Humanetics Anthropomorphic Test Device News and Radioss Model Developments

2013 European Altair Technology Conference

Turin, April 22-24, 2013

Robert Kant, Humanetics Europe GmbH

Franck Njilie, Anaïs Garo, Altair Development France

Humanetics Anthropomorphic Test Device News

and Radioss Model Developments

2 © This report is the property of Humanetics Innovative Solutions, Inc; a registered company in Plymouth, Michigan, USA. The report includes

confidential information. Copying or distribution of this information without the authorisation of Humanetics Innovative Solutions is forbidden.

Introduction

Need:

Predictive models for occupant safety simulation to support safety design

Humanetics is manufacturer of crash test dummies and FE models

Humanetics goals

Develop predictive FE dummy models

– Up-to-date to the latest dummy hardware

– Up-to-date to the latest solver code



Euro NCAP

► Euro NCAP is anticipating adding new procedures to continue the trend of cars becoming safer

► Introduction of the Q6 child, Q10 child Hybrid III 5th % and WS50

Frontal offset

EEVC ODB

Moving Deformable Barrier test

Q10 Q6 HIII 5th

HIII 50th

Frontal Full width

Q10 Q6

HIII 5th HIII 50th WS50 HIII 5th

Example for new dummy need

Q CHILD DUMMIES



OEM development participation

Frequent meetings

Requirement definition & Release approval

OEMs Humanetics local + global

Q6 model development

Partners

AUDI - Germany

BMW - Germany

DAIMLER – Germany/India

PORSCHE – Germany

Adam Opel - Germany

VOLKSWAGEN – Germany

RENAULT – France

TUB - Germany

Codes

LS-DYNA

PAMCRASH

ABAQUS

RADIOSS (in seperate project)



Q6 model development 2010 Aug

Version 0.1

2011 May

v0.2

2012 Mar

v0.9

2013 Q1

v1.0

2013

v2.0

2014

v3.0

1 2010

Sep

Release

Meeting 9 2012

Nov

2 2010

Dec

3 call

2011

Jan

4 2011

Jun

5call

2011

Jul

6 2011

Dec

7/8c

2012

Jun

10 2013

Mar



Q6 model development 2010 Aug

Version 0.1

2011 May

v0.2

2012 Mar

v0.9

2013 Q1

v1.0

2013

v2.0

2014

v3.0

1 2010

Sep

Release

Meeting 9 2012

Nov

2 2010

Dec

3 call

2011

Jan

4 2011

Jun

5call

2011

Jul

6 2011

Dec

7/8c

2012

Jun

Release v0.9: Component validation

10 2013

Mar




Sled validation: 6 load cases / 4 Q6 hardware dummies used in testing

2010 Aug

Version 0.1

2011 May

v0.2

2012 Mar

v0.9

2013 Q1

v1.0

2013

v2.0

2014

v3.0

1 2010

Sep

Release

Meeting 9 2012

Nov

2 2010

Dec

3 call

2011

Jan

4 2011

Jun

5call

2011

Jul

6 2011

Dec

7/8c

2012

Jun

10 2013

Mar







----- test ----- RADIOSS v0.2



Q10: CAE Roadmap

Pre Production (SBL-A) Production (SBL-B)

2012 2013



Q10: CAE Roadmap

Pre Production (SBL-A) Production (SBL-B)

2012 2013

CAE V1.0

2014

CAE V1.5 CAE V2.0

1. Geometry updates based on

SBL-A Hardware 1. Geometry and material updates

based on SBL-B Hardware 1. Customer Feedbacks

2. Sled Test Validations



• Test – Frontal

• Speed 6.71 m/s


Q10 v1.0: following Q6 modeling standards






Q model development

Q1 Q1,5 Q3s

Q3

FLEX PLI GTR PEDESTRIAN LEGFORM



OEM development participation

Frequent meetings

Requirement definition & Release approval

OEMs Humanetics

FLEX PLI GTR model development

Partners FORD – Germany

AUDI - Germany

BMW - Germany

DAIMLER – Germany

PORSCHE – Germany

GM – Germany

HONDA R&D – USA

HYUNDAI – Germany

JAGUAR LANDROVER - UK

VOLKSWAGEN – Germany

BASt - Germany

Codes

RADIOSS

LS-DYNA

PAMCRASH

ABAQUS



FLEX PLI GTR Model Development 2009 Apr

V 0.1alpha

2010 Aug

v1.0

2012Jan

v2.0

1 2008

Nov

Release

Meeting 8 2011

Nov

2 2009

Feb

3 2009

May

4 2009

Sep

5 2010

May

6 2010

Nov

7 2011

Mar

SN04 (2 labs) SN04 SN02

1 2013

Mar



FLEX PLI GTR Model Development New

corridor

Old

corridor

Pendulum certification Inverse “certification”

