TNO Automotive China / 2006-04-12

Frontal Impact Modeling and Applications

Contents

Frontal Impact Model

Steering System

Dummy Positioning

Restraint Systems

ODB ODB Modeling

Model Validation

1
 Frontal Impact Model

Frontal Model

Dummy System Restraint System

Vehicle System

Facet Q Dummy Airbag Belt

Steering IP Pedal Floor Vehicle Dash WS/Roof Seat

Frontal Impact Model

<Steering>
<Vehicle> <Seat>
1. Cross Member
< Floor> 1. Mount <Airbag>
2. Mounting Bracket
<Dash> 2. Cushion 1. Airbag FE Mesh
3. E.A.S.C.
< Pedal & Foot Rest> 3. Seat Back 2. Airbag Folding
4. Tilting Mechanism
< W/S & Roof> 4. Head Restraint 3. Airbag Position
5. Hub
< IP> 5. Stalk & Buckle
6. Upper & Lower Rim

<FE Belt>
1. Belt FE Mesh
2. Pre-Simulation
3. FE-Belt Position
<Contact Define>
<Characteristics>
1. Dummy to Vehicle
1. Vehicle Acceleration
<Dummy Position> 2. Dummy to Seat
2. Contact Char.
1. H-Point 3. Dummy to Steering
3. Material Char.
2. Lower Body 4. Dummy to Airbag
4. Restraint
3. Upper Body 5. Airbag Self Contact
5. Airbag Inflator
(optional)
6. Etc.
6. Dummy to FE-Belt

2
- Vehicle System

Ref_Space

J.Free_Rot_Disp

Vehicle

J.Free

Floor
J.Tran J.Tran J.Tran J.Brac J.Tran J.Brac J.Brac J.Brac J.Revo
J.Brac
Pedal Tran. Foot Rest Dash IP W/S Seat Mount Anchor Retractor D-Ring
Roof
J.Revo J.Tran

Pedal Rot. Seat Cushion

J.Revo J.Revo

Head Restraint J.Tran_Revo Seat Back Stalk J.Tran Buckle

- Vehicle System

(A simple vehicle system):
Vehicle
Floor
Firewall
Seat
IP (Instrument Panel) MB
Windshield/Roof

FE/Facet

3
- Example

(Y0-600mm)
50% AAMA 30MPH

Vehicle 2D Layout Drawing

- Example

1.

4
- Example

2. BODY

BODY MASS C.G. INERTIA

B-Vehicle 100 0.0 0.0 0.0 1.0 1.0 1.0 0.0 0.0 0.0
B-Floor 100 0.61 0.3 0.0 1.0 1.0 1.0 0.0 0.0 0.0
B-TB 10 -0.16 0.3 0.215 1.0 1.0 1.0 0.0 0.0 0.0
B-IP 8 0.21 0.3 0.27 1.0 1.0 1.0 0.0 0.0 0.0
B-WS 5 0.71 0.3 0.39 1.0 1.0 1.0 0.0 0.0 0.0
B-Seat 20 0.46 0.3 -0.05 1.0 1.0 1.0 0.0 0.0 0.0

- Example

3. BODY

Ref_Space

J.Free_Rot_Disp

B-Vehicle

J.Free

B-Floor
J.Tran J.Tran J.Tran J.Brac

B-TB B-WS B-Seat B-IP

10

5
- Example

11

- Example

4. BODY(Plane)

12

6
- Example

5. PlaneNormal

13

- Example

6.

FORCEF-D
1
0.3

W/S Floor Toe Board IP Seat

H_Slope = 1.0E7 H_Slope = 1.0E5 H_Slope = 1.0E6 H_Slope = 1.0E6 H_Slope = 1.0E6
Loading Function Loading Function Loading Function Loading Function Loading Function
0.000 0.0 0.000 0.0 0.000 0.0 0.000 0.0 0.000 0.0
0.025 500 0.025 100 0.025 800 0.030 5000 0.027 300
0.050 500 0.035 300 0.035 3000 0.080 5000 0.037 400
0.045 800 0.045 4000 0.045 500
0.055 1000
0.070 3000

14

7
- Example
| XI YI |
7. Pulse
0.0000 -0.00
0.0100 -41.96
system
0.0200 -81.29
0.0300 -115.50
0.0400 -142.47
0.0500 -160.47
0.0600 -168.40
0.0700 -165.74
0.0800 -152.67
0.0900 -130.01
0.1000 -99.18
0.1050 -81.29
0.1100 -62.11
0.1150 -41.96
0.1200 -21.15
0.1250 -0.00
AAMA 30MPH 0.2500 -0.00

15

- Example

8.

/
| XI YI |
0 0
0.07 0.1
0.2 0.1

16

8
-Dummy Positioning

1. :

Initial Joint Orientation:

Position: Dummy_jnt
Dummy_jnt AXIS1:Z:3.141rad
D12.1 AXIS2:Y:0.436rad
D20.3 Hip_jnt
D30.33 AXIS1:Y:0.05rad
Elbow_jnt Ankle_jnt
R2-0.7rad AXIS1:Z:-0.1rad
Knee_jnt
R2-0.35rad

