Biomechanical and Scaling Basis for Frontal and Side Impact Injury Assessment Reference Values.

In 1983, General Motors Corporation (GM) petitioned the National Highway Traffic Safety Administration (NHTSA) to allow the use of the biofidelic Hybrid III midsize adult male dummy as an alternate test device for FMVSS 208 compliance testing of frontal impact, passive restraint systems. To support their petition, GM made public to the international automotive community the limit values that they imposed on the Hybrid III measurements, which were called Injury Assessment Reference Values (IARVs). During the past 20 years, these IARVs have been updated based on relevant biomechanical studies that have been published and scaled to provide IARVs for the Hybrid III and CRABI families of frontal impact dummies. Limit values have also been developed for the biofidelic side impact dummies, BioSID, ES-2 and SID-IIs. The purpose of the original publication was to provide in a single document: 1) a listing of the IARVs for measurements made with the Hybrid III and CRABI families of frontal impact dummies, and for the biofidelic side impact dummies, 2) the biomechanical and/or scaling bases for these IARVs, and 3) a comparison of IARVs and regulatory compliance limits and how they affect restraint design. The purpose for republication is to correct errors in the original publication and update the regulatory compliance limits.

Age-Specific Injury Risk Curves for Distributed, Anterior Thoracic Loading of Various Sizes of Adults Based on Sternal Deflections.

Injury Risk Curves are developed from cadaver data for sternal deflections produced by anterior, distributed chest loads for a 25, 45, 55, 65 and 75 year-old Small Female, Mid-Size Male and Large Male based on the variations of bone strengths with age. These curves show that the risk of AIS ≥ 3 thoracic injury increases with the age of the person. This observation is consistent with NASS data of frontal accidents which shows that older unbelted drivers have a higher risk of AIS ≥ 3 chest injury than younger drivers.

Thoracic Injury Risk Curves for Rib Deflections of the SID-IIs Build Level D.

Injury risk curves for SID-IIs thorax and abdomen rib deflections proposed for future NCAP side impact evaluations were developed from tests conducted with the SID-IIs FRG. Since the floating rib guide is known to reduce the magnitude of the peak rib deflections, injury risk curves developed from SID-IIs FRG data are not appropriate for use with SID-IIs build level D. PMHS injury data from three series of sled tests and one series of whole-body drop tests are paired with thoracic rib deflections from equivalent tests with SID-IIs build level D. Where possible, the rib deflections of SID-IIs build level D were scaled to adjust for differences in impact velocity between the PMHS and SID-IIs tests. Injury risk curves developed by the Mertz-Weber modified median rank method are presented and compared to risk curves developed by other parametric and non-parametric methods.

Minimizing the injury potential of deploying airbag interactions with car occupants.

Minimizing the injury potential of the interactions between deploying airbags and car occupants is the major issue with the design of airbag systems. This concern was identified in 1964 by Carl Clark when he presented the results of human volunteer and dummy testing of the "Airstop" system that was being developed for aircraft. The following is a chronological summary of the actions taken by the car manufacturers, airbag suppliers, SAE and ISO task groups, research institutes and universities, and consumer and government groups to address this issue.

Rationale for and dimensions of impact surfaces for biofidelity tests of different sizes of frontal and side impact dummies.

The biofidelity impact response corridors that were used to develop the Hybrid III family of dummies were established by scaling the various biofidelity corridors that were defined for the Hybrid III mid-size, adult male dummy. Scaling ratios for the responses of force, moment, acceleration, velocity, deflection, angle, stiffness and time were developed using dimensions and masses that were prescribed for the dummies. In addition, an elastic modulus ratio for bone was used to account for the differences between child and adult bone elastic properties. A similar method is being used by ISO/TC22/SC12/WG 5 to develop biofidelity guidelines for a family of side impact dummies based on scaling the biofidelity impact response corridors that are prescribed for WorldSID, a mid-size, adult male dummy. While the various biomechanical impact response requirements for the Hybrid III family of dummies and the WorldSID are documented in the literature, the scaling used to prescribe the dimensions of the impact surfaces that are used for the various biofidelity tests for various sizes of dummies are not documented. This paper describes the rationale for how these impact surfaces should be scaled, gives the scaling equations, and gives the dimensions of the impact surfaces that should be used for the various biofidelity tests of the different sizes of adult and child dummies. For future PMHS and human volunteer tests that are conducted to define impact biofidelity guidelines, it is recommended that the impact surfaces be scaled for the test subject size so that the data can be appropriately normalized to any size subject.

Evaluation of the field relevance of several injury risk functions.

