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In the current Ford Pro-Trailer Backup Assist (TBA) system, trailer hitch angle is determined utilizing the reverse camera of the vehicle. In addition to being sensitive to environmental factors such as lighting conditions and occlusion, the vision-based approach is difficult to be applied to gooseneck or fifth wheel trailers. In this paper, a yaw rate based hitch angle observer is proposed as an alternative sensing solution for TBA. Based on the kinematic model of the vehicle-trailer, an instantaneous hitch angle is first derived by utilizing vehicle yaw rate, trailer yaw rate, vehicle velocity and vehicle/trailer parameters provided by the TBA system. Due to signal errors and parameter uncertainties, this instantaneous hitch angle may be noisy, especially at lower vehicle speed.

An L18 Taguchi-style Design of Experiments (DOE) with eight factors was used to optimize exterior mirrors for wind noise and drag. Eighteen mirror properties were constructed and tested on a full size greenhouse buck at the Lockheed low-speed wind tunnel in Marietta, GA. Buck interior sound data and drag measurements were taken at 80 MPH wind speed (0° yaw angle). Key wind noise parameters were the fore/aft length of mirror housing and the plan view angle of the mirror housing's inboard surface. Key drag parameters were the fore/aft length of the mirror housing, the cross-section shape of the mirror pedestal, and the angle of the pedestal (relative to the wind).

As the complexity of automotive chassis control systems increases with the introduction of technologies such as yaw and roll stability systems, processes for model-based development of chassis control systems becomes an essential part of ensuring overall vehicle safety, quality, and reliability. To facilitate such a model-based development process, a vehicle modeling framework intended for chassis control development has been created. This paper presents a design methodology centered on this modeling framework which has been applied to real world driving events and has demonstrated its capability to capture vehicle dynamic behavior for chassis control development applications.

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.

Among the development phases of an automotive vehicle one can point out the definition of the main characteristics of its suspensions like for example the suspension kinematics and compliances properties. Suspension definition phase can be understood as the following scenario: given a suspension type, which hard points (geometric) and what values of stiffness for the whole system will result in a desired dynamic behavior for the vehicle as well as production feasibility. This present work intends to show the influence of some suspension properties on the global dynamic behavior of the vehicle, having as a target an efficient suspension design. In terms of global dynamic behavior this work point out some control parameters, which describe the vehicle transient and steady-state properties. Those parameters are: Yaw phase lag, understeer gradient, Steady state acceleration gain and yaw overshoot during a maneuver like brake in a turn and power-off in a curve.

Far-side occupants are not addressed in current government regulations around the world even though they account for up to 40% of occupant HARM in side impact crashes. Consequently, there are very few crash tests with far-side dummies available to researchers. Sled tests are frequently used to replicate the dynamic conditions of a full-scale crash test in a controlled setting. However, in far-side crashes the complexity of the occupant kinematics is increased by the longer duration of the motion and by the increased rotation of the vehicle. The successful duplication of occupant motion in these crashes confirms that a sled test is an effective, cost-efficient means of testing and developing far-side occupant restraints or injury countermeasures.

The biomechanical injury assessment for an occupant in a planar vehicle-to-vehicle collision often requires a kinematic analysis of impact-related occupant motion. This analysis becomes more complex when the collision force is eccentric to the center of gravity on a struck vehicle because the vehicle kinematics include both translation and potentially significant yaw rotational rates. This study examines the significance of vehicle yaw on occupant kinematics in eccentric (off-center) planar collisions. The paper describes the calculation of the instantaneous center of rotation (ICR) in a yawing vehicle post-impact and explores how mapping this quantity may inform an occupant’s trajectory when using a free particle “occupant” analysis. The study initially analyzed the impact-related occupant motion for all the outboard seat positions in a minivan using several hypothetical examples of eccentric vehicle-to-vehicle crash configurations with varying PDOF, delta-V, and yaw rate.

NHTSA has recently been petitioned to address the protection of second-row children in rear crashes due front seatback performance. The protection of children is important. However, it is more complex than assessing front seat performance in rear impacts. Viano, Parenteau (2008 [1]) analyzed cases of serious-to-fatally injured (MAIS 3+F) children up to 7 years old in the second row in rear impacts involving 1990+ model year vehicles using 1997-2005 NASS-CDS. They observed that intrusion was an important factor pushing the child forward into the back of the front seat, B-pillar or other front structure. To help assess whether stiffening the front seats would be beneficial for second-row child safety, the 2008 study was updated using more recent data and model year vehicles. In the present study, 1997-2015 NASS-CDS data were analyzed for serious-to-fatally (MAIS 3+F) injured 0- to 7-year old children in the second row with 1994+ model year vehicles.