Old and new draft corridors

Next:

► Guarantee that models represent finalized hardware and adjusted corridors

► Validate the models against new data generated with up-to-date hardware legs

Version 2.0 fits quite good to latest hardware in recent consortium sled validation

WORLDSID



WorldSID WorldSID 50th WorldSID 5th



Number of dummies sold Dates SBL Parts which changed

12 Pre Production 2003 A Original Design

ISO Document Release May 15, 2004

Release for Production June 6, 2004 C Major changes including: torso, neck, ribs,

battery assembly, pelvis, & instrumentation

11 dummies made to SBL C 4/ 2005 – 5/2006

SBL D released May 15, 2005 D Changes to: lower neck bracket & spacer,

pelvis instrumentation, shoulder clevis asm.,

spine box plates

10 Dummies made to SBL D 3/2007 – 6/2009

SBL E released Nov 1, 2008 E Changes to: battery container/cover,

IRTRACC system, torso asm, ribs, shoulder

clevis asm., shoes

31 dummies made to SBL E

to date

8/2010 – 4/2013

SBL F released April 2013 F Changes to: Jacket, ankle, lift bracket and

2D IRTRACC is made standard

Summary of WSID 50th Standard Build Levels



WorldSID 50th performance

► Performance

Component

Single rib drop

Head drop

Neck Pendulum

Arm drop

Full dummy level

shoulder impact

Thorax impact w and w/o arm

Abdomen impact

Pelvis impact

Sled test



► Performance

Component

Single rib drop

Head drop

Neck Pendulum

Arm drop

Full dummy level

shoulder impact


Abdomen impact

Pelvis impact

Sled test




► Performance

Component

Single rib drop

Head drop

Neck Pendulum

Arm drop

Full dummy level

shoulder impact


Abdomen impact

Pelvis impact

Sled test




WorldSID WorldSID 50th WorldSID 5th

Item Total number

Nodes 113757

Beam / springs 348 / 80

SH3N/SHELL 13930 / 68536

Solid 78187

Time steps (ms) 0.52*10-3

Item Total number

Node 77094

Beam / Spring 240 / 36

Sh3n/Shell 10398 / 34830

Brick 75153

Time steps (µs) 0.775

H350



H350 – v7.1

Test 1 Test 2 Test 3

• Reduced noise (increased inertia of joint springs)

• More realistic friction in (ankle) joints

• and more…

v7.0.1 v7.1

ES2 AND ES2-RE



ES2 – v4.1.3

• Improved upper arm foam material

model

• Improved rib foam material model

• More realistic friction in joints

hip, ankle, neck

• Arm to rib edge contact added

• and more...



ES2 Validation Sled test Test 1 Test 2 Test 3 v4.1.1 v4.1.3



ES2 Validation Sled test Test 1 Test 2 Test 3 v4.1.1 v4.1.3

OUTLOOK

FTSS Denton

34

Harmonisation

Different brands → Different designs, materials and geometries

FTSS Denton

35

Reduce hardware variability

Harmonization → Next step to reach more reliable CAE predictions

(more constant correlation)

Harmonisation



HIII5 stiff

HIII5 stiff

HIII5 stiff

HIII5 soft

HIII5 soft

HIII5 soft

HIII5 stiff

HIII5 soft

Sled test

Variability

Hardware extremes

Next step to reach more reliable predictions

RADIOSS DUMMY MODEL OVERVIEW



Radioss dummy model overview ATD type

Hybrid III 50th male

(Humanetics)

Hybrid III 5th female

(Humanetics)

Hybrid III 95th large male

(Humanetics)

ES2 / ES2 re

Left and Right hand

(Humanetics)

WorldSID 50th

Left and Right hand

(Humanetics)

WorldSID 5th

(Humanetics)

SIDIIs BLC / SIDIIs BLD

Left and Right hand

(Humanetics)

Biorid IIg

(Altair)

ATD type

CRABI 12

(Humanetics)

P18, P3, P6

(Altair)

P3, P6, P10

(Altair)

Q1

(Humanetics)

Q1.5

(Humanetics)

Q3 and Q3s

(Humanetics)

Q6 frontal and side

(Humanetics)

Q10 frontal and side

(Humanetics)

HIII 6 Years old

(Altair)

HIII 3 Years old

(Altair)

HIII 10 Years old

(Humanetics)

CONCLUSION



Conclusion

► New dummy’s are being specified in new procedures requiring new models

– New models are being developed: Q6, Q10, WorldSID50, WorldSID5, FLEX PLI GTR

► Existing dummy models see further improvements – Up-to-date to the latest dummy hardware

– Up-to-date to the latest solver code

– Improved predictions

– Outlook: Harmonization → Next step to reach more reliable CAE predictions

Humanetics RADIOSS Models are developed in co-operation with Altair

Thanks