An evaluation of the four injury risk curves proposed in the NHTSA NCAP for estimating the risk of AIS>= 3 injuries to the head, neck, chest and AIS>=2 injury to the Knee-Thigh-Hip (KTH) complex has been conducted. The predicted injury risk to the four body regions based on driver dummy responses in over 300 frontal NCAP tests were compared against those to drivers involved in real-world crashes of similar severity as represented in the NASS. The results of the study show that the predicted injury risks to the head and chest were slightly below those in NASS, and the predicted risk for the knee-thigh-hip complex was substantially below that observed in the NASS. The predicted risk for the neck by the Nij curve was greater than the observed risk in NASS by an order of magnitude due to the Nij risk curve predicting a non-zero risk when Nij = 0. An alternative and published Nte risk curve produced a risk estimate consistent with the NASS estimate of neck injury. Similarly, an alternative and published chest injury risk curve produced a risk estimate that was within the bounds of the NASS estimates. No published risk curve for femur compressive load could be found that would give risk estimates consistent with the range of the NASS estimates. Additional work on developing a femur compressive load risk curve is recommended.

Pediatric head contours and inertial properties for ATD design.

Child head trauma in the United States is responsible for 30% of all childhood injury deaths with costs estimated at $10 billion per year. The common tools for studying this problem are the child anthropomorphic test devices (ATDs). The headform sizes and structural properties of child ATDs are based on various anthropometric studies and scaled Hybrid III mass and center of gravity (CG) properties. The goals of this study were to produce pediatric head and skull contours, provide estimates of pediatric head mass, mass moment of inertia and CG locations, and compare the head contours with the current child ATD head designs. To that end, computer tomography (CT) scans from one hundred eighty-five children in twelve age groups were analyzed to develop three-dimensional head and skull contours. The contours were averaged to estimate head and skull contours for children aged 1-month to 10-years. Inertial properties were estimated from a small sample of post- mortem human subjects (PMHSs). This paper provides new equations for estimating the moments of inertia and anatomical landmarks in the head. There were reasonable agreement between the estimates for head masses obtained from analysis of the CT scans of the PMHS heads and the estimates obtained using the volumetric scaling rule used in ATD design work. The regression of the pediatric head sizes was found to be non-linear, with different regression slope for ages 1M to 18M and 18M to 120M. The 12M CRABI and 36M Hybrid III heads were found to be different by 10 and 18mm, respectively, from the average human CT contours due to the differences in the occipital condyle placement relative to the nasion.

Effects of shoulder belt limit forces on adult thoracic protection in frontal collisions.

Three-point restraint systems have been installed in vehicles since the early 1960s. However, it wasn't until the automatic protection rule became effective for 1987 Model Year vehicles that manufacturers began installing 3-point restraints with force-limiting shoulder belts and frontal airbags for the driver and right front passenger. This was the first time that all vehicle manufacturers had to certify that their cars would meet the 50th percentile, adult male protection requirements in the 48 km/h frontal, rigid-barrier test specified in FMVSS 208. To assess the effectiveness of these certified 3-point restraint systems, a search was done of the 1988-2005 NASS data for 3-point belted, front outboard-seated, adult occupants in passenger vehicles that were equipped with airbags and that were involved in frontal, towaway collisions. These data showed that i) half of the occupants with AIS > or = 3 chest injuries were in collisions with a DeltaV < or = 40 km/h; ii) for older occupants (50+ years), half experienced their chest injuries at DeltaVs < or = 34 km/h; and iii) the chest injury rate for the older occupants was more than double that of the younger occupants. An analysis was done to estimate the effectiveness of various levels of shoulder belt limit loads in reducing chest injuries to older occupants. The result of the analysis indicated that a 2.5 kN shoulder belt limit load would substantially reduce shoulder belt-induced AIS > or = 3 chest injuries in 99 percent of frontal collisions to all adult, front outboard seated occupants whose normalized bone strengths are greater than 0.4.

Side Impact Response Corridors for the Rigid Flat-Wall and Offset-Wall Side Impact Tests of NHTSA Using the ISO Method of Corridor Development.

The purpose of this paper is to compare the biofidelity rating schemes of ISO/TR9790 and the NHTSA Bio Rank System. This paper describes the development of new impact response corridors being proposed for ISO/TR9790 from the results of a recent series of side-impact sled tests. The response data were analyzed by methods consistent with ISO/TR9790, including normalization by impulse-momentum analysis and the elimination of subjects that sustained six or more rib fractures. Unlike ISO/TR9790, this paper proposes the elimination of the data from tests in which the timing and the sequence of loading of the individual impact plates were inconsistent compared to other tests conducted with the same impact wall configuration. As a result of differences in the analysis methods, data selection criteria, and the method of corridor construction, the impact response corridors proposed here are different from those developed by NHTSA, despite the fact that both sets of corridors were developed from the same series of sled tests. Responses of the ES-2 and ES-2re side impact dummies are compared to both sets of corridors. The response corridors developed in this paper are proposed as an addition to and not a replacement for those given in the 1999 revision of ISO/TR9790.

