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The search for improvements in occupant protection under vehicle impact is hampered by a real lack of reliable biomechanical data. To help fill this void, General Motors has initiated joint research with independent researchers such as the School of Medicine, U. C. L. A. – in this case to study localized head and facial trauma — and has developed such unique laboratory tools as “Tramasaf,” a human-simulating headform, and “MetNet,” a pressure-sensitive metal foam. Research applied directly to product design also has culminated in developments such as the Side-Guard Beam for side impact protection.

The purpose of this study is to help understand the thoracic response and injury mechanisms in high-energy, limited-stroke, lateral velocity pulse impacts to the human chest wall. To impart such impacts, a linear impactor was developed which had a limited stroke and minimally decreased velocity during impact. The peak impact velocity was 5.6 ± 0.3 m/s. A series of BioSID and cadaver tests were conducted to measure biomechanical response and injury data. The conflicting effects of padding on increased deflection and decreased acceleration were demonstrated in tests with BioSID and cadavers. The results of tests conducted on six cadavers were used to test several proposed injury criteria for side impact. Linear regression was used to correlate each injury criterion to the number of rib fractures. This test methodology captured and supported a contrasting trend of increased chest deflection and decreased TTI when padding was introduced.

As the driving population ages, there is a need to understand the accident patterns of older drivers. Previous research has shown that side impact collisions, usually at an intersection, are a serious problem for the older driver in terms of injury outcome. This study compares the frequency of side impact, intersection collisions of different driver age groups using state and national police-reported accident data as well as an in-depth analysis of cases from a fatal accident study. All data reveal that the frequency of intersection crashes increases with driver age. The state and national data show that older drivers have an increase frequency of intersection crashes involving vehicles crossing paths prior to the collision compared to their involvement in all crash types. When taking into account traffic control devices at an intersection, older drivers have the greatest involvement of multiple vehicle crashes at a signed intersection.

Heidelberg-type side impact sled tests were conducted using SID side impact dummies. These tests were run under similar conditions to a series of cadaveric sled tests funded by the Centers for Disease Control in the same lab. Tests included 6.7 and 9 m/s (15 and 20 mph) unpadded and 9 m/s padded tests. The following padding was used at the thorax: ARSAN, ARCEL, ARPAK, ARPRO, DYTHERM, 103 and 159 kPa (15 and 23 psi) crush strength paper honeycomb, and an expanded polystyrene. In all padded tests the dummy Thoracic Trauma Index, TTI(d) was below the value of 85 set by federal rulemaking (49 CFR, Part 571 et al., 1990). In contrast, cadavers in 9 m/s sled tests did not tolerate ARSAN 601 (MAIS 5) and 23 psi (159 kPa) paper honeycomb (MAIS 5), and 20 psi (138 kPa) Verticel™ honeycomb (MAIS 4), but tolerated 15 psi (103 kPa) paper honeycomb (average thoracic MAIS 2.3 in six tests).

This report presents the test methods and results of a study involving lap/shoulder belted dummies in dynamic dolly rollover tests and inverted vehicle drop tests. Data are presented showing dummy neck loadings resulting from head impacts to the vehicle interior as the vehicle contacts the ground. Comparison of the number and magnitude of axial neckloads are presented for rollcaged and production vehicles, as well as an analysis of the factors which influence neckloads under these conditions.

Although rollover crashes represent a small fraction (approximately 3%) of all motor vehicle crashes, they account for roughly one quarter of crash fatalities to occupants of cars, light trucks, and vans (NHTSA Traffic Safety Facts, 2004). Therefore, the National Highway Traffic Safety Administration (NHTSA) has identified rollover injuries as one of its safety priorities. Motor vehicle manufacturers are developing technologies to reduce the risk of injury associated with rollover collisions. This paper describes the development by General Motors Corporation (GM) of a suite of laboratory tests that can be used to develop sensors that can deploy occupant protection devices like roof rail side air bags and pretensioners in a rollover as well as a discussion of the challenges of conducting this suite of tests.

