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This is an overview of air bag injuries, a review of the literature and descriptions of air bag related injuries to the various body areas. Some unusual injuries are also included. The cases presented are from the author's files and one from the Special Studies Division of NHTSA.

The Human Motion Simulation Framework is a hierarchical set of algorithms for physical task simulation and analysis. The Framework is capable of simulating a wide range of tasks, including standing and seated reaches, walking and carrying objects, and vehicle ingress and egress. In this paper, model predictions for the terminal postures of standing object transfer tasks are compared to data from 20 subjects with a wide range of body dimensions. Whole body postures were recorded using optical motion capture for one-handed and two-handed object transfers to target destinations at three angles from straight ahead and three heights. The hand and foot locations from the data were input to the HUMOSIM Framework Reference Implementation (HFRI) in the Jack human modeling software. The whole-body postures predicted by the HFRI were compared to the measured postures using a set of measures selected for their importance to ergonomic analysis.

In a review of 540 crashes in which the steering-wheel airbag deployed, 38% of the drivers sustained some level of upper extremity injury. The majority of these were AIS-1 injuries including abrasions, contusions and small lacerations. In 18 crashes the drivers sustained AIS-2 or-3 level upper extremity injuries, including fractures of the radius and/or ulna, or of the metacarpal bones, all related to airbag deployments. It was determined that six drivers sustained the fracture(s) directly from the deploying airbag or the airbag module cover. The remaining 12 drivers had fractures from the extremity being flung into interior vehicle structures, usually the instrument panel. Most drivers were taller than 170 cm and, of the 18 drivers, 10 were males.

From our crash investigations of air bag equipped passenger cars, a subset of upper extremity injuries are presented that are related to air bag deployments. Minor hand, wrist or forearm injuries-contusions, abrasions, and sprains are not uncommonly reported. Infrequently, hand fractures have been sustained and, in isolated cases, fractures of the forearm bones or of the thumb and/or adjacent hand. The close proximity of the forearm or hand to the air bag module door is related to most of the fractures identified. Steering wheel air bag deployments can fling the hand-forearm into the instrument panel, rearview mirror or windshield as indicated by contact scuffs or tissue debris or the star burst (spider web) pattern of windshield breakage in front of the steering wheel.

Digital human models (DHM) are now widely used to assess worker tasks as part of manufacturing simulation. With current DHM software, the simulation engineer or ergonomist usually makes a manual estimate of the likely worker standing location with respect to the work task. In a small number of cases, the worker standing location is determined through physical testing with one or a few workers. Motion capture technology is sometimes used to aid in quantitative analysis of the resulting posture. Previous research has demonstrated the sensitivity of work task assessment using DHM to the accuracy of the posture prediction. This paper expands on that work by demonstrating the need for a method and model to accurately predict worker standing location. The effect of standing location on work task posture and the resulting assessment is documented through three case studies using the Siemens Jack DHM software.

Mechanisms of thoraco-abdominal trauma were investigated utilizing unembalmed, repressurized human cadavers subjected to frontal impact with a steering wheel assembly. The focus of this research program was on trauma to the soft-tissue organs surrounded by the thoracic cage, as well as on the kinematic response of the thoracic cage. The results are compared to other thoraco-abdominal research programs conducted at the University of Michigan Transportation Research Institute (UMTRI) during the last eight years.

From the authors' files, case examples of thoracolumbar injuries sustained by lap-shoulder belted front seat occupants, in frontal crashes, are presented. Additional cases were found in a review of the clinical literature. The biomechanical literature was reviewed, identifying laboratory studies on thoracolumbar spinal injuries. Suggested mechanisms in the production of these injuries in frontal type car crashes are postulated.

Based on an analysis of the National Automotive Sampling System (NASS) database from calendar years 1995-2000, over 30,000 fractures and dislocations of the knee-thigh-hip (KTH) complex occur in frontal motor-vehicle crashes each year in the United States. This analysis also shows that the risk of hip injury is generally higher than the risks of knee and thigh injuries in frontal crashes, that hip injuries are occurring to adult occupants of all ages, and that most hip injuries occur at crash severities that are equal to, or less than, those used in FMVSS 208 and NCAP testing. Because previous biomechanical research produced mostly knee or distal femur injuries, and because knee and femur injuries were frequently documented in early crash investigation data, the femur has traditionally been viewed as the weakest part of the KTH complex.

A review of the UM series and of NCSS, NASS, CPIR and FARS Files, as well as Michigan accident data files was undertaken, as well as a review of the NTSB “Rear Seat Study”. From these files rear seat occupany is approximately 10%, with children 6 years of age or less being 1/5th of these. About 50-60% of those in the sear seat are adults. Most of the injuries are at the lower AIS levels, with adults being more seriously injured. Of the more serious or fatal injuries, the head and face predominate by far, in all types of crashes involving unrestrainded rear seat occupants. When belts are worn there are few seriously or fatally injured rear occupants and of these, the abdominal area predominates. From available data, rear lap-belted passengers have the same MAIS level (or less) when compared to their front seat lap-shoulder belted counterparts.

The potential of digital human modeling to improve the design of products and workspaces has been limited by the time-consuming manual manipulation of figures that is required to perform simulations. Moreover, the inaccuracies in posture and motion that result from manual procedures compromise the fidelity of the resulting analyses. This paper presents a new approach to the control of human figure models and the analysis of simulated tasks. The new methods are embodied in an algorithmic framework developed in the Human Motion Simulation (HUMOSIM) laboratory at the University of Michigan. The framework consists of an interconnected, hierarchical set of posture and motion modules that control aspects of human behavior, such as gaze or upper-extremity motion. Analysis modules, addressing issues such as shoulder stress and balance, are integrated into the framework.

