1. Vehicle crash safety introduction
a.Crash injury and fatality data from USA
b.Distribution of different crash types
c.Active safety and passive safety
2. Vehicle frontal crash modes
a. Frontal rigid barrier
b. Frontal offset deformable barrier
c. Frontal angular, Oblique cart impact
d. Out of position tests, driver and passenger, SAB, SAC
e. HYGE and Servo sled tests
f. Component tests
g. Moving Deformable Barrier tests
h. Side Pole test
i. Progressive Moving Deformable Barrier cart impact
3. Biomechanics
a.Human anatomy
b.AIS injury scale
c.Chest injury
d.Head injury
e.Neck Injury
f.Femur injury
g. Foot, ankle and tibia injury
4. Frontal and side test dummies and injury metrics (30 minutes)
a. 50th, 5th, 95th, THOR 50th
b. 3yr, 6yr, 1 yr
c. Frontal dummy metrics
d. ES2, SIDIIs, WorldSID
5. Video – Vehicle Safety History
6. Frontal crash mechanics
a. Crash pulse, front loaded, rear loaded
b. Project using Excel:
i. Calculate vehicle velocity and crush from pulse
ii. Get maximum crush, time to zero velocity
iii. Pulse comparison, front-loaded and rear loaded pulses
c. Intrusions
d. Occupant to restraint gaps and restraint characteristics
e. Belted vs. unbelted occupant
Project: Given pulse, restraint characteristics, occupant mass, find occupant responses
g. Airbag quickness and stiffness
h. Belt slack, pretension, EMR
Project: Given pulse, occupant mass, restraint boundaries, find best restraint characteristics
j. Driver vs. passenger
k. Typical crash event
Project: Given restraint characteristics, occupant mass, find optimal pulse shape.
m. 5th percentile female submarining
7. Front Impact Hands on Project
8. Front Impact Case Studies
——DAY TWO——
1. Side Impact Mechanics
a. Vehicle structure
b. Door intrusion
c. Door profile, stiffness
d. Airbags
2. Crash sensor (30 minutes)
a. Airbag & pretensioner firing & non-firing conditions
b. Sensor crash tests
3. US regulations (30 minutes)
a. FMVSS 208
b. FMVSS 215
c. FMVSS 201
d. FMVSS 301
4. US public domain tests (20 minutes)
a. NCAP
b. IIHS frontal offset
5. European regulations (15 minutes)
a. ECE 94
b. ECE 16
6. European public domain tests (15 minutes)
a. Euro-NCAP
7. Numerical data processing (30 minutes)
a. Filtering and SAE J211 guidelines
b. HIC, Nij, Cumdur, V*C calculations
c. Numerical integration, differentiation, occupant relative travel
8. Vehicle crash computer modeling (CAE) (135 minutes)
a. Vehicle structure CAE, finite element method
i. Finite element method
ii. Explicit and implicit solvers
iii. Unibody and body on frame vehicles
b. Occupant CAE, rigid body dynamics
i. Madymo, occupant CAE tool
ii. Rigid bodies
iii.Mechanical joints
iv. Joint stiffness
v. Ellipsoids and rigid FE mesh
vi. Planes
vii. Elliptical cylinders
viii. Contacts
ix. Acceleration fields
x. Prescribed motion
xi. Airbag models
xii. Seatbelt modeling, seat integrated belt system
xiii. Vehicle interior, IP, knee bolster, Steering wheel, Steering column, floor, dash, seat
xiv. Vehicle pitch and yaw
xv. Madymo and LsDyna coupling
xvi. Out of position modeling, CFD
c.CAE assumptions and limitations
9. Side Imact Hands On Project
10. Side Impact Case Studies
——DAY THREE——
11. DOE and Optimization (40 minutes)
a. DOE used in component test, HYGE sled and CAE
b. Optimization in CAE
c. Robust design using CAE
12. Frontal Restraint system (90 minutes)
a. Airbag, Inflator, single & dual stage
i. Closed tank test, 10 ms rise rate, peak pressure
ii. Drawbacks of tank tests
iii. Airbag shape, fabric, tether, venting
iv. Airbag module cover design
b. Crash sensor, Restraint Control Module (RCM)
c. Seatbelt, D-rings
d. Retractors, torsion bars
e. Buckle pretensioner
f. Retractor pretensioner
g. Steering column stroke
h. Steering wheel lower and upper rims
I. Knee bolster
18. Side Impact Restraint System
a. Side Airbags:
b. Thorax
c. Thorax-Head Combo
d. Pelvis-Thorax (PTSAB)
e. Shoulder
f. Air Curtains
19. Real world crashes – safety for the aging population, crash severity distribution
20. Summary |
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