Presents

NPRM for Ejection Mitigation: The Latest Safety Standard -

Overview and DiscussionMay 20, 2010

Burlington, Wisconsin

Troy, Michigan

Akron, New York

Greer, South Carolina

MGABegan in New York, 1977Independent test servicesISO/IEC 17025:2005 AccreditedSpecializes in: Safety Regulations (FMVSS, ECE, SAE, ASTM, MIL-STD, etc.), Vibration, Durability, Life Cycle, Environmental, Equipment, etc.Industries served include: Automotive, Military, Aerospace, Rail, Battery, Mobility, Other Transportation, etc.

Manassas, Virginia

Presenters

D.J. WhitesideMGA Research - MI

Jason GilhamMGA Research - NY

Webinar OverviewBasic Requirements & MethodologyPhase-In ScheduleImpactor SpecificationsPreliminary SetupTargetingTime DelayPre-Breaking the WindowManufacturer DeliverablesReviewQ&A

Basic Requirements & Methodology

EvolutionOccupant ejections from rollover crashes are a significant concernNov 30, 2006 –Memorandum of procedure used to research ejection countermeasuresDec 2, 2009 – Official Notice of Proposed Rulemaking (NPRM) released

Purpose§ 571.226 Standard No. 226;

Ejection Mitigation.S1. Purpose and Scope. This standard establishes requirements for ejection mitigation systems to reduce the likelihood of complete and partial ejections of vehicle occupants through side windows during rollovers or side impact events.

RequirementS4.2.1 … the most outboard surface of the ejection headform must not displace more than 100 millimeters beyond the zero displacement plane.

Zero Disp. Plane

Airbag

≤ 100 mm

Countermeasures

Design is open to possibilitiesMost likely to be side curtain airbags

Basis of researchLarger, longer inflation, stronger, etc.

Laminated glazing

Rationale for the Component Test

Intended to ensure that gaps or openings do not form that would allow for partial or full ejectionsAdvantages over rollover crash tests: Higher repeatability, revealed deficiencies in window coverage, etc.Each window opening would have as many as 4 applicable targets

Procedure: Alternative 1Test each target to an impact speed of 16 km/h (10 mph) after a 6 second time delay of the countermeasure deployment.Next, test all 4 targets again to an impact speed of 24 km/h (15 mph) after a 1.5 second time delay of the countermeasure deployment.Results in a total of 8 tests per window opening.

Procedure: Alternative 2Test each target to an impact speed of 16 km/h (10 mph) after a 6 second time delay of the countermeasure deployment. Next, test only the one target which received the highest excursion value during the 16 km/h series again to an impact speed of 24 km/h (15 mph) after a 1.5 second time delay of the countermeasure deployment. Results in a total of 5 tests per window opening.

Procedure: Non-Deployable Alternative

Test each target to both the 16 km/h and 24 km/h impact speedsResults in a total of 8 tests per window opening.

Additional Notes

Manufacturer option: Windows are to be removed, retracted or closed, or up and in a pre-broken condition Horizontal guided linear impactor with an attached featureless headform

Effective moving mass of 18 kg (50th % head / shoulder)Impactor is perpendicular and enters from the opposite side of the target window firing in the outboard direction.

Vehicle Application

Passenger cars, multipurpose passenger vehicles, trucks, buses with a GVWR of 10,000 lbs or lessIncludes convertibles and vehicles with partitions (i.e. police cruisers) Excludes vehicles with modified roofs, vehicles without doors (i.e. delivery trucks), and walk-in vans

Benefit AnalysisProjected to save an estimated 402 lives and prevents 310 serious injuries annuallyAdded cost: $34/light vehicle and $583 million for the full curtain countermeasure

Phase-In Schedule

DatesFinal rule: January 31, 2011 per NPRMIf rule does take place in January 2011, then NHTSA proposes:

20 percent of each manufacturer’s vehicle fleet built during the first production year beginning three years after publication of a final rule (for illustration purposes, September 1, 2014) 40 percent of each manufacturer’s vehicle fleet built during the production year beginning (for illustration purposes, September 1, 2015)75 percent of vehicles manufactured during the production year beginning (for illustration, September 1, 2016)All vehicles (without use of advanced credits) manufactured on or after (for illustration, September 1, 2017)

