status of nhtsa’s roof crush researchroof crush phase 1 - approach • computer simulation to...
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Status of NHTSA’sRoof Crush Research
Donald T. WillkeNational Highway Traffic Safety Administration
SAE Government/Industry MeetingMay 10, 2004
Roof Crush
• Phase 1 – Determine Plate Angles
• Phase 2 – Initial Fleet Evaluation
• Phase 3 – Expanded Fleet Evaluation
Roof CrushPhase 1 - Approach
• Computer Simulation to Select Test Conditions– 5° pitch, 25° roll– 10° pitch, 45° roll
• Tested 3 Pairs of Vehicles– 1997 Dodge Grand Caravan– 1998 Chevrolet S-10 Pickup– 2002 Ford Explorer
• Compared Force vs. Displacements• Compared Damage to Real World
Roof CrushPhase 1 - Summary
• No Trend in Energy ‘Absorbed’• No Trend in Peak Force• No Trend in Far-Side Lateral Crush• More Vertical Crush in 5° x 25°• Any Differences Were Very Subtle
– Not distinguishable in subjective evaluation of photographs of roof damage
Roof CrushPhase 2 - Approach
• Test 10 Recent Model Vehicles• Load Plate Angles - 5° pitch, 25° roll• Test to 254 mm of Load Plate
Displacement• Collect Force vs. Displacement Data• Collect Headroom Measurement Data
Roof CrushPhase 2 - Vehicles: One From Each Type/Size
• Passenger Cars:– 2002 Ford Mustang– 2002 Toyota Camry– 2001 Ford Crown Victoria
• Sport Utility Vehicles:– 2002 Honda CR-V– 2002 Ford Explorer*– 2001 Chevrolet Tahoe
* Data from Phase 1
• Pickup Trucks:– 1998 Chevrolet S-10
Pickup*– 2002 Dodge Ram 1500
Pickup
• Vans:– 1997 Dodge Grand
Caravan*– 1999 Ford E-150
Econoline Van
Roof CrushPhase 2 - Roof Attachment Point
• Seat Track Position & Seat Back Angle for 50th
Male per FMVSS 208• Locate H-Point Using OSCAR Device
– x and z coordinates
• Identify ‘Top of Head’– Located for first vehicle by seating H-3 dummy– Used translation of OSCAR x and z coordinates for
remaining vehicles– y coordinate from centerline of seat
• Locate Point Vertically Above ‘Top of Head’– On interior roof liner– On exterior hard roof
Roof CrushPhase 2 – Initial Headroom
0.0
50.0
100.0
150.0
200.0
250.0
300.0
Mustan
g
S-10 P
UCam
ry
Explor
er
Crown V
ic
Carav
an CR-V
Ram PU
Taho
e
E-150
Van
Hea
dro
om
(m
m)
to roof
to brace
to liner
Roof CrushPhase 2 – String Potentiometer Attachment
3 string potentiometers were used to track the roof point initially above the drivers head
Roof CrushPhase 2 - Results
Percent of Vehicle Weight vs. Displacement To 254 mm Load Plate Displacement
0%
50%
100%
150%
200%
250%
300%
350%
0 25 50 75 100 125 150 175 200 225 250 275
Average Displacement (mm)
Per
cen
t of V
ehic
le W
eig
ht
1997 Dodge Grand Caravan 1998 Chevrolet S10 Pickup 2002 Ford Explorer 2002 Dodge Ram 1500 Pickup2002 Toyota Camry 2002 Ford Mustang 2001 Chevrolet Tahoe 2002 Ford Crown Victoria2002 Honda CRV 1999 Ford E150 Van
Roof CrushPhase 2 - Results
Maximum Force Achieved Within 125 mm External Crush
0
50
100
150
200
250
300
350
400
Mini-Coo
per*
S-10 P
U
Mustan
gCam
ry
Mazda
6* CR-V
Carava
n
Crown V
ic
Explo
rer
Soren
to*
Windsta
r*
Ram PU
TrailB
lazer*
Taho
e
E-150
Van
Per
cen
t Veh
cile
Wei
gh
t (%
)
Roof CrushPhase 2 - Results
Percent of Vehicle Weight vs. Headroom Remaining to Roof To 254 mm Load Plate Displacement
0%
50%
100%
150%
200%
250%
300%
350%
-120-100-80-60-40-20020406080100120140160180200220240260
