Search Results

The reduction of vehicle exhaust particle emissions is a success story of European legislation. Various particle number (PN) counters and calibration procedures serve as tools to enforce PN emission limits during vehicle type approval (VTA) or periodical technical inspection (PTI) of in-use vehicles. Although all devices and procedures apply to the same PN-metric, they were developed for different purposes, by different stakeholder groups and for different target costs and technical scopes. Furthermore, their calibration procedures were independently defined by different stakeholder communities. This frequently leads to comparability and interpretation issues. Systematic differences of stationary and mobile PN counters (PN-PEMS) are well-documented. New, low-cost PTI PN counters will aggravate this problem. Today, tools to directly compare different instruments are scarce.

The active safety of tractor / trailer-combinations plays an important role in regard to traffic safety in general. For improving the active safety of tractor / trailer-combinations, it is necessary to investigate the interactions between the towing vehicle and the trailer during braking maneuvers. This paper describes the ECE-regulations for the braking force distributions of tractor/full trailer- and tractor / semitrailer-combinations. The influence of different layouts of the braking systems within these regulations on the coupling forces between tractor and trailer and the driving performance of the units during braking is investigated. The dynamical behaviour of a tractor/full-trailer-combination and a tractor / semitrailer-combination are both discussed with the aid of simulations of the ISO-standard testing procedures “Braking in a turn” and “Braking straight ahead”.

In this contribution functional safety is discussed from a car manufacturer's point of view. Typical elements of a safety standard concerning safety activities during the product development process are described as well as management and other supporting processes. Emphasis is laid on the aspect of risk assessment and the determination of safety classes. Experiences with methods for safety analysis like FTA or FMEA are discussed and pros and cons of quantitative safety assessment are argued.

In the early stages of conceptual design the available geometric data are very coarse and the lifespan of a design idea is very short. The structural evaluation and improvement of a design has to take both facts into account. Its focus is on the total vehicle and its performance. This can be estimated by a modeling technique, which is adequate for the lack of geometric details. Static and dynamic global stiffness as well as some aspects of crash and NVH have to be considered. Optimization will lead to the proper sizing and some indication of the potential of the structure. In order to maintain high quality standards this approach has to be supported by specialized CAE tools and extensive rules on modeling techniques and analysis procedures.

A new simulation tool was established and approved by TRW as part of the continuous improvement of the development process. This tool allows the OEM and the system supplier to keep high quality even with further reduced development times. The introduction of the tool in a side air-bag development program makes it possible to ensure high development confidence with a reduced number of vehicle crash tests and late availability of interior component parts.

Handling characteristics, ride comfort and active safety are customer relevant attributes of modern premium vehicles. Electronic control units offer new possibilities to optimize vehicle performance with respect to these goals. The integration of multiple control systems, each with its own focus, leads to a high complexity. BMW and ITK Engineering have created a tool to tackle this challenge. A simulation environment to cover all development stages has been developed. Various levels of complexity are addressed by a scalable simulation model and functionality, which grows step-by-step with increasing requirements. The simulation environment ensures the coherence of the vehicle data and simulation method for development of the electronic systems. The article describes both the process of the electronic control unit (ECU) development and positive impact of an integrated tool on the entire vehicle development process.

If a tail light bulb burns out, the failure will be detected by an electronic light check module. The missing tail light will be substituted by the stop light function. The luminous intensity of the stop light will be automatically reduced to the tail light level. If a car is equipped with rear fog lights, a faulty brake light can be substituted, similarly by a reduced rear fog light. Today the hazard warning signal has the same frequency as the turn signal indicator. If one side of a car is blocked by for example another car then it is not possible to differentiate between the aforementioned signal types. Therefore the hazard warning information is lost. The suggested new hazard warning signal consists of a double-flash with a short break, the time period is nearly unchanged.

