q10 euro ncap 2020 hardware & fe model updates€¦ · a major update release of q10 euro ncap...

Q10 EURO NCAP 2020 HARDWARE& FE MODEL UPDATES Jerry Wang (Ph. D) & Fuchun Zhu

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Contents

• Part One – Brief of Q10 Euro NCAP 2020 upgrade kit • Part Two – Q10 Euro NCAP 2020 FE model updates

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2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Overview time line of Q10 developments

RequirementsDesign and Prototyping

Validation and Evaluation

EU funded projectEPOCh

Abdomen pressure sensor integration

FeedbackDesign updatesProduction

Hip liner

ASIS Load Cell

Requirements Q10 2020FE supported Trade off studyDesign and Prototyping

ValidationEvaluation

Euro NCAP initiative

Q10 2020 Final designProduction

Future harmonization with Euro NCAP?

UNECE Regulation 129

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Q10 Changes Driven By Euro NCAP Child WG

• Seating Posture◦ Match UMTRI Child Anthropometry – head and neck position

• Proper Belt Engagement and Kinematics◦ Shoulder belt – shoulder pad◦ Lap belt – thigh flesh

• Mass distribution improvement◦ Migrate mass from pelvis to thorax

• Other usage issues experienced in testing◦ Foot interference with front seat◦ Scapula interference with shoulder rubber and ribcage

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Euro NCAP 2020 Q10 Contents• Euro NCAP Child WG Decision: Sept 2018• Head and neck position at neck base

◦ Reposition the dummy according to UMTRI child seating posture

◦ Forward shift the neck by 20 mm◦ Rotate the head rearward by 5.3 degrees

• Shoulder liner to cover shoulder joints• Scapula eliminated • Mass shift pelvis to thorax 1.4 kg• Upper legs with solid flesh• Lower legs with shorter feet

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Q10 Euro NCAP 2020 Kit Status• Euro NCAP Q10 Upgrade Kit is finalized and available for the users• Euro NCAP New Test Protocol takes effective on Jan 1, 2020

• Euro NCAP Dynamic Tests – total 30 channels, plus 4 optional◦ Head acceleration x,y,z◦ Upper neck force Fx, Fy, Fz, moment Mx, My, Mz◦ Shoulder force Fx, Fy, Fz◦ T1 acceleration y (side only)◦ Chest (T4) acceleration x,y,z,◦ Chest displacement and rotation◦ Lumbar spine force Fx, Fy, Fz and moment Mx, My, Mz◦ Pelvis acceleration x,y,z◦ Pubis force Fy (side only)◦ Iliac wing (L&R) force Fx, My (optional)

MK-FO-00036C, Rev A

Part Two: Q10 Euro NCAP 2020 FE Models Development

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2015 2016 2017 2018 2019

Q10 2020 V1.0 Concept Model V1.1 V1.2

Reports to Euro NCAP, Advisory Board and Conferences

V1.0 Full Prototype 2017

New Q10Euro NCAP 2020 Design. FE model available for evaluation

Hardware Status• Validation/Testing• Third Party Evaluation

FE model release 3rdQ 2019

Q10 Dummy Model Development History/Status

March 2018: Based on evaluation results, Euro NCAP CWG decided for limited updateby restoring some original Q10 parts

Design/FE analysis loop done in all stages of development-concept to launch!

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• FEA V1.1 Model developed to follow Euro NCAP 2020 specifications; and released late 2018;

• V1.1 dynamic performance to mimic hardware closely;

• Updated parts of known materials, known geometry change◦ Solid/rigid metal parts spine and pelvis◦ Solid/rigid scapula◦ Solid/elastic shoulder pad*◦ Solid/elastic lower leg◦ Solid/elastic thigh flesh current production*

• Extra option (feature): *stiffness parameter variables in FEA model (Thigh, Shoulder liner)

Q10 Euro NCAP 2020 Dummy Model v1.1

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• V1.1 model represents the state of art design and functionality of the hardware kit/materials

• Thigh flesh/Shoulder liner parameters for stiffness variation

• Additional parameters on Jacket, neck, hip shields to help users run belt slip on shoulder and chin to clavicle contact studies

Q10 Euro NCAP 2020 Dummy Model v1.1

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• V1.1 SK model released in April 2019• The SK (side kit) arm with shoulder assembly is fitted on

the Euro NCAP 2020 v1.1 model• Modified scapula

Q10 Euro NCAP 2020 SK Dummy Model v1.1

MK-FO-00036C, Rev A

New Validation Tests for v1.2 ModelPlanned Release Date: 9/2019

• Neck mini sled tests• Lumbar spine mini sled tests• Abdomen foam drop tests• APTS pendulum impact tests

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• Focus on validating combined bending/torsion mode;• Total of 40 tests were executed at multiple speeds, with/without neck cable;• Considering possible hardware variations - two necks.

Neck Mini Sled Tests

Impactvelocity

Neck1 (EJ8877) Neck 2 (EJ6567)

With cable

Without cable

With cable Without cable

2 m/sTest 1 √ √ √ √

Test 2 √ √ √ √

3 m/sTest 1 √ √ √ √

Test 2 √ √ √ √

4 m/sTest 1 √ √ √ √

Test 2 √ √ √ √

5 m/sTest 1 √ √ √ √

Test 2 √ √ √ √

6 m/sTest 1 √ √ √ √

Test 2 √ √ √ √

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• Neck kinematics to replicate loading level seen in a vehicle test.• Initial Position reference for FEA established via Laser scanning.• Validation based on 3 independent sets of signals.a. Ballast Acceleration & Angular velocity outputs.b. Upper Neck Loadcell Forces & Moments.c. Lower Neck Loadcell Forces & Moments. c

b

a

Neck Mini Sled Tests

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Upper Neck Loads: 6 m/s (with Cable)

• Focused on Upper Neck Loadcell signals - important for EuroNCAP injury rating.

