Structural optimisation in vehicle development for the current Euro NCAP side crash protocol:​ how to minimise the structural changes due to the current barrier stiffness and geometry

Crespo, Sergio; Perez‐Rapela, Daniel; Román‐Marín, Joaquín; Martin‐Vázquez, Francesc; Luzón‐Narro, Javier; Arregui‐Dalmases, Carlos

Affiliations

¹Applus+ IDIADA, Tarragona, Spain

²University of Virginia, USA

³Centro Técnico de SEAT, S.A, Barcelona, Spain

⁴Universitat Politècnica de Catalunya, Barcelona‐Tech., Spain

Abstract and keywords

The current Euro NCAP side impact protocol introduces the dummy WorldSID 50th percentile, which exhibits a much more complex performance than the EuroSID‐II; and AE‐MDB barrier, which causes new loading patterns in the structure.

The aim of this study is to identify the key differences between the past and current Euro NCAP protocols and propose countermeasures to achieve the new requirements using a mid‐sized previously designed vehicle. Outcomes from a possible Euro NCAP increase in crash speed from 50 km/h to 60 km/h were also evaluated. Finite Element Method (FEM) tools were used, including validated and correlated models with experimental full car tests.

With the current protocol, the most critical anatomical area observed in this research was the pelvis. The countermeasures proposed and evaluated to decrease the load on this area were:

sill and B‐pillar redesign;
stiffness reduction of the door panel;
door beam optimisation;

After the application of the structural countermeasures, the sacroiliac force decreased by 24.9% and the pubic force decreased by 32.5%. Furthermore, similar results were obtained in the 60 km/h test. This countermeasure describes a potential strategy to enhance occupant protection in mid‐sized cars without increasing the cost or weight of the vehicle.

Keywords: AE‐MDB, crashworthiness, Euro NCAP, side crash, WorldSID 50th, FEM

Links

URL: http://www.ircobi.org/wordpress/downloads/irc16/pdf-files/82.pdf

Cited Works (7)

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