Headroom Remaining (mm)
Per
cen
t of V
ehic
le W
eig
ht
1997 Dodge Grand Caravan 1998 Chevrolet S10 Pickup 2002 Ford Explorer 2002 Dodge Ram 1500 Pickup2002 Toyota Camry 2002 Ford Mustang 2001 Chevrolet Tahoe 2001 Ford Crown Victoria2002 Honda CRV 1999 Ford E150 Van
All vehicles reached 150% of vehicle weight with significant head room remaining
* to brace
Only 1 vehicle did not have a peak force above 200% of vehicle weight, but it still had positive head room at the end of the test
Headroom Remaining at 150% Vehicle Weight
0
50
100
150
200
250
300M
usta
ng
Cam
ry
Cro
wn
Vic
CR
-V *
Exp
lore
r
Taho
e
S-1
0 P
U
Ram
PU
Car
avan
E-1
50 V
an
Hea
dro
om
Rem
ain
ing
(mm
)
to roofto liner
Headroom Remaining at 200% Vehicle Weight
0
20
40
60
80
100
120
140
160
180
200
Mus
tang
Cam
ry
Cro
wn
Vic
CR
-V *
Exp
lore
r
Taho
e
S-1
0 P
U
Ram
PU
Car
avan
E-1
50 V
an
Hea
dro
om
Rem
ain
ing
(mm
)
to roofto liner
* to brace
4 vehicles had a peak force above 300% of vehicle weight, and 2 of these had positive head room remaining
8 of the 10 vehicles had a peak force above 250% of vehicle weight, and 6 of these had positive head room remaining
Headroom Remaining at 250% Vehicle Weight
-50
0
50
100
150
200M
usta
ng
Cam
ry
Cro
wn
Vic
CR
-V *
Exp
lore
r
Taho
e
S-1
0 P
U
Ram
PU
Car
avan
E-1
50 V
an
Hea
dro
om
Rem
ain
ing
(mm
)
to roofto liner
Headroom Remaining at 300% Vehicle Weight
-100
-50
0
50
100
150
Mus
tang
Cam
ry
Cro
wn
Vic
CR
-V *
Exp
lore
r
Taho
e
S-1
0 P
U
Ram
PU
Car
avan
E-1
50 V
an
Hea
dro
om
Rem
ain
ing
(mm
)
to roofto liner
Roof CrushPhase 3 - Approach
• Test 10 Recent Model Vehicles• Load Plate Angles - 5° pitch, 25° roll• Test to 254 mm of Load Plate
Displacement• Collect Force vs. Displacement Data• Document Time of Liner-to-Head
Contact
Roof CrushPhase 3 - Vehicles
• Passenger Cars:– 2003 Ford Focus– 2003 Chevrolet Cavalier– 2001 Ford Taurus– 2003 Chevrolet Impala
• Sport Utility Vehicles:– 2003 Subaru Forester– 2002 Nissan Xterra– 2003 Ford Expedition
• Pickup Trucks:– 2003 Toyota Tacoma– 2003 Ford F-150
• Van:– 2003 Chevrolet Express
(15-passenger)
Roof CrushPhase 3 – Dummy Placement
• Hybrid-III 50th Male• Positioned per
FMVSS 208• Arms and Legs
Removed• Contact Switch on
Head and Liner
Roof CrushPhase 3 - Results
Percent of Vehicle Weight vs. DisplacementTo 254 mm Load Plate Displacement
0%
50%
100%
150%
200%
250%
300%
350%
400%
450%
500%
0 50 100 150 200 250 300
Displacement (mm)
Per
cen
t of V
ehic
le W
eig
ht
Ford Focus Chevrolet Cavalier Ford Taurus Chevrolet Impala Subaru Forester
Nissan Xterra Ford Expedition Toyota Tacoma Pickup Ford F-150 Pickup Chevrolet Express Van
Roof CrushPhase 3 - Results
Percent of Vehicle Weight vs. DisplacementTo Head Contact
0%
50%
100%
150%
200%
250%
300%
350%
400%
450%
500%
0 20 40 60 80 100 120 140 160 180 200
Displacement (mm)
Per
cen
t of V
ehic
le W
eig
ht
Ford Focus Chevrolet Cavalier Ford Taurus Chevrolet Impala Subaru ForesterNissan Xterra Ford Expedition Toyota Tacoma Pickup Ford F-150 Pickup Chevrolet Express Van
Roof CrushPhase 3 - Results
Maximum Force Prior to Head Contact
0%
50%
100%
150%
200%
250%
300%
350%
400%
450%
500%
Focu
s
Cavali
er
Tauru
s
Impa
la
Fores
terXter
ra
Exped
ition
Taco
maF-1
50
Expre
ss Va
n
Per
cen
t o
f V
ehic
le W
eig
ht
THE END
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