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“Spotlight on Design” features video interviews and case study segments, focusing on the latest technology breakthroughs. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. In the episode “Composite Materials: Advanced Materials and Lightweighting” (30:20), Molded Fiber Glass Companies, known for its deep involvement in the creative development of the molded fiberglass process for the Corvette, demonstrates the manufacturing of sheet molded composite for fiberglass parts. Tanom Motors introduces the Tanom Invader, a blend between an automobile and a motorcycle made exclusively with composite materials. Finally, Euro-Composites demonstrates the manufacturing of honeycomb core material made out of aramid paper and phenolic resin used in aircraft structures.

TERBAN® hydrogenated nitrile rubber (HNBR) is a specialty elastomer used in demanding engineering applications such as the automotive, heavy duty, and industrial markets. It has excellent combination of heat, oil and abrasion resistance in addition to its high mechanical strength, very good dynamic and sealing properties. This paper will present data on aging HNBR for five thousand hours in an aggressive and un-stabilized B30A biodiesel fuel blend (70% ULSD, 30% SME, and an aggressive additive package) and explore the effect of HNBR polymer properties and vulcanizate composition on the performance in such fuel blends. Presenter Victor Nasreddine

Since 2006 Oak Ridge National Labs (ORNL) and the Pacific Northwest National Labs (PNNL) have conducted research of injection molded long glass fiber thermoplastic parts funded by U.S. DOE. At DOE's request, ACC's Plastics Division Automotive Team and USCAR formed a steering committee for the National Labs, whose purpose was to provide industry perspective, parts materials and guidance in processing. This ACC affiliation enabled the plastics industry to identify additional key research requirements necessary to the success of long glass fiber injection molded materials and their use in the real world. Through further cooperative agreements with Autodesk Moldflow and University of Illinois, a new process model to predict both fiber orientation distribution and fiber length distribution is now available. Mechanical property predictive tools were developed and Moldflow is integrating these models into their software.

Experimental methods and computational applications related to tire and wheel systems as well as vehicle dynamics and simulation topics are included in the 40 papers in this technical paper collection.

The 9 papers in this technical paper collection focus on occupant protection in accident reconstruction. Topics include: particle image velocimetry; heavy truck engine retarders; repeatability and reliability of drag sled testing; pedestrian impact on low friction surface; photogrammetric measurement error associated with lens distortion; passenger vehicle response to low-speed impacts involving a tractor semitrailer; and more.

The papers in this collection focus on the latest research related to methods and techniques for reconstructing vehicular crashes involving wheeled and tracked vehicles, pedestrians, and roadside features. Emphasis is placed on experimental data and theoretical methods that will enable reconstructionists to identify, interpret and analyze physical evidence from vehicular crashes.

Active Safety and Driver assistance systems are gaining importance as many passive safety systems have already been found to have yielded significant safety benefits that are possible from the deployment of those systems in the fleet. Similar success will much depend upon how fast these systems proliferate the entire passenger vehicle fleet. It will also depend on the deployment strategies used by the industry and the government as well as consumer acceptance and market demand for these systems. Additionally, opportunities exist to use the information gained from the various onboard sensors and vision systems in active safety systems for improving the effectiveness of today’s passive safety systems such as seat belts, airbags, and post-crash safety systems even further by the integration of active and passive safety systems.

Abstract Potential collisions with oncoming traffic while turning left belong to the most safety-critical situations accounting for ~25% of all intersection crossing path crashes. A Left Turn Assist (LTA) was developed to reduce the number of crashes. Crucial for the effectiveness of the system is the design of the human-machine interface (HMI), i.e. defining how the system uses the calculated crash probability in the communication with the driver. A driving simulator study was conducted evaluating a warning strategy for two use cases: firstly, the driver comes to a stop before turning (STOP), and secondly, the driver moves on without stopping (MOVE). Forty drivers drove through three STOP and two MOVE scenarios. For the STOP scenarios, the study compared the effectiveness of an audio-visual warning with an additional brake intervention and a baseline. For the MOVE scenarios, the study analyzed the effectiveness of the audio-visual warning against a baseline.

Recent field data have shown that the occupant protection in vehicle rear seats failed to keep pace with advances in the front seats likely due to the lack of advanced safety technologies. The objective of this study was to optimize advanced restraint systems for protecting rear seat occupants with a range of body sizes under different frontal crash pulses. Three series of sled tests (baseline tests, advanced restraint trial tests, and final tests), MADYMO model validations against a subset of the sled tests, and design optimizations using the validated models were conducted to investigate rear seat occupant protection with 4 Anthropomorphic Test Devices (ATDs) and 2 crash pulses.

This paper presents a review on pedestrian impact reconstruction methodology and offers a comprehensive review of the literature. Several types of analyses are discussed which can be used to reconstruct the accident scenario using the facts collected from the scene. Inclusive in this review is the utilization of skid mark analysis, debris analysis, injury/damage match-up, trajectory analysis, nighttime visibility, and alcohol effects. The pedestrian impact reconstruction methodology is illustrated with a real world case example to point out different observations which can provide insight into the pedestrian/vehicle collision reconstruction approach. The literature review provides a broad foundation of information on pedestrian impact reconstruction and can be used to supplement the techniques presented in this paper in areas related to pedestrian impact. Research advances in the area of pedestrian impact reconstruction are also discussed in this paper.