From the crash investigation files at the University of Michigan Transportation Research Institute (UMTRI), the crashes involving deployed airbags were reviewed. The total number of deployments is 898 of which 764 are frontal crashes with the principal direction of force (PDF) at 11-1 o’clock. Of the drivers in these frontal crashes 83% were using the belt restraint. Overall, seven of ten drivers have an AIS-0 or 1 level injury as the maximum or highest injury severity level (MAIS). Of the survivors, one in six had a moderate level injury (AIS-2) as their most significant injury and one in nine had an MAIS 3 or greater injury. Fatalities are rare. There is a difference between injury severity frequencies of belted vs. non-belted drivers. Three-quarters of the belted drivers had minor injuries compared to only half of those not belted. A difference was also noted at the AIS-2 level—belted vs. unbelted 14% vs. 23%.

This paper presents an analysis of front seat outboard occupants in frontal and rollover crashes. These occupants were lap belted, lap-shoulder belted or were unrestrained. In the frontal crash the lap-shoulder belt reduces the occurrence of the severe, serious, critical-to-life injuries, and fatalities in all regions of the body (head, neck, thorax, lower torso and extremities). In addition, there is a strong association between belt usage and the occupant escaping from the crash with no injury. In rollover crashes, belts reduce the frequency of the more severe injuries by preventing the occupant from being ejected. For those occupants not ejected from the car, belts effectively reduce fatalities and the more serious injuries.

An analysis of 211 automobiles having the ball-type E.A. device (GM cars - 1972–1980), involved in frontal crashes was made to determine the relationship between driver injury and the steering assembly. The majority of the drivers had MAIS of 0 or 1 (66%). The head was the most frequently injured body region with the lower extremities next in frequency. Of the unrestrained drivers studied, 43% had a thoracic injury, the majority of which were minor. There is no correlation between injury severity and steering rim or spoke deformation, or the amount of E.A. column compression. Specific terminology for certain aspects of the E.A. performance are suggested.

Standing reach envelopes are important tools for the design of industrial and vehicle environments. Previous work in this area has focussed on manikin-based (where a few manikins are used to simulate individuals reaching within the region of interest) and population-based (where data are gathered on many individuals reaching in a constrained environment) approaches. Each of these methods has merits and shortfalls. The current work bridges the manikin- and population-based approaches to assessing reach by creating population models using kinematic simulation techniques driven by anthropometric data. The approach takes into account body dimensions, balance, and postural cost to create continuous models that can be used to assess designs with respect to both maximal and submaximal reaches. Cost is quantified as the degree to which the torso is involved in the reach, since the inclination of the torso is a good measure of lower-back load and may be related to subjective reach difficulty.

An appropriately contoured lumbar support is widely regarded as an essential component of a comfortable auto seat. A frequently stated objective for a lumbar support is to maintain the sitter's lumbar spine in a slightly extended, or lordotic, posture. Although sitters have been observed to sit with substantial lordosis in some short-duration testing, long-term postural interaction with a lumbar support has not been documented quantitatively in the automotive environment. A laboratory study was conducted to investigate driver posture with three seatback contours. Subjects† from four anthropometric groups operated an interactive laboratory driving simulator for one-hour trials. Posture data were collected by means of a sonic digitizing system. The data identify driver-selected postures over time for three lumbar support contours. An increase of 25 mm in the lumbar support prominence from a flat contour did not substantially change lumbar spine posture.

Efficient methods for simulating operators performing part handling tasks in manufacturing plants are needed. The simulation of part handling motions is an important step towards the implementation of virtual manufacturing for the purpose of improving worker productivity and reducing injuries in the workplace. However, industrial assembly tasks are often complex and involve multiple interactions between workers and their environment. The purpose of this paper is to present a series of industrial simulations using the Human Motion Simulation Framework developed at the University of Michigan. Three automotive assembly operations spanning scenarios, such as small and large parts, tool use, walking, re-grasping, reaching inside a vehicle, etc. were selected.

The side impact, recently and currently the subject to of much debate, controversy and proposed NHTSA rule making, is a difficult type of crash to significantly reduce serious injuries and fatalites. Results from real-world crash investigations presents a confusing picture for the near-side passenger compartment crash. A direct relationship between the amount of crush and injury severity levels (MAIS) is not apparent. Exemplar cases of tow-a-way/injury crashes are presented at all AIS injury level of drivers in crashes with direct driver door crush damage.

Eight whole fresh-frozen cadavers (6 female, 2 male) that were elderly and/or female were laterally impacted using UMTRI's dual-sled side-impact test facility. Cadavers were not excluded on the basis of old age or bone diseases that affect tolerance. A thinly padded, multi-segment impactor was used that independently measured force histories applied to the shoulder, thorax, abdomen, greater trochanter, iliac wing, and femur of each PMHS. Impactor plates were adjusted vertically and laterally toward the subject so that contact with body regions occurred simultaneously and so that each segment contacted the same region on every subject. This configuration minimized the effects of body shape on load sharing between regions. Prior to all tests, cadavers were CT scanned to check for pre-existing skeletal injuries. Cadavers were excluded if they had pre-existing rib fractures or had undergone CPR.

Workstation design is one of the most essential components of proactive ergonomics, and digital human models have gained increasing popularity in the analysis and design of current and future workstations (Chaffin 2001). Using digital human technology, it is possible to simulate interactions between humans and current or planned workstations, and conduct quantitative ergonomic analyses based on realistic human postures and motions. Motion capture has served as the primary means by which to acquire and visualize human motions in a digital environment. However, motion capture only provides motions for a specific person performing specific tasks. Albeit useful, at best this allows for the analysis of current or mocked-up workstations only. The ability to subsequently modify these motions is required to efficiently evaluate alternative design possibilities and thus improve design layouts.