Evaluation of the ES-2re Dummy in Biofidelity, Component, and Full Vehicle Crash Tests.

This technical paper presents the results from tests conducted with the ES-2re, a version of the ES-2 side impact dummy that was modified by the National Highway Traffic Safety Administration (NHTSA) to improve its performance in crash tests. Through the series of biofidelity tests conducted on the ES-2re, described in International Standards Organization (ISO) Technical Report (TR)9790 (1999), the OSRP observed a final overall biofidelity ranking of 4.1 for the ES-2re, which corresponds to an ISO classification of "marginal." The biofidelity of the ES-2re is compared to that of the ES-2 and the WorldSID. Repeatability was also evaluated on the ES-2re based on the biofidelity test data. Additional pendulum tests were performed to assess the response of the dummy in oblique loading conditions, and results indicate that oblique loading from the front leads to significantly reduced rib deflections. To evaluate inconsistencies observed in the response of the ES-2, the OSRP analyzed the shoulder biofidelity via additional sled and drop tests. Due to the shoulder design of the ES-2 and ES-2re, the dummies appear to have significant sensitivity to initial conditions, potentially increasing variability in full vehicle tests. Finally, the responses of the ES-2re in full vehicle tests are compared to those of the ES-2 and the WorldSID.

Biomechanical and scaling bases for frontal and side impact injury assessment reference values.

In 1983, General Motors Corporation (GM) petitioned the National Highway Traffic Safety Administration (NHTSA) to allow the use of the biofidelic Hybrid III midsize adult male dummy as an alternate test device for FMVSS 208 compliance testing of frontal impact, passive restraint systems. To support their petition, GM made public to the international automotive community the limit values that they imposed on the Hybrid III measurements, which were called Injury Assessment Reference Values (IARVs). During the past 20 years, these IARVs have been updated based on relevant biomechanical studies that have been published and scaled to provide IARVs for the Hybrid III and CRABI families of frontal impact dummies. Limit values have also been developed for the biofidelic side impact dummies, BioSID, EuroSID2 and SID-IIs. The purpose of this paper is to provide in a single document: 1) a listing of the IARVs for measurements made with the Hybrid III and CRABI families of frontal impact dummies, and for the biofidelic side impact dummies, 2) the biomechanical and/or scaling bases for these IARVs, and 3) a comparison of IARVs and regulatory compliance limits and how they affect restraint design.

Guidelines for assessing the biofidelity of side impact dummies of various sizes and ages.

The Human Mechanical Simulation Subcommittee of the Human Biomechanics and Simulation Standards Committee of the Society of Automotive Engineers took on the task of defining test procedures and associated response guidelines to be used to assess the level of biofidelity of side impact dummies that are being developed. This paper describes the results of their efforts. Guidelines are provided for assessing the levels of biofidelity of dummies that represent 6-, 12-, and 18-month-old infants, 3-, 6-, and 10-year-old children, and of dummies that represent a small female, midsize male and large male adults. These guidelines were developed by normalizing the side impact biofidelity guidelines that were established by the International Standards Organization for the head, neck, shoulder, thorax, abdomen and pelvis of the midsize adult male. The ISO guidelines can be used to define biofidelity guidelines for any size or age of dummy provided pertinent geometric, inertial and tissue properties are specified.

ES-2 Dummy Biomechanical Responses.

This technical paper presents the results of biomechanical testing conducted on the ES-2 dummy by the Occupant Safety Research Partnership and Transport Canada. The ES-2 is a production dummy, based on the EuroSID-1 dummy, that was modified to further improve testing capabilities as recommended by users of the EuroSID-1 dummy. Biomechanical response data were obtained by completing a series of drop, pendulum, and sled tests that are outlined in the International Organization of Standardization Technical Report 9790 that describes biofidelity requirements for the midsize adult male side impact dummy. A few of the biofidelity tests were conducted on both sides of the dummy to evaluate the symmetry of its responses. Full vehicle crash tests were conducted to verify if the changes in the EuroSID-1, resulting in the ES-2 design, did improve the dummy's testing capability. In addition to the biofidelity testing, the ES-2 dummy repeatability, reproducibility and durability are discussed. Finally, this technical paper will compare the biofidelity ratings of the current adult side impact dummies with the ES-2 dummy, which received an overall dummy biofidelity rating of 4.6.