Development of a Frontal Small Overlap Crashworthiness Evaluation Test

Figures & data

Fig. 1 Side view (top) and overhead schematic (bottom) of vehicle structural elements.

Fig. 2 Small overlap crash configurations: collinear (top), barrier (center), oblique (bottom).

Table 1 Matrix of crash tests

	2007–2011	2004–2011	2011–2012
Test	Ford Fusion	Mitsubishi Galant	Volvo S60
Collinear	X	X	X
Oblique	X	X
Pole 250	X	X
Flat 50	X	X	X
Flat 150	X	X	X
ODB	X	X	X

Fig. 3 Barrier geometry and vehicle overlap.

Fig. 4 Location of occupant compartment intrusion points (left toepan not shown).

Fig. 5 Schematic of vehicle dynamics from 0 to 120 ms in Fusion flat 150 test.

Fig. 6 Vehicle center of gravity lateral displacement.

Fig. 7 Still images showing outboard movement of dummy in Galant collinear test.

Table 2 Driver dummy air bag interaction by crash type for each vehicle

Air bag interaction	Fusion	Galant	S60
Pole 250	Minimal	Minimal	—
Collinear	Minimal	Partial	Stable
Flat 150	Minimal (complete miss)	Minimal	Partial
Flat 50	Minimal	Partial	Stable
ODB	Stable	Stable	Stable

Fig. 8 Example of dummy's head completely missing frontal air bag in Fusion flat 150 test.

Table 3 Occupant compartment intrusion data (cm)

Occupant	Collinear			ODB			Pole 250		Flat 150			Oblique		Flat 50
compartment location	Fusion	Galant	S60	Fusion	Galant	S60	Fusion	Galant	Fusion	Galant	S60	Fusion	Galant	Fusion	Galant	S60
Lower
Hinge pillar lower	15	9	2	19	8	3	16	15	21	23	5	38	19	32	24	21
Footrest	9	8	2	17	7	1	10	14	14	19	3	4	21	28	24	10
Left toepan	6	4	2	13	3	1	9	11	12	12	3	3	19	26	21	8
Brake pedal	5	4	1	11	5	1	6	13	8	9	3	3	9	20	13	6
Upper
Steering wheel	2	1	0	5	1	0	1	3	1	2	1	1	0	8	6	7
Hinge pillar upper	4	4	1	7	3	3	6	10	8	12	3	14	3	18	15	15
Upper dash	5	5	1	16	7	2	10	12	12	15	2	18	5	29	20	15
Left instrument panel	12	9	2	15	6	2	14	14	21	22	3	3	13	28	22	16
Lateral
Rocker panel 1	23	10	3	22	6	4	26	12	30	19	4	27	8	32	15	7
Rocker panel 2	14	1	1	11	0	1	19	1	15	3	3	23	0	27	2	2

Fig. 9 Average occupant compartment intrusion by crash configuration.

Fig. 10 Lateral steering wheel movement by crash configuration.

