Cercetare Semestrul 2

Pedestrian Protection and its Implications on Front-Ends
Dr. Dominic Seibert, Andreas Koukal

Agenda
1. Pedestrian Protection - Motivation, State of the Art and Future Trends

2. Front-Ends - Scope and Design Conflicts
3. Processes in Front-End Development
4. Virtual Testing - State of the Art in Industry and Research, Future Trends
5. Summary
2 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

Agenda

5. Summary

Pedestrian Protection (Motivation, State of the Art and Future Trends)
► Motivation - Fatalities in Road Traffic in 2008 [IRTAD]
100%
90% Other / Unknown
andere/unbek.
80% Passenger
Pkw/Kombi cars
MZR
Mot. two-wheelers
70%
Radfahrer
Cyclists
60% Fußgänger
Pedestrians
50%
40%
30%
20%
10%
0%

► Motivation - Fatalities in Road Traffic in Germany from 1980 - 2008 (normalized) [IRTAD]
0%
-10%
-20%
-25%
-30%
-40%
-50%
-60%
Other / Unknown
andere/unbek. -69%
-69%
-70% Pkw/Kombi
Passenger cars -73%
-80% MZR
Mot. two-wheelers
-75%
Radfahrer
Cyclists
-90% -89%
Fußgänger
Pedestrians
-100%
80
82
84
86
88
90
92
94
96
98
00
02
04
06
no 008
10
19
19
19
19
19
19
19
19
19
19
20
20
20
20
20
2
se
og
Pr
► Pedestrian Protection - Accident Analysis [GIDAS, 2006]
4.2% Other 2.3% Vehicle driving straight on,

standing pedestrian
7.1%
Intersection after turning off
59.0%
27.4%
Crossing pedestrian, straight road

no line-of-sight obstruction
Crossing pedestrian, straight road
with line-of-sight obstruction
► Important Result: 86% of pedestrian accidents involve crossing pedestrians

► Pedestrian Protection - Chronology of a Pedestrian Collision
Secondary Collision -
Primary Collision - Vehicle
Environment
1. Contact 2. Contact 3. Contact

Leg Torso / Head Undefined Time

► Pedestrian Protection - State of the art
Adult Head Impactor Homologation
► 2009/78/EC
Child Head Impactor
► GTR No.9
Upper Leg Impactor
Lower Leg Impactor Consumer Tests

(e.g. EuroNCAP)
Deformation Zones Energy absorbing Parts

► Future Trends - Active Bonnet
Sensors Actuator (Hinge)

- Acceleration - Mechanical (Spring)
- Pressure - Pyrotechnic
- Pneumatic (Gas cartridge)
Signal processing
- Control unit with power electronics
- Algorithm

► Future Trends - Integrated Safety
Active Safety Crash Passive Safety
Time
t = 0ms
Active Passive
(Preventive Pedestrian Protection) (State of the art)

► Summary
► Pedestrian Protection has been introduced to further reduce fatalities in Public Traffic.
The OEMs are aware of their Social Responsibility and have invested in this field.
► Pedestrian Protection is relevant for the homologation of a car.
► Pedestrian Protection is developed and tested as an impactor method, for

repeatability and reproducibility reasons.
► The post crash passive pedestrian protection methods are tending towards saturation
as far as field effectivity is concerned. (This could be shown studying the injury risk
curves corresponding to these different levels)
► Active Protection is the future, due to its higher Field Effectivity and will be the major
focus of development in the next years.

Agenda

5. Summary

Front-Ends (Scope and Design Conflicts)
► Scope - Assemblies of the Front Vehicle
Bonnet
Hinge
Frontklappe
Scharnier
Wiper
Frontend incl. Cooler Wischer
Frontend inkl. Kühler
Headlight Car Body

Scheinwerfer Karosserie
Fender
Kotflügel
Bumper System
Stossfängersystem Motor Package
Motorpackage
Crash Management System

Crashmanagementsystem
► Scope - Terminology “Front-End”
Bonnet
Frontklappe
Fender
Kotflügel
Frontend
Frontend
(KU-Montageträger)
Bumper System
Stossfängersystem
Crash Management System

Crashmanagementsystem

► Complexity of the Bumper System for a given Audi car
Equipment Options Variants
Bumper System Standard : S-Line 2
Fog Light with : with out 3
Headlight Cleaning System with : with out 6
Audi Parking System with : with out 12
Licence Plate Cover / Front Grill with out : Japan : China 28
Colour 13 Colours 364