Objective: This study involved a number of different tests addressing theories for recliner and track release of front seats in rear impacts. It addresses the validity of the theories. Method: Several separate test series were conducted to address claims made about recliner and track release of front seats in rear impacts. The following theories were evaluated to see the validity of the issues: 1 Recliner teeth slipping with minimal damage to the teeth 2 Recliner teeth bypass by disengaging and re-engaging under load without damaging the teeth 3 Recliner shaft bending and torque releasing the recliners 4 Track release by heel loading 5 Track release with occupant load on the seat 6 Recliner handle rotation causing recliner release 7 Double pull body block tests Results: Many of the theories were found to be uncorroborated once actual test data was available to judge the merits of the issue raised. The laboratory tests were set-up to specifically address particular issues.

The desire for greater fuel efficiency and reduced emissions have accelerated a shift from traditional materials to design solutions that more closely match materials and their properties with key applications. The Multi-Material Lightweight Vehicle (MMLV) Project presents cutting edge engineering that meets future challenges in a concept vehicle with weight and life-cycle assessment savings. These results significantly contribute to achieving fuel reduction and to meeting future Corporate Average Fuel Economy (CAFÉ) regulations without compromising vehicle performance or occupant safety.

It is likely that use of urea-based selective catalytic reduction (SCR) will be needed to meet U.S. Tier 2 diesel emission standards for oxides of nitrogen (NOx). The ideal ratio of ammonia (NH3) molecules to NOx molecules (known as alpha) is 1:1 based on urea consumption and having NH3 available for reaction of all of the exhaust NOx. However, SCR efficiency can be less than 100% at low temperatures in general, and at higher temperatures with high exhaust SCR catalyst space velocities. At the low temperatures where NOx conversion efficiency is low, it may be advantageous to reduce the alpha ratio to values less than one (less NH3 than is needed to convert 100% of the NOx emissions) to avoid NH3 slip. At higher space velocities and high temperatures, the NOx conversion efficiency may be higher with alpha ratios greater than 1. There is however concern that the additional NH3 will be slipped under these conditions.

While SAE double inverted flares have been in use for decades, leaking joints continue to be a problem for OEMs in production settings consuming time and energy to detect and correct them before releasing vehicles from the assembly plant. It should be noted that this issue is limited to first-time vehicle assembly; once a flared brake tube joint is sealed at the assembly plant it remains sealed during normal customer usage. From their inception through the late 1980s most brake tubes have been 3/16″ nominal diameter. With the advent of higher flow requirements of Traction Control and Yaw/Stability control systems, larger tubes of 1/4″ and 5/16″ size have also been introduced. While it was known that the first-time sealing capability of the 3/16″ joint was not 100%, leakers were generally containable in the production environment and the joint was regarded as robust.

This study assesses front seat occupant responses in rear impacts with active head restraints (AHR) and conventional head restraints (CHR) using field accident data and test data from the Insurance Institute for Highway Safety (IIHS). 2003-2015 NASS-CDS data were analyzed to determine injury rates in 1997+ model year seats equipped with AHR and CHR. Results indicated that less than 4% of occupants were in seats equipped with AHR. Crashes of delta-V <24 km/h accounted for more than 70% of all exposed front seat occupants, irrespective of head restraint design. Rear crashes with a delta-V < 24 km/h included 35.6% fewer occupants who sustained a MAIS 1-2 injury overall and 26.4% fewer who sustained a MAIS 1-2 cervical injury in vehicles equipped with AHR compared to CHR. In IIHS 16 km/h rear sled tests, the biomechanical response of an instrumented BioRID was evaluated on seats with AHR and CHR. HIC15 and concussion risk were calculated from head acceleration data.

Obesity rates are increasing among the general population. This study investigates the effect of obesity on ejection and injury risk in rollover crashes through analysis of field accident data contained in the National Automotive Sampling System-Crashworthiness Data System (NASS-CDS) database. The study involved front outboard occupants of age 15+ years in 1994+ model year vehicle rollover crashes. Occupants were sorted into two BMI groups, normal (18.5 kg/m2 ≤ BMI < 25.0 kg/m2) and obese (BMI ≥30 kg/m2). Complete and partial ejection risks were first assessed by seating location relative to roll direction and belt use. The risk of serious-to-fatal injuries (MAIS 3+F) in non-ejected occupants were then evaluated. The overall risk for complete ejection was 2.10% ± 0.43% when near-sided and 2.65% ± 0.63% when far-sided, with a similar risk for both the normal and obese BMI groups.