Table 4 Dummy injury measures ^a

	Oblique		Flat 50		Pole 250		Flat 50	Flat 150			ODB			Collinear
Injury measure	Galant	Fusion	Galant	Fusion	Galant	Fusion	S60	Fusion	Galant	S60	Galant	S60	Fusion	Fusion	Galant	S60
HIC15	249	207	119	196	85	130	113	50	125	85	77	76	190	129	102	132
Nij tens–extens	0.21	0.24	0.29	0.2	0.25	0.22	0.14	0.13	0.16	0.12	0.21	0.1	0.13	0.18	0.22	0.14
Nij tens–flex	0.2	0.18	0.23	0.27	0.25	0.31	0.2	0.24	0.27	0.23	0.17	0.14	0.22	0.37	0.28	0.12
Nij comp–extens	0.18	0.18	0.16	0.09	0.02	0.02	0	0.04	0	0.06	0.06	0.02	0.04	0.04	0.04	0.02
Nij comp–flex	0.1	0.11	0.07	0.13	0.01	0	0.1	0.01	0.01	0.05	0.02	0.16	0.01	0.03	0.01	0
Neck comp (kN)	0.4	0.3	0.1	0.2	0.1	0	0.2	0.1	0	0.2	0.1	0.2	0.1	0.1	0.1	0.1
Neck tens (kN)	0.8	1	1.3	1.2	1.2	1.5	0.9	0.9	1.5	1	0.9	0.6	1	1.4	1.3	0.6
Thorax acc 3 ms (g)	58	41	37	36	34	36	33	29	33	31	28	26	30	35	41	31
Viscous criterion (m/s)	0.5	0.3	0.2	0.2	0.2	0.1	0.1	0.2	0.1	0.1	0.2	0.1	0.2	0.3	0.2	0.1
Chest deflection (mm)	−41	−36	−23	−29	−26	−22	−18	−23	−19	−16	−27	−17	−26	−31	−27	−20
Sternum defl rate (m/s)	−1.6	−2.3	−1.4	−2.5	−1.3	−1	−0.7	−1.9	−0.8	−0.9	−1	−1	−2	−1.9	−1.4	−1
L knee defl (mm)	0	−6	−6	−9	−9	−5	−5	−7	−10	0	−1	−1	−9	−8	−7	0
L upper tibia index	1.36	0.79	0.56	0.96	0.55	0.56	0.38	1.11	0.74	0.54	0.46	0.17	0.64	0.81	0.49	0.38
L low tib ax force (kN)	−12.6	−4.3	−3.9	−6.1	−2.9	−2.4	−1.8	−3.3	−3.5	−2.1	−1.3	−1	−1.3	−4.1	−2.2	−1.8
L lower tibia index	2.31	1.47	0.49	0.77	0.43	0.34	0.36	1.74	0.87	0.54	0.22	0.11	0.43	0.88	0.22	0.31
L foot res acc (g)	177	131	121	121	75	61	66	116	104	31	35	33	83	106	52	38
R knee defl (mm)	0	−11	−1	−1	0	−1	−4	0	0	0	0	0	−6	−2	−1	0
R upper tibia index	0.63	0.76	0.34	0.32	0.47	0.46	0.33	0.44	0.38	0.48	0.26	0.35	0.38	0.48	0.28	0.34
R low tib ax force (kN)	−5.8	−2.9	−2.5	−3.5	−1.3	−2.6	−2.8	−2.8	−1.3	0	−1.5	−0.2	−1.9	−4.7	−1.4	−0.4
R lower tibia index	1.43	1.1	0.28	0.21	0.66	0.61	0.45	0.54	0.33	0.4	0.21	0.27	0.12	0.4	0.37	0.42
R foot res acc (g)	89	101	76	69	125	100	57	57	59	32	45	43	39	74	41	42
L fem force (kN)	4.2	3.54	4.58	4.56	2.26	4.76	4.27	5.56	3.1	0.28	0.41	0.14	3.74	2.12	0.99	0.36
L fem impulse (Ns)	6.2	—	29.9	89.3	—	82.9	10.4	31.1	—	—	—	—	—	—	—	—
L KTH risk (%)	1.6	0.8	2.2	2.2	0.1	2.6	1.7	4.6	0.5	0	0	0	1	0.1	0	0
R fem force (kN)	1.15	3.76	0.4	2.11	0.61	2.3	2.74	1.03	0.02	0.03	0.05	0.19	1.27	1.16	0	0.03
R fem impulse (Ns)	—	—	—	—	—	—	—	—	—	—	—	—	—	—	—	—
R KTH risk (%)	0	1	0	0.1	0	0.2	0.3	0	0	0	0	0	0	0	0	0
^a Values equal to or greater than 80 percent of the injury assessment reference value are shown in bold. tens = tension; extens = extension; comp = compression; acc = acceleration; defl = deflection; tib = tibia; ax = axial; res = resultant; fem = femur; KTH = knee-thigh-hip.

Fig. 11 Occupant kinematics and structural intrusion combine to increase risk of head injury.