ImpactorSpecifications

Requirements From NPRM

Must not deflect downward more than 20 mm when a 27 kg mass is attached to the posterior surface of the headformUnobstructed velocity

10 percent of the 24 km/h velocity15 percent of the 16 km/h velocity

Average force to move 225 mm rearward at a rate of 50 (±13) mm per second must not exceed 570 N and have a standard deviation of no more than 30 N

Includes 27 kg mass

MGA Impactor Design

Research and Development

3+ years of impactor developmentResearch driven by the Ejection Mitigation test guidelines included in a 2006 memorandum released by NHTSA

Critical design characteristics included:1. Minimal friction2. Minimal impactor size (height and width)3. Direct displacement output4. Impactor delay5. Impactor protection

Research and Development (cont.)

VRTCMGA supplied NHTSA’s Vehicle Research and Test Center (VRTC) with a 5th generation FMVSS 226 (Ejection Mitigation) ImpactorAwarded the project in August 2009, Operational at VRTC since January 2010Turn-key System Included:

3-axis (dual speed) FrameImpact WorkstationEjection Mitigation Impactor (with instrumentation)Featureless Headform (ATD 7306-1 –certified skull and skin)Onsite training at VRTC

Procurement Package

Procurement specifications included in NHTSA’s July 2009 Solicitation involved:

1. Low coefficient of friction (static and dynamic)

2. Programmable time delay3. Repeatability4. Minimal radial deflection5. Time until peak velocity

MGA complied with all NHTSA

recommendations

Preliminary Setup

Test Conditions

At least 1 hour at temperature and relative humidity of 23.5 ± 5.5°C and 40.0 ± 30.0 %RHFluid levels fullTires inflated Load the vehicle to its unloaded vehicle weight (UVW) If necessary, remove the steering wheel and seats from the vehicle during targeting or testing

Alignment

Align the vehicle perpendicular to the Ejection Mitigation Impactor frame with the assistance of a laser level.Raise the vehicle off its suspension; longitudinal and vertical axes to ± 1 degreeOpposite side/rear doors open or removed; all other doors are fully closed and latched but not locked

Targeting

Tangency

226.1 mm

226.1 x cos (15 deg) = 218.4 226.1 mm

Due to the shape and angle of the windows, measurements made relative to the glass will not be accurateMeasurements must be perpendicular to the vehicle

15°

Geometric CenterCan be found in CAD -CentroidEstablishes 4 quadrantsAlso used in window pre-break procedureUpper front and lower rear targets automatically eliminatedMGA procedure on next slides simplifies process

CG

Targeting: Step 1For each daylight opening measured, place the window in the fully retracted position.

Targeting: Step 2aMove head form in the X and Z axis towards the general primary target locations

Targeting: Step 2bUse shim blocks to ensure 25 ± 2 mm of space between the head form and the daylight opening (i.e. tangent to the periphery including 50 millimeters inboard, Y axis, of the window glazing)CMM head form perimeter for calculation of the head form center

25 mm

25 mm

1

2

3

4 C

Side daylight opening means, other than a door opening, the locus of all points where a horizontal line, perpendicular to the vehicle vertical longitudinal plane, is tangent to the periphery of the opening, including the area 50 millimeters inboard of the window glazing, but excluding any flexible gasket material or weather stripping used to create a waterproof seal between the glazing and the vehicle interior.

Daylight opening includes unique trim designs that do not follow the window perimeter

50 mm

Targeting: Step 3aNote the X-axis and Z-axis displacement between the centers of the 2 primary targets. Divide the X-axis displacement by 3. If (X-axis / 3) < 135 mm and vertical distance < 170 mm, proceed to Step 5.