This paper presents an extensive research program undertaken to develop improved side impact test methods. The development of a component side impact test device along with an associated test procedure are reviewed. The results of accident data analysis techniques to define anatomical areas most likely to be injured during side impact and definition of test device response corridors based on human surrogate testing conducted by the Association Peugeot/Renault and the University of Heidelberg are discussed. The relationship of response corridors and accident data analysis in earlier phases of the project resulted in definition and development of a component side impact test device to represent the human thorax. A test program to evaluate and compare component and full-vehicle test results is presented.

This paper presents the results of a series of over 30 impact sled simulations of racing car frontal crashes conducted as part of the GM Motorsports Safety Technology Research Program. A Hyge™ impact sled fitted with a simulated racing car seat and restraint system was used to simulate realistic crash loading with a mid-size male Hybrid III dummy. The results of tests, in the form of measured loads, displacements, and accelerations, are presented and comparisons made with respect to the levels of these parameters seen in typical passenger car crash testing and to current injury threshold values.

Various types of padding have been used in side impact sled tests with cadavers. This paper presents a summary of performance of the padding used in NHTSA and WSU/CDC sled tests, and a summary of material properties of padding used in cadaveric sled tests. The purpose of this paper is to provide information on padding performance in cadavers, rather than optimum padding performance in dummies.

After a rear end impact, various clinical symptoms are often seen in car occupants (e.g. neck stiffness, strain, headache). Although many different injury mechanisms of the cervical spine have been identified thus far, the extent to which a single mechanism of injury is responsible remains uncertain. Apart from hyperextension or excessive shearing, a compression of the cervical spine can also be seen in the first phase of the impact due to ramping or other mechanical interactions between the seat back and the spine. It is hypothesized that this axial compression, together with the shear force, are responsible for the higher observed frequency of neck injuries in rear end impacts versus frontal impacts of comparable severity. The axial compression first causes loosening of cervical ligaments making it easier for shear type soft tissue injuries to occur.

This paper describes a numerical simulation technique applicable to the FMVSS 214 side impact test through the use of the finite element method (FEM) technology. The paper outlines the development of the side impact dummy (SID), moving deformable barrier (MDB) and the test vehicle FEM models, as well as the development of new advanced constitutive models of materials and algorithms in LS-DYNA3D which are related to the topic. Presented in the paper are some initial simulation problems which were encountered and solved, as well as the correlation of the simulation data to the physical test.

Side impact dummy (SID) is a human-like test device used in the National Highway Transportation Safety Administration (NHTSA) mandated side impact test of vehicles sold in the USA. A finite element model of SID has been developed at GM as a part of a project to simulate the side impact test. The objective is to better predict physical test results by replacing traditional rigid-body lumped parameter models with a finite element model. The project included, besides mesh generation, the development of new LS-DYNA3D constitutive models for rubber and foam-like materials, and enhancements of contact interface and other algorithms. This paper describes the GM SID finite element model and its performance in side impact test simulations.

The overall highway fatality rate has dropped almost contintinously since 1925, from 20 to 2.5 per hundred million miles of travel in 1984. Still, the almost 44, 000 fatalities in 1984 can, and will, be decreased. In 1983, 5, 475 of the 42, 584 highway fatalities were in accidents involving medium or heavy trucks. Only 18% of these were occupants of the trucks themselves. 82% were pedestrians or occupants of the “other vehicle.” The greatest number of combination truck accidents take place on two-lane rural roads. Single-vehicle accidents are responsible for 70% of heavy truck occupant fatalities. Doubles and heavier trucks appear to be as safe as other heavy trucks. Rollover and ejection are responsible for the greatest number of truck occupant fatalities.

The overall highway fatality rate has dropped almost continuously since 1925, from 20 to 2.5 per 100 million miles of travel in 1984. Still, the almost 44,000 fatalities in 1984 can and will be decreased. In 1983, 5,475 of the 42,584 highway fatalities were in accidents involving medium or heavy trucks. Only 18 percent of these were occupants of the trucks themselves; 82 percent were pedestrians or occupants of the other vehicle. The greatest number of combination truck accidents takes place on two-lane rural roads. Single-vehicle accidents are responsible for 70 percent of heavy truck occupant fatalities. Doubles and heavier trucks appear to be as safe as other heavy trucks. Rollover and ejection are responsible for the greatest number of truck occupant fatalities. When asked about her top priority as the new Secretary of Transportation, Mrs. Dole replied, “There's no higher mandate for the Department than to promote safety….”