17

-Dummy Positioning

18

9
-Dummy Positioning

2. Pre-Simulation:

19

-Dummy Positioning

2. Pre-Simulation:

damp

XMADgicToolsImport
INITIAL.JOINT_POS

20

10
 Steering

21

Steering

22

11
 Steering

A:0.0465
B:0.099
C:0.02523
D:0.0597
E:0.1664
F:0.0932
G:0.2836

23

Steering

24

12
-

1
2

25

5
6/7

26

13
-

27

28

14
-

Wheel rim local

coordinate sys

29

-Steering

wheel rim ,hub ,cover

wheel rim , collapsed column

30

15
-Seat

Ref_Space

J.Free_Rot_Disp

Vehicle

J.Free

Floor
J.Tran J.Tran J.Tran J.Brac J.Tran J.Brac J.Brac J.Brac J.Revo
J.Brac
Pedal Tran. Foot Rest Dash IP W/S Seat Mount Anchor Retractor D-Ring
Roof
J.Revo J.Tran

Pedal Rot. Seat Cushion

J.Revo J.Revo

Head Restraint J.Tran_Revo Seat Back Stalk J.Tran Buckle

31

-Seat

Skeleton

32

16
-Seat

Seat cushion

Seat back

Head restraint

Restraint

33

- Restraint System-Belt

1.

Driver Side: Points:

Retractor Retractor_pnt
Web Grabber Anchor_pnt
Film spool
Buckle_pnt
Prentensioner
Dring_pnt / Guide_pnt
Force payout
Payin time
Points on Dummy
Load limiter
Multi levels
Belt Segments

34

17
- Restraint System-Belt

1.

RibsLowRHS_pnt

AbdomenInsertL_pnt

35

- Restraint System-Belt

2. webbing

36

18
- Restraint System-Belt

3.
Film spoolWeb grabber

37

- Restraint System-Belt

4.

Payin Time

38

19
- Restraint System-Belt

4.

Force Payout

39

- Restraint System-Belt

5.

40

20
- Example

Retractor point: 1.0 0.6 0.1
D-ring point: 1.1 0.55 0.8
Buckle point: 0.75 0.1 0.15
RibsLowRHS_pnt
Anchor point: 0.8 0.55 0.01

AbdomenInsertL_pnt

41

- Example

Film Spool
0.00 0.0 0.000 0.0
0.01 2600 0.040 1000.0
0.02 4000 0.065 15000.0
0.04 6000
0.06 7600 IS (Initial Strain) AL (Additional Length)
0.08 9000
Shoulder belt: IS=0AL=0
0.10 10000
0.12 11200 Lap belt: IS=-0.04AL=0.201
BT Friction:
D-ring: 0.05 Buckle: 0.2 Others: 0.1
>=0.5ms-1

42

21
- Restraint System-Belt

6. FE

INITIAL.FE_MODELFE

DBuckleRestraint_Kelvin

BuckleAnchorRestraint_Kelvin

FEdampingALPHA_COEF=10

KelvinCharacteristicsKelvin<5N

FEFE
INITIAL.FE_MODEL

43

- Airbag

Airbag Mesh

Tether

Folding

Inflator

Vent hole

TTF

44

22
- Airbag

Inflator

Tank
- Pressure
- Temperature

Inflator

Mounting Table
Load Cell: Thrust Force

45

ODB-ODB Modeling

Ref_Space

J.Free_Rot_Disp

Vehicle

J.Free

Floor
J.Tran J.Tran J.Tran J.Brac J.Tran J.Brac J.Brac J.Brac J.Revo
J.Brac
Pedal Tran. Foot Rest Dash IP W/S Seat Mount Anchor Retractor D-Ring
Roof
J.Revo J.Tran

Pedal Rot. Seat Cushion

J.Revo J.Revo

Head Restraint J.Tran_Revo Seat Back Stalk J.Tran Buckle

46

23
ODB-ODB Modeling

v v v v v v v
a a = a o + r + ( r )

JOINT_FREEJOINT_FREE_ROT_DISP

ACC_X, ACC_Y, ACC_Z, ACC_ANG_Z, ACC_ANG_Y

B-pillar Right

Trunk

B-pillar Left

47

ODB-ODB Modeling

ODB

Direction X(i) Y(j) Z(k)

Position
Rear Left(1) Acc_L_x Acc_L_y Acc_L_z

Rear Right(2) Acc_R_x Acc_R_y Acc_R_z

Trunk(3) Acc_T_y Acc_T_z

48

24
ODB-ODB Modeling

Acceleration at Rear Center Point (: 1i, 2i, 1j, 2j, 3j, 1k, 3k)

Acc _ x = ( Acc _ L _ x + Acc _ R _ x ) 2

Acc _ y = ( Acc _ R _ y + Acc _ R _ y ) 2

Acc _ z = Acc _ T _ z Acc _ Ang _ y Disp (Trunk Re ar )

Acc _ Ang _ z = ( Acc _ T _ y Acc _ y ) Disp (Trunk Re ar )

Acc _ Ang _ y = ( Acc _ T _ z Acc _ L _ z ) Disp (Trunk Re ar )

49

ODB-ODB Modeling

Acceleration at Rear Center Point (: 1i, 2i, 1j, 2j, 3k)

Acc _ x = ( Acc _ L _ x + Acc _ R _ x ) 2

Acc _ y = ( Acc _ L _ y + Acc _ R _ y ) 2

Acc _ z = Acc _ T _ z Acc _ Ang _ y Disp (Trunk Re ar )

Acc _ Ang _ z = ( Acc _ R _ x Acc _ L _ x ) Disp (Re arR Re arL )

Acc _ Ang _ y = Acc _ Z Disp (Trunk Engine )

50

25
-Model Validation

MADYMO

MADYMO
Ride-down

MADYMO

51

-Model Validation

:
1.

2.

52

26
-Model Validation

x-z-


HIC

53

-Model Validation

FE

Joint Force

Motion

1m

Force-Elongation

54

27
-Model Validation

55

-Model Validation

Sled Test

56

28