► Future Trend - “Soft Nose” Other Brands
VW Group

► Design Conflicts
► Pedestrian Protection vs. Design
► Pedestrian Protection vs. Bonnet Stiffness
► Pedestrian Protection vs. Low Speed Test (Insurance Classification)
► Pedestrian Protection vs. Front Vehicle Package
Stiffness
Design
Pedestrian Protection Low Speed Test
Package
► Pedestrian Protection vs. Design

► Short Front Overhang
Dynamic and Sportive Exterior
► Flat Contour

► Pedestrian Protection vs. Bonnet Stiffness

► Wind Load
► Tension at the Lock
► “Special Load Cases”
Compression
Tension

► Pedestrian Protection vs. Low Speed Test (Insurance Classification)

► No Damage to the Frontend and Cooler Lower Load Path has to be “opened”
► Large Crash Boxes Less space for Pedestrian Protection Foam
Lower Load Path

Crash Boxes
Ped. Pro. Foam

► Pedestrian Protection vs. Front Vehicle Package

► Conflict with Air Intake
► Sensors for Driver Assistance Systems

► Summary
► Terminology “Front-End” has been clarified in the English and German context.
► The Complexity of Front-Ends (in terms of numbers of variants) is quite significant

and constitutes a major burden in development, quality assurance, production and
logistics both for the OEM and the Suppliers.
► Given the limited package space in a car, Pedestrian Protection generates many
Design Conflicts
► Observation of market trends shows a tendency to an increased use of the “Soft

Nose” - Technology in the Front-End, with advantages especially for Pedestrian
Protection and Low Speed Insurance Test.

Agenda

5. Summary

Processes in Front-End Development
► Product Development Process at Audi (PP)

Homologation EuroNCAP
Target Design Virtual First Pre-

production SOP
Definition Freeze Prototype Prototype
Ped. Pro. Simulations

Ped. Pro. Tests
Component Tests
Component Development Production-Vehicle Development

Product Definition
Product Development

► Other Functions influencing Pedestrian Protection
Low Speed
Influence Crash Tests SOP
(Insurance)
Climate Shaking
Fatigue Test
(Audi Test)
Ped. Pro. Development
Component Development Production-Vehicle Development

Product Definition
Product Development

► Summary
► Given the typical Product Development Process of a car, Front-End development

marks the very beginning and the very end of the design cycle, for its concept
relevance and the complexity of the testing requirements, respectively.
► Component Tests will gain importance as they bridge the gap between the virtually
driven concept phase and the availability of first physical prototypes or preproduction
cars.
► As the understanding of the component requirements grows, suppliers will be more

and more able to pre-optimize their components without the need of a full vehicle.
► The key to a stable Front-End development process lies in the quality of virtual
methods that represent the physical tests relevant for the release towards the end of
the development cycle.

Agenda

5. Summary

Virtual Testing (State of the Art in Industry and Research, Future Trends)
► Motivation for Virtual Testing

► Experiments are Cost and Time consuming
► No Prototypes in early stages of the Development Process
► Simulation offers much more Information

► Quantity of Virtual Testing at Audi (cumulated)

► Some Challenges in Virtual Testing for Pedestrian Protection

► Crash and Fracture Behaviour of Polymers
► Climate Shaking Fatigue Test
► Low Speed Crash
► Evaluation of the Field Effectivity

► Crash and Fracture Behaviour of Polymers - Challenges

► Complex Material Behaviour New Material Models
► Influence of Manufacturing Process (e.g. Fibre Orientation)
► Complex Fracture Behaviour
[SIMLab]

► Climate Shaking Fatigue Test - Challenges

► Material Behaviour (Creep, Temperature, Fatigue)
Temperature [°]
► Simulation -
Coupling of thermal and mechanical Behaviour
Time [h]
Amplitude [g] Frequency [Hz]

► Low Speed Crash - Challenges

► Crash- and Fracture Behaviour of Polymers
► Joints and Connectors
(AZT Insurance Test, 16 km/h, 10°)

► Evaluation of the Field Effectivity
System Specification System Simulation
Safety
System A Real World Benefit
of different Systems
System A
System B
Real World in-depth

Accident Data (GIDAS) Safety
Seriously Fatally
System B
injured injured

► Summary
► Virtual Testing is the key to successfully manage the challenges in automotive

Front-End development in a cost efficient manner.
► Simulation gets more and more important in Pedestrian Protection Development,

yet accuracy needs further improvement, especially for the polymer components in
the presence of unexpected fracture. Coupling of process simulation with structural
simulation constitutes an important element to ensure seamless collaboration
between Supplier and OEM.
► Other disciplines affecting Front-End design, such as the simulation of Low Speed
Crash and Climate Shaking Fatigue Test also need improvement.
► Simulation methods are continuously being developed both by OEMs and

Suppliers. Given the limitations of simulation and the relevance of experimental
testing in the launching phase, each company has to find its way to optimize the
interaction between virtual and physical testing methods.

