Dashboard Stiffness Control for Reducing Knee Injury in Frontal Crashes

Across the world different regulations are applicable for side impact, each require a different restraint system approach. However it would be much more cost effective to develop one single restraint system suitable for all global requirements. An efficient methodology has been to optimize the restraint system for multiple load cases simultaneously, resulting in a restraint system specification that will ensure that global targets are met. The methodology combines the use of testing and efficient numerical simulation to find a solution in the most effective way. ABSTRACT Across the world different regulations are applicable for frontal impact, each require a different restraint system approach. However it would be much more cost effective to develop one single restraint system suitable for all global requirements. Flexible and reliable development approach has to be used for quick evaluations of various safety system configurations and conditions. An efficient methodology has been developed to optimize the frontal restraint system for multiple load cases simultaneously, Resultant restraint system specification to specification to meet global targets. The methodology combines the use of testing and MADYMO modelling techniques in combination with advanced DoE (Design of Experiments) analysis to find a solution in the most effective way. ABSTRACT In frontal crashes, one of the primary reasons for occupant injuries is hard contact with the vehicle interiors. While restraints like airbags, seat belt pre- tensioners etc. help in preventing direct contact of the upper body region; vehicle interiors play a critical role in controlling the lower body region injuries. Knee injuries can be controlled in various ways as follows:? Avoiding contact with the dashboard by use of buckle pre-tensioners etc • Using restraints like knee airbags • Optimizing the dashboard profile and stiffness at the contact locations All the above options have their own advantages and limitations. This paper explains the effect of dashboard stiffness tuning for controlling knee injuries in a frontal crash. The development methodology and some validation tools are discussed using a case study. ABSTRACT Bumper systems play an important role in energy management during vehicle accidents. Bumpers beams are generally designed to withstand impacts of up to 4 km/h (ECE42, FMVSS-581) and need to withstand low speed 15 km/h offset insurance crash tests to determine damageability and repairability features (RCAR-42) of vehicle design. Globalization of Automotive industry is forcing the designers to propose those designs, which can be introduced, to market quickly and which have lower costs and better quality. This paper presents work a novel design solution of a thermoplastic solitary bumper beam intended to reduce bumper weight and cost, meeting low speed damageability and RCAR impact requirements. A thermoplastic (PC/PBT) solitary beam is proposed that