The expected improved performance of a combined restraint system where an airbag supplements the conventional safety belt was not reflected in reduced g-values on the dummy's chest. However, by the distribution of force over the wider area of the airbag and the corresponding reduction of the specific pressure exerted by the three point belt, improved occupant protection is actually produced. Therefore, measurable quantities other than acceleration should be selected to evaluate the risk of chest injury, such as belt load or chest deflection. A new method to measure the deflection of dummy ribs with strain gauges has been developed. The resulting data indicate a significantly reduced chest deflection when a combined system is used.

The driving simulator is a computer-controlled tool to study the interface between driver and vehicle response under simulated traffic conditions. It permits a controllable, reproducible and cost-effective study of vehicle parameters up to the limits of active safety under non-dangerous conditions. It also permits driver participation in judging vehicle handling characteristics, and in evaluating the ‘feel’ of the steering, suspension, braking, and drive train, including the driver's environment, beginning with the initial vehicle design stages. The paper will describe fully the concept, design and planned activities as well as report on the new possibilities of using the driving simulator as a research and development tool.

Daimler-Benz considers safety belts as the fundamental and essential restraining system. The company began offering a Supplemental Restraint System option consisting of a driver airbag system and an emergency tensioning belt retractor for the passenger in December 1980. The functional reliability of the system has proven satisfactory.

Information on the driving stability can be obtained in the form of oversteer or understeer tendencies and acceleration limits on a circular path. Up to now the calculations have only been made on an ideal, even roadway. Significant dynamic characteristics, such as the tuning of the shock absorbers, which also play a role in evaluating the stability of a vehicle in a driving test, are thereby not included in the calculations. In this paper the unevenness of the roadway is taken into consideration in calculating steady state cornering tests. Different vehicle models can be evaluated in regard to their handling or active safety with the aid of the driver's steering actions required to keep the car on course.

In order to reduce the severity of injuries to pedestrians and cyclists, the sheetmetal contact zones of Mercedes-Benz cars are constructed of a yielding, smooth-surfaced design. Unfortunately, contradictory demands are made on some components. This is particularly true for the bumper in which avoiding or reducing the cost of repair requires a greater bumper height, overhang, and stiffness, which run counter to the requirements of pedestrian protection. Despite this conflict, however, the bumpers of recently developed Mercedes-Benz cars offer a high degree of pedestrian protection since they are faced with rigid foam. To assist in both mathematical and experimental pedestrian impact simulation, standard test dummies should be modified by reducing the stiffness at the waist in order to achieve a higher degree of faithfulness to human behaviour.

Safety considerations at Daimler-Benz are based on real-world accidents from which internal test procedures are derived. The example of the frontal collision is a clear illustration of this. In a crash against a flat, full car width barrier, a rare occurrence in real-world accidents, the impact energy is distributed over the entire width of the car. The majority of real-world frontal crashes, however, involve only partial overlap of the front. An adequately designed structure has to absorb the crash energy before it deforms the passenger compartment, i. e. by distributing the impact forces, and strategically located components must avoid the formation of blocks. In particular, the passenger compartment must be sufficiently stiff. Restraint systems and interior padding can only serve their protective purpose to their fullest if the survival space for the occupants is maintained intact.

Daimler-Benz have developed an automatically/electronically controlled traction system, the 4MATIC. Great store has been set by active safety. This paper deals with the problems involved in 4-Wheel drive and analyzes the reasons which led to the 4MATIC concept. Depending on the conditions encountered, the drive components engage automatically one after the other in the sequence front-wheel drive - interaxle differential lock - rear axle differential lock. The engagement, and thus the approaching limits of driving dynamics, is indicated to the driver by an indicator lamp so that he can adjust to the deteriorated conditions in time. A further important advantage of this system is the automatic disengagement of the differential locks when braking so that the anti-lock braking remains fully effective.