The acquisition of digital evidence from automobiles has become commonplace, with the number of data sources within vehicles continually growing. To that end, the potential for evidence spoliation is real in that the acquisition of data from one source could interfere with the data stored in another source. The purpose of this recommended practice is to provide information to assist in eliminating or at least minimizing the potential for evidence spoliation and also providing guidance as to when decisions must be made to prioritize the order of data collection.

Dynamic impact test represent various automotive collision conditions. The impact testing recommended practice is intended to recognize the capabilities of autonomous vehicles while at the same time recognizing the vehicle fleet into which they are introduced will consist of non-autonomous vehicles for a considerable period of time. The scope of the document is to cover the range of impact conditions expected taking into account the capabilities of the vehicle and the impact testing technology now available for performance evaluation including virtual and physical testing.

To develop a recommended practice for taking photographs of a damaged vehicle to preserve evidence.

Abstract Management of expressway networks has been mainly focused on defect management without looking at the correlations with accidental risks. This causes unsustainability in expressway infrastructure maintenance since such defects may not be a contributing factor toward public safety. Thus it is necessary to incorporate accidental events for decision-making in infrastructure management. This study has developed a novel approach to machine learning (ML) that incorporates actual primary data from the last 10 years of single-vehicle accidents (SVA) by collisions with motorway facilities, or so-called single-vehicle collisions with fixed objects. The ML is firstly aimed at identifying the influential factors of SVA in relation to finding effective countermeasures for accidents by integrating the correlation analysis, multiple regression analysis, and ML techniques. The study reveals that wet pavement conditions have a significant effect on SVA.

For over 30 years, field research and laboratory testing has consistently demonstrated that proper utilization of a seat belt dramatically reduces the risk of occupant death or serious injury in motor vehicle crashes. The injury prevention benefits of seat belts require that they remain fastened during collisions. Federal Motor Vehicle Safety Standards and SAE Recommended Practices set forth seat belt requirements to ensure proper buckle performance in accident conditions. Numerous analytical and laboratory studies have investigated buckle inertial release properties. Studies have repeatedly demonstrated that current buckle designs have inertial release thresholds well above those believed to occur in real-world crashes. Nevertheless, inertial release theories persist. Various conceptual amplification theories, coupled with high magnitude accelerations measured on vehicle frame components are used as support for these release theories.

This document provides recommended practices for impact testing of ground vehicle that are also aero-capable. The scope characterizes recommended impact testing taking into account the unique design characteristics involved in aero-capable ground vehicle

Abstract Purpose: Obesity can be a contributing factor to decrease head injuries in motor vehicle collisions (MVCs). We sought to assess whether obesity is associated with decreased head injury from MVCs by sex. Methods: This study was a retrospective observational study and evaluated crash data from 1997 to 2015 obtained from the International Center for Automotive Medicine. Patients were categorized into normal, overweight, and obesity subgroups. The primary endpoint was serious head injury. Multivariate logistic regression analysis was performed, and adjusted odds ratios (AORs) of subgroups were calculated for study outcomes adjusted for any potential confounders. Results: Among enrolled 588 patients, 262 were male with 30.9% normal, 40.1% overweight, and 29.0% obesity subgroups, and 326 were female with 44.8% normal, 24.8% overweight, and 30.4% obesity subgroups.

This document describes the assessment methods and physical requirements associated with the manual handling of carts and dollies, specific to material handling systems. All possible designs and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the shelf” design, always consult the responsible Ergonomics Department. Force guidelines were primarily developed referencing the push/pull psychophysical Snook data contained in A Guide to Manual Materials Handling (second edition) by Mital, Nicholson and Ayoub (NY: Taylor & Francis, 1997). The force guidelines accommodate 75% of female capabilities and 99% of male capabilities. Factors that were included in the established guideline include: push / pull distances, vertical hand height, horizontal hand height, frequency and wheel / castor alignment and load rating. These factors were used to develop a conservative force guideline.

A generalized MADYMO minor rear crash vehicle model with BioRIDII ATD was developed and validated using the mean response of previously published 12 km/h delta-V rear crash tests. BioRIDII simulation pelvis, thorax and head x-axis accelerations, as well as head y-axis angular acceleration, fell within corridors defining +/- one standard deviation of the mean BioRIDII crash test responses. Peak sagittal plane BioRIDII upper neck forces and moments in the simulation were on par with the mean values observed from the crash tests. After the model was validated for 12 km/h delta-V, the model was further exercised by performing simulations with (1) a Hybrid III 50th percentile occupant and (2) by reducing the pulse by 40% of its original value. Results indicate that this generalized minor rear crash model could be useful in accurately estimating occupant kinematics and kinetics in minor crashes up to at least 12 km/h delta-V as an alternative to expensive and time consuming crash testing.