Agenda

5. Summary

Summary
Pedestrian Protection and its Implications on Front-Ends
► It is well known that Pedestrian Protection has significantly changed the manner to
develop Front-Ends, in many cases leading to a new design language. Front-Ends which
do not satisfy Pedestrian Protection may not be sold in many important markets.
► The post crash passive pedestrian protection methods are tending towards saturation as
far as Field Effectivity is concerned.
► Given the limited package space in a car, Pedestrian Protection generates many Design
Conflicts.
► Component Tests will gain importance as they bridge the gap between the virtually
driven concept phase and the availability of first physical prototypes or preproduction
cars.
► Virtual Testing is the key to successfully manage the challenges in automotive Front-End
development in a cost efficient manner.
► Active Protection is the future, due to its higher Field Effectivity and will be the major
focus of development in the next years.

Thank you.

References
[IRTAD] Data Source: IRTAD (International Road Traffic and Accident Database)
http://internationaltransportforum.org/irtadpublic/index.html
[GIDAS] VW-GIDAS Accident database 2006

(Basis: 649 Frontal collisions between pedestrians and cars/MPV, MAIS 2+,
no multiple collision, no skidding vehicles)
[SIMLab] Polanco-Loria Mario, A.H. Clausen, T. Berstad, O.S. Hopperstad (2011),

Constitutive model for thermoplastics with structural applications,
International Journal of Impact Engineering 37, 12, 1207-1219

Cercetare Semestrul 2

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Pedestrian Protection and its Implications on Front-Ends

Dr. Dominic Seibert, Andreas Koukal

1. Pedestrian Protection - Motivation, State of the Art and Future Trends

2 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

1. Pedestrian Protection - Motivation, State of the Art and Future Trends

3 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Motivation - Fatalities in Road Traffic in 2008 [IRTAD]

4 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Pedestrian Protection - Accident Analysis [GIDAS, 2006]

4.2% Other 2.3% Vehicle driving straight on,

Crossing pedestrian, straight road

► Important Result: 86% of pedestrian accidents involve crossing pedestrians

6 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Pedestrian Protection - Chronology of a Pedestrian Collision

1. Contact 2. Contact 3. Contact

7 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Pedestrian Protection - State of the art

Adult Head Impactor Homologation

Lower Leg Impactor Consumer Tests

Deformation Zones Energy absorbing Parts

8 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Future Trends - Active Bonnet

Sensors Actuator (Hinge)

9 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Future Trends - Integrated Safety

Active Safety Crash Passive Safety

10 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Pedestrian Protection is relevant for the homologation of a car.

► Pedestrian Protection is developed and tested as an impactor method, for

11 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

1. Pedestrian Protection - Motivation, State of the Art and Future Trends

12 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Scope - Assemblies of the Front Vehicle

Headlight Car Body

Crash Management System

► Scope - Terminology “Front-End”

Crash Management System

14 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Complexity of the Bumper System for a given Audi car

Equipment Options Variants

Bumper System Standard : S-Line 2

Fog Light with : with out 3

Headlight Cleaning System with : with out 6

Audi Parking System with : with out 12

Licence Plate Cover / Front Grill with out : Japan : China 28

Colour 13 Colours 364

15 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Future Trend - “Soft Nose” Other Brands

16 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

Pedestrian Protection Low Speed Test

► Pedestrian Protection vs. Design

18 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Pedestrian Protection vs. Bonnet Stiffness

19 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Pedestrian Protection vs. Low Speed Test (Insurance Classification)

Lower Load Path

Ped. Pro. Foam

20 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► Pedestrian Protection vs. Front Vehicle Package

21 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends

► The Complexity of Front-Ends (in terms of numbers of variants) is quite significant

► Observation of market trends shows a tendency to an increased use of the “Soft

22 Dr. D. Seibert, A. Koukal - Pedestrian Protection and its Implications on Front-Ends