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A computational model of a mid-size sport utility vehicle was developed using MADYMO. The model includes a detailed description of the suspension system and tire characteristics that incorporated the Delft-Tyre magic formula description. The model was correlated by simulating a vehicle suspension kinematics and compliance test. The correlated model was then used to simulate a J-turn vehicle dynamics test maneuver, a roll and non-roll ditch test, corkscrew ramp and a lateral trip test, the results of which are presented in this paper. The results indicate that MADYMO is able to reasonably predict the vehicle and occupant responses in these types of applications and is potentially suited as a tool to help setup a suite of vehicle configurations and test conditions for rollover sensor testing. A suspension system sensitivity study is presented for the laterally tripped non-roll event.

An assessment tool was developed for rollover CAE signals evaluation to assess primarily the qualities of CAE generated sensor waveforms. This is a key tool to be used to assess CAE results as to whether they can be used for algorithm calibration and identify areas for further improvement of sensor. Currently, the method is developed using error estimates on mean, peak and standard deviation. More metrics, if necessary, can be added to the assessment tool in the future. This method has been applied to various simulated signals for laboratory-based rollover test modes with rigid-body-based MADYDO models.

CAE has played a key role in development of the rollover safety technology by reducing the required number of prototypes. CAE-led Design Of Experiments (DOE) studies have helped in developing the process to minimize the number of CAE runs and to optimize use of the prototypes. This paper demonstrates the use of CAE/DOE for the design and optimization of rollover vehicle prototypes and also investigates effects of various factors in the selection of vehicle configuration for rollover sensor calibration testing. The process described herein has been successfully applied to vehicle programs. Modeling and analysis guidelines are also presented for CAE engineers to help in optimizing vehicle prototypes at program level.

This paper presents an image analysis of a laboratory-based rollover crash test using camera-matching photogrammetry. The procedures pertaining to setup, analysis and data process used in this method are outlined. Vehicle roll angle and rate calculated using the method are presented and compared to the measured values obtained using a vehicle mounted angular rate sensor. Areas for improvement, accuracy determination, and vehicle kinematics analysis are discussed. This paper concludes that the photogrammetric method presented is a useful tool to extract vehicle roll angle data from test video. However, development of a robust post-processing tool for general application to crash safety analysis requires further exploration.

Full vehicle dynamic crash tests are commonly used in the development of rollover detection sensors, algorithms and occupant protection systems. However, many published studies have utilized component level rollover test fixtures for rollover related occupant kinematics studies and restraint system evaluation and development. A majority of these fixtures attempted to replicate only the rotational motion that occurs during the free flight phase of a typical full vehicle rollover crash test. In this paper, a description of the methods used to design a new dynamic component rollover test device is presented. A brief summary of several existing rollover component test methods is included. The new system described in this paper is capable of replicating the transfer of lateral energy into rotational vehicle motion that is present in many tripped laboratory based rollover crash tests.

A number of studies, using data from NASS-CDS, have shown a large percentage of rollover crashes can be classified as tripped events. In many cases, the requirements for a tripped rollover detection algorithm are driven by the timely activation of an occupant containment device. To meet these requirements rollover detection algorithms have been developed by utilizing vehicle roll rate, lateral and vertical accelerations data collected primarily from laboratory tests. This study identifies and examines several challenges associated with developing a rollover detection algorithm with enhanced capabilities. Enhancement of the detection algorithm is explored by considering additional vehicle responses: forward velocity and sideslip angle. With the additional signals, discrimination of rollover crashes from other crash modes is discussed. Potential field/laboratory test modes are proposed to generate the additional vehicle signals.