Neck Mini Sled Tests

TestV1.1V1.2

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Lower Neck Loads: 6 m/s (with Cable)

Neck Mini Sled Tests

TestV1.1V1.2

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Ballast Kinematics angular velocity: 6 m/s (with Cable)

Neck Mini Sled Tests

TestV1.1V1.2

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• Focus on validating combined bending/torsion mode;• Total of 32 tests were executed at multiple speeds, with/without lumbar cable;• Considering possible hardware variations - two lumbar spines.

Impactvelocity

Lumbar 1 (EJ2521) Lumbar 2 (EJ5778)

With cable

Without cable

With cable Without cable

3 m/sTest 1 √ √ √ √

Test 2 √ √ √ √

4 m/sTest 1 √ √ √ √

Test 2 √ √ √ √

5 m/sTest 1 √ √ √ √

Test 2 √ √ √ √

6 m/sTest 1 √ √ √ √

Test 2 √ √ √ √

Lumbar Spine Mini Sled Tests

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b

a

Lumbar Spine Mini Sled Tests• Lumbar kinematics to replicate loading level seen in a vehicle test• Initial Position reference for FEA established via Laser scanning.• Validation based on 2 independent sets of signals.a. Ballast Acceleration & Angular velocity outputs.b. Lumbar Spine Loadcell Forces & Moments.

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Ballast Kinematics angular velocity: 6 m/s (with Cable)

Lumbar Spine Mini Sled Tests

TestV1.2

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Loadcell loads: 6 m/s (with Cable)

Lumbar Spine Mini Sled Tests

TestV1.2

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Motivation for additional testing:1. Abdomen stiffness is an important parameter which affects the kinematics of upper torso flexion, chin to

chest contact & Neck Fz;

2. CAE customers reported that the abdomen material is very stiff and leads to over-prediction of the Upper Neck Fz forces;

3. Humanetics proposed an interim solution by validating the abdomen insert using the TU-B sled setup;

4. The next step is to validate the Abdomen using a drop test setup.

Stiffer AbdomenTuned (softer) Abdomen

Upper Neck Force-Z

Abdomen Insert

Abdomen Foam Drop Tests

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• Component level tests with isolated the abdomen;• Total of 27 tests were executed at multiple speeds;• Hardware variability-three test subjects.

Drop Tower Setup

Impactvelocity

Abdomen 1 (EJ4177)

Abdomen 2(DY 7779)

Abdomen 3(Q10-10001)

1.55 m/s

Test 1 √ √ √

Test 2 √ √ √

Test 3 √ √ √

2.51 m/s

Test 1 √ √ √

Test 2 √ √ √

Test 3 √ √ √

3.38 m/s

Test 1 √ √ √

Test 2 √ √ √

Test 3 √ √ √

Abdomen Foam Drop Tests

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Abdomen Foam Drop Tests (without skin)

Drop speed: 1.55m/s2.51 m/s3.38 m/s

TestV1.1V1.2

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Abdomen Foam Drop Tests (with skin)

Drop speed: 1.55m/s2.51 m/s3.38 m/s

TestV1.1V1.2

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• APTS (Abdomen Pressure Twin Sensor) are used for Abdomen injury assessment. Injury criteria are under ECE regulation R129. The sensor is used in the Q family dummies and THOR family dummies;

• Earlier beta version sensor model released in December 2016;• Further work planned for the sensor validation based on component

testing

APTS sensor FE model development

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• Sensor validation based on Component Tests – multiple speeds

APTS 50 mm test @ 0.74 m/stest @ 1.13 m/sFE in Red

• Peak pressure (bar) values/timing profile of the sensormatch with the validation domain of the ECE-R129legislation requirements.

APTS sensor FE model development

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• FE data validation based ono Thorax repeat tests at multiple speeds.o Use high-speed videos for kinematic correlation.o Total of 40 dummy channels used for FE/test correlation.o Positioning reference-Tilt sensors and laser pendulum alignment

Full Dummy Validations: Thorax Frontal Impact

Tilt sensor outputs

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Tilt sensor outputs

Full Dummy Validations: Thorax Lateral Impact• FE data validation based on

o Thorax repeat tests at multiple speeds.o Use high-speed videos for kinematic correlation.o Total of 40 dummy channels used for FE/test correlation.o Positioning reference-Tilt sensors and laser pendulum alignment

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Tilt sensor outputs

• FE data validation based ono Pelvis repeat tests at multiple speedso Use high-speed videos for kinematic correlationo Total of 40 dummy channels used for FE/test correlationo Positioning reference-Tilt sensors and laser alignment of pendulum

Full Dummy Validations: Pelvis Lateral Impact

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A major update release of Q10 Euro NCAP 2020 dummy FE model v1.2 is scheduled for September 2019.

Additional component validations – Abdomen/Neck/Lumbar Spine/APTSFull body validations – Thorax/Pelvis/Abdomen/FemurAddress customer feedbacksMeet Euro NCAP 2020 specifications

In Summary

MK-FO-00036C, Rev A

Thank you for your attention

Acknowledges: Q10 Euro NCAP 2020 FE model development team members

Renuka JagadishVinit Manjarekar

Apoorva Lakshminarayana