This report deals with the development and use of the Daimler-Benz Isohuman Simulation Model for the mathematical simulation of dummy behaviour in an impact environment. Designated ISM, this computer program package is capable of handling both automobile occupant and pedestrian kinematics. Daimler-Benz safety engineers use the ISM to evaluate new safety designs before performing actual laboratory tests. The ISM code uses the theoretical algorithm of Prof. Wittenburg. The dummy is represented by 11 rigid body elements. Realistic and accurate simulations are assured by the fact that a considerable number of functional and sophisticated algorithms were developed to involve the different interactions of dummy-to-belt or dummy-to-vehicle. In particular, considerable work is being done to introduce a more precise and realistic dummy and vehicle geometry.

Distribution of load has a major influence on type and severity of chest injuries. The introduction of the Hybrid III dummy into crash testing along with the requirement to measure sternum deflection for injury assessment has brought about the need to evaluate how well its thorax senses various loading conditions. Tests revealed that different load distributions, i.e. due to a diagonal shoulder belt or an airbag, did not produce the expected chest deflection patterns. This appears to be the result of both a relatively stiff sternum assembly and a nonsuitable design of the clavicle. Chest compression responses became more realistically when both, sternum and clavicle of the Hybrid II were mounted into the Hybrid Ill's thorax. As a consequence, this study suggests that the thorax of the Hybrid III dummy must be improved.

The risk of head or chest injuries is usually evaluated by means of acceleration measurements using a dummy. Unfortunately, this data provides no information on load distribution over the contact areas which is often related to localized fractures of the bony structure. Therefore, new methods of measuring local forces were developed. 1. Pressure indicating devices attached to a dummy's face are capable of monitoring the local pressure during impact; foil's color change is interpreted by means of digital image analysis. 2. A velocity sensitive viscous tolerance criterion was calculated from the chest compression response of a dummy instrumented with strain gauges on the ribs. The application of advanced techniques in laboratory tests clearly supports the experience of improved protection potential through the use of airbag systems.

Sensing and acting elements to guarantee the locking functions of seat belt retractors can emit noise when the retractor is subjected to externally applied vibrations. For these elements to function correctly, stiffness, inertia and friction needs to be in tune, leading to a complex motion resistance behavior, which makes it delicate to test for vibration induced noise. Requirements for a noise test are simplicity, robustness, repeatability, and independence of laboratory and test equipment. This paper reports on joint development activities for an alternative test procedure, involving three test laboratories with different equipment. In vehicle observation on parcel shelf mounted retractors, commercially available test equipment, and recent results from multi-axial component tests [1], set the frame for this work. Robustness and reliability of test results is being analyzed by means of sensitivity studies on several test parameters.

Seatbelt retractors as important part of modern safety systems are mounted in any automotive vehicle. Their internal locking mechanism is based on mechanically sensing elements. When the vehicle is run over rough road tracks, the retractor oscillates by spatial mode shapes and its interior components are subjected to vibrations in all 6 degrees of freedoms (DOF). Functional backlash of sensing elements cause impacts with neighbouring parts and leads to weak, but persistent rattle sound, being often rated acoustically annoying in the vehicle. Current acoustic retractor bench tests use exclusively uni-directional excitations. Therefore, a silent 2 DOF test bench is developed to investigate the effect of multi-dimensional excitation on retractor acoustics, combining two slip-tables, each driven independently by a shaker. Tests on this prototype test bench show, that cross coupling between the two perpendicular directions is less than 1%, allowing to control both directions independently.

From an acoustical point of view, the integration of seatbelt retractors in a vehicle is a real challenge that has to be met early in the vehicle development process. The buzz and rattle noise of seat belt retractors is a weak yet disturbing interior noise. Street irregularities excite the wheels and this excitation is transferred via the car body to the mounting location of the retractor. Ultimately, the inertia sensor of the locking mechanism is also excited. This excitation can be amplified by structural resonances and generate a characteristic impact noise. The objective of this paper is to describe a simulation method for an early development phase that predicts the noise-relevant low frequency local modes and consequently the contact of the retractor with the mounting panel of the car body via the finite element method.