In today's automotive market, rollover protection systems are drawing an increasing attention. Unlike in conventional frontal and side impact events where linear accelerometers are used to detect the crash severity and make decision on deployment/non-deployment of the air bag restraint systems, rollover events require a new detection method using angular rate sensors. In the past, various angular rate sensors have been used in navigation systems to calculate pitch angle, or in camcorders for image stabilization. These sensors work at a low dynamic operating range, i.e. less than 100 degrees/sec. Angular rate sensors in automotive applications demand a higher dynamic capacity greater than 250 degrees/sec. (or °/s). This paper reviews automotive grade angular rate sensors currently being introduced for rollover protection system applications.

An attractive strategy for joining metallic as well as non-metallic substrates through adhesive bonding. This technique of joining also offers the functionality for joining dissimilar materials. However, doubts are often expressed on the ability of such joints to perform on par with other mechanical fastening methodologies such as welding, riveting, etc. In the current study, adhesively-bonded single lap shear (SLS), double lap shear (DLS) and T-peel joints are studied initially under quasi-static loading using substrates made of a grade of mild steel and an epoxy-based adhesive of a renowned make (Huntsman). Additionally, single lap shear joints comprised of a single spot weld are tested under quasi-static loading. The shear strengths of adhesively-bonded SLS joints and spot-welded SLS joints are found to be similar. An important consideration in the deployment of adhesively bonded joints in automotive body structures would be the performance of such joints under impact loading.

This paper examines the use of camera-matching video analysis techniques to quantify the vehicle dynamics and deformation for a dolly rollover test run in accordance with the SAE Recommended Practice J2114. The method presented enables vehicle motion data and deformation measurements to be obtained without the use of the automated target tracking employed by existing motion tracking systems. Since it does not rely on this automated target tracking, the method can be used to analyze video from rollover tests which were not setup in accordance with the requirements of these automated motion tracking systems. The method also provides a straightforward technique for relating the motion of points on the test vehicle to the motion of the vehicle's center-of-mass. This paper, first, describes the specific rollover test that was utilized. Then, the camera-matching method that was used to obtain the vehicle motion data and deformation measurements is described.

Many rollover safety researches have been conducted experimentally and analytically to investigate the underlying causes of vehicle accidents and develop rollover test procedures and test methodologies to help understand the nature of rollover crash events. In addition, electronic and/or mechanical instrumentation are used in dummy and vehicle to measure their responses that allow both vehicle kinematics study and occupant injury assessment. However, method for measurement of dynamic structural deformation needs further exploration, and means to monitor vehicle-to-ground contact load is still lacking. Thus, this paper presents a method for determining the vehicle-to-ground load during laboratory-based rollover tests using results obtained from a camera-matching photogrammetric technology as inputs to a FE SUV model using a nonlinear crash analysis code.

The seatbelt system, originally designed for protecting occupants in frontal crashes, has been reported to be inadequate for preventing occupant head-to-roof contact during rollover crashes. To improve the effectiveness of seatbelt systems in rollovers, in this study, we reviewed previous literature and proposed vertical head excursion corridors during static inversion and dynamic rolling tests for human and Hybrid III dummy. Finite element models of a human and a dummy were integrated with restraint system models and validated against the proposed test corridors. Simulations were then conducted to investigate the effects of varying design factors for a three-point seatbelt on vertical head excursions of the occupant during rollovers. It was found that there were two contributing parts of vertical head excursions during dynamic rolling conditions.

An experimental study was conducted using a dynamic rollover component test system (ROCS) to study the effects of activating a pyro-mechanical buckle pre-tensioner and an electric retractor on the driver and front right passenger head and pelvis excursions. The ROCS is a unique system capable of producing vehicle responses that replicate four distinct phases of a tripped rollover: trip initiation, roll initiation, free-flight vehicle rotation, and vehicle to ground contact. This component test system consists of a rigid occupant compartment derived from a mid-size SUV with complete 1st row seating and interior trim, a simulated vehicle suspension system and an elastic vehicle-to-ground-contact surface. The ROCS system was integrated with a Deceleration Rollover Sled (DRS). Dynamic responses of the ROCS system, including both the rigid compartment and occupant, were measured and recorded.