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This paper describes (1) the development of a component test methodology for testing a cooling module including radiator, condenser and trans. cooler, and (2) the associated CAE model development. A series of light truck/SUV cooling module component tests were conducted to obtain their characteristics as inputs for frontal impact and sensor modeling development. First, the cooling module component CAE sub-model was developed using soft springs along with fine-mesh sheet metal shell elements. Second, simulated sub-model results were correlated fairly well with the test data. Third, this component CAE sub-model was then incorporated into a full vehicle CAE model that was used for frontal impact (NCAP) and sensor development. Results indicated that the proposed test method for cooling module components provided consistent data and the results from cooling module sub-model can be incorporated into the full vehicle CAE model for improving the quality and accuracy of CAE models.

In order to provide an improved countermeasure for occupant protection, a new type of active reversible preload seatbelt (ARPS) is presented in this paper. The ARPS is capable of protecting occupants by reducing injuries during frontal collisions. ARPS retracts seatbelt webbing by activating an electric motor attached to the seatbelt retractor. FCW (Forward Collision Warning) and LDW (Lane Departure Warning) provide signals as a trigger to activate the electric motor to retract the seatbelt webbing, thus making the occupant restraint system work more effectively in a crash. It also helps reduce occupant’s forward movement during impact process via braking. Four important factors such as preload force, preload velocity and the length and timing of webbing retraction play influential roles in performance of the ARPS. This paper focuses on studying preload performance of ARPS under various test conditions to investigate effects of the aforementioned factors.