclusions will be drawn regarding the frequency and injury severity of car-to-LTV’s and car to narrow objects.

Lower extremity injuries in frontal automotive crashes usually occur with footwell intrusion where both the knee and foot are constrained. In order to identify factors associated with tibial shaft injury, a series of numerical simulations were conducted using a finite element model of the whole human body. These simulations demonstrated that tibial mid-shaft injuries in frontal crashes could be caused by an abrupt change in velocity and a high rate of footwell intrusion.

A MADYMO model of a racing car and driver was driven by 3-D accelerations recorded in actual crashes. Helmet, belt restraint, and padding characteristics were obtained from dynamics tests. Model results of HIC, head accelerations and neck forces and moments were studied along with driver injuries to provide insight into the efficacy of current injury assessment parameters used with the head and neck of crash test dummies. The results are also used to discuss the kinematics performance of the crash test dummy neck as modeled by the MADYMO version of the Hybrid III midsize male crash test dummy.

The structure of the racecar has been the subject of much discussion with regard to crash safety. The stiffness of the structure, the amount of crush and the resulting deceleration were being judged, in some instances, as too stiff or not stiff enough for the driver. Much of this discussion centered on crash incidents for which no deceleration data were available from crash recorders (black boxes). In this paper, crash test dummy (Anthropomorphic Test Device ATD) results are compared for various idealized deceleration-time histories (deceleration pulses) that represent various structural crush characteristics. A crash velocity of 64.4 KPH (40 MPH) against a wall was used to represent a life threatening energy level.

A nonlinear foam was added to a previously created three-dimensional finite element model of the Hybrid III dummy chest which consisted of six steel ribs, rib damping material, the sternum, a spine box and a pendulum. Two standard calibration pendulum impact tests for a Hybrid III dummy chest were used to validate the new model. An explicit finite element analysis code PAM-CRASH was utilized to simulate the dynamic process. At impact velocities of 6.7 m/s and 4.3 m/s, the force and deflection time history as well as the force-deflection plots showed good agreement between model predictions and calibration data. Peak strains also agreed well with experimental data.