A system for simulating structural intrusion in automobile full-frontal and frontal-offset crashes in the laboratory sled test environment

Abstract

A sled system capable of producing structural intrusion in the footwell region of an automobile has been developed. The system couples the hydraulic decelerator of the sled to actuator pistons attached to the toepan and floorpan structure of the buck. Characterization of the footwell intrusion event is based on developing a toepan pulse analogous to the acceleration pulse used to characterize sled and vehicle decelerations. Sled tests with the system indicate that it is capable of accurately and repeatably simulating toepan/floorpan intrusion into the occupant footwell. Test results, including a comparison of lower extremity response between intrusion sled tests and no intrusion sled tests, indicate that this system is capable of repeatable, controlled structural intrusion during a sled test impact. Test results also suggest that lower extremity forcing during footwell intrusion is significantly larger than such forcing with no intrusion, and that response and risk of injury for occupants in frontal or frontal-offset crashes are more severe.