Finite element models of human body segments have been developed in recent years. Numerical simulation could be helpful when understanding injury mechanisms and to make injury assessments. In the lower leg injury research in NISSAN, a finite element model of the human ankle/foot is under development. The mesh for the bony part was taken from the original model developed by Beaugonin et al., but was revised by adding soft tissue to reproduce realistic responses. Damping effect in a high speed contact was taken into account by modeling skin and fat in the sole of the foot. The plantar aponeurosis tendon was modeled by nonlinear bar elements connecting the phalanges to the calcaneus. The rigid body connection, which was defined at the toe in the original model for simplicity, was removed and the transverse ligaments were added instead in order to bind the metatarsals and the phalanges. These tendons and ligaments were expected to reproduce a realistic response in compression.

Seventeen Heidelberg type cadaveric side impact sled tests, two sled-to-sled tests, and forty-four pendulum tests have been conducted at Wayne State University, to determine human responses and tolerances in lateral collisions. This paper describes the development of a simplified finite element model of a human occupant in a side impact configuration to simulate those cadaveric experiments. The twelve ribs were modeled by shell elements. The visceral contents were modeled as an elastic solid accompanied by an array of discrete dampers. Bone condition factors were obtained after autopsy to provide material properties for the model. The major parameters used for comparison are contact forces at the level of shoulder, thorax, abdomen and pelvis, lateral accelerations of ribs 4 and 8 and of T12, thoracic compression and injury functions V*C, TTI and ASA.

Fatal crash circumstances for 48 belted female drivers were studied in-depth and compared to those of 83 belted male drivers in a similar population of vehicles. Women had a higher incidence of crashes on slippery roads, during lane changes and passing maneuvers than men who had a higher rate of aggressive driving and speed related crashes (χ2 = 10.47, p < 0.001). Driver-side damage was significantly more frequent in female than male crashes (χ2 = 5.74, p < 0.025) and women had a higher fraction of side impacts (45.9% v 31.4%) and crashes during daylight (87.0% v 72.3%, χ2 = 3.65, p < 0.05) than men. Women also had a higher fraction of potentially avoidable crashes than men (57.5% v 39.0%) and a lower involvement related to aggressive driving (10.6% v 25.6%). These differences were statistically significant (χ2 = 5.41, p < 0.025).

A deformable finite element dummy model was used to simulate air bag interaction with in-position passenger side occupants in frontal vehicle crash. This dummy model closely simulates the Hybrid III hardware with respect to geometry, mass, and material properties. Test data was used to evaluate the validity of the model. The calculated femur loads, chest acceleration and head acceleration were in good agreement with the test data. A semi-rigid dummy model (with rigid chest) was derived from the deformable dummy to improve turnaround time. Simulation results using the semi-rigid dummy model were also in reasonable agreement with the test data. For comparison purpose, simulations were also performed using PAMCVS, a hybrid code which couples the finite element code PAMCRASH with the rigid body occupant code. The deformable dummy model predicted better chest acceleration than the other two models.

Three-dimensional film analysis was used to study the response of the shoulder and thoracic skeleton of cadavers to lateral sled tests conducted at Wayne State University. The response of the shoulder structure was of particular interest, although, it is perhaps the most difficult skeletal structure to track in a side impact. Results of the three-dimensional film analysis are given for rigid impacts at 6.7 and 9.1 meters per second, and for padded impacts averaging 9 meters per second. Results from a two-dimensional film analysis are included for the impacted clavicle which could not be tracked by the three-dimensional film analysis. Displacements at various locations on the shoulder and thoracic skeleton were normalized to estimate the response of a fiftieth percentile male.

Injuries to the thorax and abdomen comprise a significant percentage of all occupant injuries in motor vehicle accidents. While the percentage of internal chest injuries is reduced for restrained front-seat occupants in frontal crashes, serious skeletal chest injuries and abdominal injuries can still result from interaction with steering wheels and restraint systems. This paper describes the design and performance of prototype components for the chest, abdomen, spine, and shoulders of the Hybrid III dummy that are under development to improve the capability of the Hybrid III frontal crash dummy with regard to restraint-system interaction and injury-sensing capability.