Crashworthiness investigation on a Carbon Fiber Reinforced Plastic solar vehicle

Abstract

This article presents a research study involving different simulations of crash tests by means of the finite element explicit dynamic software Ansys LS-Dyna to determine the roadworthiness of a fully composite chassis lightweight solar vehicle and its conformity to the World Solar Challenge (WSC) regulations. Furthermore, the paper describes the results of crash test simulations in conditions comparable with those of the standard homologation test, with an initial velocity of 15.5 m/s against a rigid barrier considering overlaps of 50% and 100%. The velocity measured at the base of the seat was later used in a sled test with a dummy to calculate the Head Injury Criterion (HIC), a number proportional to the probability of head injury caused by the impact. The values remained within the threshold of acceptability with overlap at 50% but exceeded the limit with the 100% overlap. With no load limiter implemented in the model, the seatbelt caused contact forces with the chest up to 14 kN against 6 kN of the typical load limiter used in road cars to limit damage to ribs and internal organs. Finally, the possibility of improving the front crash box was investigated by changing the crash box’s planar sandwich structure with corrugated ones and layup without foam between the carbon layers. Various values of semi-amplitudes (A) of the sinusoidal profile have been tested. With a value of A of 6 mm, the capacity to absorb energy from an impact at 9 m/s was close to the original configuration.