Vehicle structures are designed to manage impact forces and transfer crash energy, in addition to their primary purpose of connecting all the vehicle powertrain, suspension, steering, HVAC, electronics, occupant accommodation, and weatherproofing. With the introduction of new rear impact requirements, the design of rear structures has evolved and the use of high strength steel has increased. This study objective was to assess the effect of new FMVSS 301 requirements on vehicle responses. NHTSA conducted 33 offset rear crash tests at 80 km/h with vehicles that pre-dated the newer FMVSS 301R requirements and 88 with vehicles that complied with the newer requirements, with a 2009-2015 model year range. The vehicles were grouped by size and the permanent crush was tabulated. Overall, the struck-side maximum crush decreased in the newer model vehicles. Seven matches with pre and post 301R were identified on the same make and model vehicle of different generations.

This study assesses vehicle and occupant responses in six vehicle-to-vehicle high-speed rear impact crash tests conducted at the Exponent Test and Engineering Center. The struck vehicle delta Vs ranged from 32 to 76 km/h and the vehicle centerline offsets varied from 5.7 to 114 cm. Five of the six tests were conducted with Hybrid III ATDs (Anthropometric Test Device) with two tests using the 50th male belted in the driver seat, one test with an unbelted 50th male in the driver seat, one test with a 95th male belted in the driver seat, and one with the 5th female lap belted in the left rear seat. All tests included vehicle instrumentation and three tests included ATD instrumentation. The ATD responses were analyzed and compared to corresponding IARVs (injury assessment reference values). Ground-based and onboard vehicle videos were synchronized with the vehicle kinematic data and biomechanical responses.

There has been a general consensus in the scientific literature that a rim gouging, not scraping, into a roadway surface generates very high forces which can cause a vehicle to overturn in some situations. However, a paper published in 2004 attempts to minimize the forces created during wheel rim gouging and the effect on vehicle rollover. This paper relied largely on heavily filtered lateral acceleration data and discounted additional test runs by the authors and NHTSA that did not support the supposed conclusions. This paper will discuss the effect of rim gouging using accepted scientific methods, including full vehicle testing where vehicle accelerations were measured during actual rim gouging events and static testing of side forces exerted by wheels mounted on a moving test fixture. The data analyzed in this paper clearly shows that forces created by rim gouges on pavement can be thousands of Newtons and can contribute to vehicle rollover.

Industry trends towards lighter, more aerodynamically efficient road vehicles have the potential to degrade a vehicle’s response to crosswinds. In this paper, a methodology is outlined that indirectly couples a computational fluid dynamics (CFD) simulation of the vehicle’s aerodynamic characteristics with a multi-body dynamics simulation (MBD) to determine yaw, roll and pitch response characteristics during a severe crosswind event. This one-way coupling approach mimics physical test conditions outlined in open loop test procedure ISO 12021:2010 that forms part of the vehicle sign-off criterion at Ford Motor Company. The methodology uses an overset mesh CFD method to drive the vehicle through a prescribed crosswind event, providing unfiltered predictions of vehicle force and moment responses that are used as applied forces in the MBD model. The method does not account for changes in vehicle attitude due to applied aerodynamic forces and moments.

Globalization in the automotive industry has resulted in a tremendous competitive advantage to those companies who can internally communicate ideas and information effectively and in a timely manner. This paper discusses one such effort related to objectively testing vehicles for steering and handling characteristics by implementing standard test procedures, data acquisition hardware and analysis methods. Ford Motor Company's Vehicle Dynamics Test Section has refined a number of test procedures to the point that, with proper training, all design and development engineers can quickly acquire, analyze and share test results. Four of these procedures and output are discussed in detail.

This paper describes (1) the findings from the implementation of a component test methodology for body, engine and transmission mounts [1, 2 and 3], and (2) the associated CAE model development and mount design robustness enhancement. A series of component tests on light truck body, engine and transmission mounts have been conducted to not only obtain their characteristics as inputs for crashworthiness analysis, but also drive mount design direction for frontal impacts.