Z < 170

X/3 < 135

Targeting: Step 3bOtherwise, establish the two secondary targets by dividing the horizontal distance into thirds:

Use a CMM to locate the X-axisOffset the daylight opening using the 25 mm shims

CMM head form perimeter

Targeting: Step 4Target centers: If horizontal and vertical distances are less than 135 mm and 170 mm respectively, eliminate targets in order per the NPRM table Note if only one criteria is met, do not eliminate a target for that step

Z < 170

X < 135

Targeting: Step 4

Upper PrimaryUpper Primary to Lower Primary4.

Lower or Remaining SecondaryLower Primary to Lower or Remaining Secondary3.

Upper or Remaining SecondaryUpper Primary to Upper or Remaining Secondary2.

Upper SecondaryUpper Secondary to Lower Secondary1.

Eliminate this targetMeasure the distance of these target centersStep

Targeting: Step 5

If absolute distance between primary centers ≥ 360 mm, establish one “bisect” or “intermediate”target by dividing the horizontal and vertical distances by halfCMM head form perimeter

Targeting: Step 6If absolute distance between primary centers < 360 mm, then only the two primary targets exist If both the horizontal and vertical distances are less than 135 mm and 170 mm respectively, than only the lower primary target existsEliminate targets rearward of 600 mm behind the rearmost occupant SgRP, or in Row 4 and beyond

Target Labeling

Targeting for Unique Window Shapes

Targeting for Unique Window Shapes

Time Delay

Impact Delay Calculation

Example:400

=Example:

200-

Example:600

Contact with the Airbag

(mm)

Airbag Maximum Inflation(mm)

Displacement Value at Window (mm)

Find the displacement when the impactor contacts the airbag

Impact Delay Calculation

Example: 0.2

=Example:

6.0-

Example: 6.2

Time Offset (s)Test Req. Time (s)

Time at Contact Disp (s)

Calculate how much time beyond the target delay was achieved at the contact displacement

Impact Delay Calculation

Example: 5.8

=Example:

0.2-

Example: 6.0

Program Time Delay (s)Time Offset (s)Test Req. Time

(s)

Calculate the true impact delay required to contact the airbag

Pre-Breaking the Window

Mark geometric center (centroid) of the daylight openingUsing a Hole Pattern Template, mark the surface of the window glazing in a horizontal and vertical grid of points separated by 50 ± 2 mm

One point coincident within ±2 mm of the geometric center of the daylight opening

Punch holes starting with the inside surface of the window and the forward-most lowest mark

Use a Center Punch; tip 5 ± 2 mm diameter 150 ± 25 N of force to activate (spring adjustment)±10 degrees perpendicular to the window surface100 ± 10 mm × 100 ± 10 mm piece of Rigid Material as a reaction surface

Procedure

Move rearward, then upward to next rowRepeat the process on the outside surface of the windowIf punching a hole causes the glazing to disintegrate, halt the breakage procedure and advance to the next section to proceed with the test series

Procedure (cont.)

Manufacturer Deliverables

Process Reality per Window

5 airbags5 panes of glass

8 airbags8 panes of glass

With Glass

5 airbags8 airbagsWithout Glass

Alternative 2 (5 tests)Alternative 1 (8 tests)Test Type

x 5 or 8 tests each

Other DeliverablesVehicleAirbag squib (harness) Airbag mating fastenersOptional headliner trim

Review

Excursion requirement ≤ 100 mmCountermeasure likely to be larger side curtain airbag3 options:

Test each target to 16 km/h, 6 sec delay and to 24 km/h, 1.5 secdelay after deploymentTest each target to 16 km/h, 6 sec delay and one maximum excursion target to 24 km/h, 1.5 sec delay after deploymentTest each target to both 16 km/h and 24 km/h with no delay

18 kg linear guided impactorFinal rule projected for Jan 2011 and phases-in between 2014 - 2017

Test Summary

Question & Answer Session

Thank you for your participation.

For more information, please contact:DJ Whiteside: dj.whiteside@mgaresearch.comJason Gilham: jason.gilham@mgaresearch.com

Or visit:www.mgaresearch.com

Next Month’s WebinarTitle: Material Testing for Quality InteriorsDate: June 17, 2010 at 1:30 pm to 3:00 pm EST