Calsonic Kansei North America (CKNA)

27000 Hills Tech Court,

Farmington Hills, MI 48331

Vali Farahani – Technical Specialist

Mark Corritore – Senior CAE Engineer

Sal Maaita – Senior CAE Group Manager

Altair Engineering, Inc.

Altair Engineering Inc.

Aditya Jayanthi – Application Engineer

Shan Bala – Project manager

An Automated Head Impact Process Setup

for Automobile Instrument Panel (IP)

Application

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An Automated Head Impact Process

Presentation Outline

• Objective

• CalsonicKansei Corporation Background

• Head Impact Overview

• FMVSS201 Regulations

• Introduction

• HF Positioning Manual Process

• HF Positioning Automation Process

• Automated Results Versus Manual

• Automation of Post Processing (Available V14.0)

• Benefits

• HF Automation Demo

• Acknowledgements

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An Automated Head Impact Process

Objective:

To develop an advanced script algorithm to automate

the HF positioning on instrument panel (IP) for head

impact crash application using current commercial

available software HyperMesh®.

To enhance the script on HM-V14.0 for post processing

to generate final report automatically in power point

format.

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CalsonicKansei Production and Development Operations CalsonicKansei is a Tier-I auto supplier and established in August 25, 1938

Global headquarters in Saitama-City, Japan

It operates a global network across the world

Global Consolidated number of employees are about 24,000

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CalsonicKansei Major Client Base

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CalsonicKansei Major Products/Commodities

Center Console Box

HVAC Systems Electronic Systems

AC Compressors

Cockpit Module Systems Exhaust Systems

Front End Module

Meter HVAC Control Switches

ABCUBCM ODS

HCCOND

EVAPMotor/Fan

FLEX Pipe

Manifold/CC

EXST Assy

Motor Fan Assy

Radiator Assy

AC Condenser

RCS

HVAC Unit

CPM

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An Automated Head Impact Process

head impact Overview

When a car is accelerated and crushed into another vehicle or

any rigid object , the occupant’s head impacts

CPM/Instrument Panel.

INST

Vehicle Speed

The purpose of Head Impact analysis is to protect occupant’s

head during the vehicle crash from fatal injury.

Head Impact simulation is a part of early stage of the IP

design development and it is commonly done in automotive

industry to meet FMVSS201 Regulations.

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An Automated Head Impact Process

FMVSS201 RegulationsFMVSS201 Regulations state that when a target point on Instrument

Panel within “Head Impact Zone” is impacted by:

A 6.8 kg (15 lb.), 165 mm (6.5 in) diameter Head Form (HF)

at a velocity of 14.7±0.2 MPH

with the pendulum adjustable length of 29 to 33 inches,

The deceleration of HF shall not exceed 80g continuously for more

than 3 milliseconds.

HF

HF Pivot Point

Adjustable Length

IP

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An Automated Head Impact Process

Introduction

In the past, to asses the head impact performance of IP, CKNA CAE group

had to perform a lengthy manual process to position each HF within IP

impact zone. As a part of manual process, analyst assigns initial velocity

to HF, define contacts between HF and IP, create input/output control

cards and export LS-DYNA input data.

In order to simplify the HF positioning and developing a more efficient

process, CalsonicKansei North America (CKNA) CAE group decided to

work with Altair Engineering Inc. to develop an advance algorithm to

automate the HF setup using current commercial available software

HyperMesh®.

script will automatically position HF from a user prepared input excel file

in .csv format based on a selected seating reference point. The script

calculates the impact angle for each point automatically and positions the

HF at the impact point. The surface contacts between HF and IP are

created automatically for all positioned Head Forms.

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An Automated Head Impact Process

HF Manual Process Flow Chart for Head Impact Setup

Positioned

HF

HF Pivot

Point

Calculate HF

Angle of Rotation

Start

Process In CAD

System By DE

Determine HI

Marking Zone

Define HF

Target points

Determine HF

Center of Rotation

Position HF for Each Target Point

Assign Initial Velocity to HF

Define constraint for HF

Create Contacts Between HF & IP

Create Input/Output Control Cards

Assign Mass Moment of Inertia to HF

Define Surface contacts for CPM

Export out the data for LS-Dyna

Analyst Receives Setup info From DEPassenger

Zone

Driver

Zone

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An Automated Head Impact Process

Head Form (HF) Manual With Post Processing Plots

Acceleration

3ms-G

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An Automated Head Impact Process

HF Positioning on IP Automation Process

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An Automated Head Impact Process HF Automation Template Flow Chart Structure

Load IP Head Impact Template

Import IP (CPM)

Import HF

Specify SgR Point

Position HF

Define Contacts

Export out Decks

GUI Description

Process Manager

Launch HyperMesh

Select User Profile Crash

Radios

LsDyna

PamCrash

Solver OptionsSTART

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An Automated Head Impact Process

Process for Importing IP and HF FE Models

GUI Description (IP FEM)

GUI Description (HF FEM)

File TypeLsDyna

HyperMeshHF FEM ApplySelect HF with

Lin/rot Velocity2

File TypeLsDyna

HyperMeshIP FEM Apply1

File Format

Imported IP Assembly & HF

HF

IP

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An Automated Head Impact Process

Positioned HF for Selected Target Points

Specify

SgRP

By Node

By Coordinates

Specify Direction

of Vehicle MotionApply3

User Options

GUI Description

Specify HF Zone

Marking on IP

By Node

Position

HF’sApply4

Remove

Penetration

Specify

HF

Target

or pivot

.CSV File GUI Description

Angle of Rotations are calculated

automatically for each target point

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An Automated Head Impact Process

Define Contacts and Export out the Decks for Solver

Define Automatic Single

Surface Contact

Apply to Save

Surface Contact

5

6

Create output Directory

Export out decks for

Selected Target Points

Master

FileIP File HF File

Target

File

Submit Master

File to Server

GUI Description

GUI Description

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An Automated Head Impact Process

Automation Results Versus Manual

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An Automated Head Impact Process

Automation Results Versus Manual

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An Automated Head Impact Process

Automation of Post Processing ( Available in HM V14.0)

Load Vehicle Safety Tools preference file.

Available for Radioss and Dyna results

Input vehicle direction, Clip Threshold,

SAE filter

Load Defaults file which points to IP deck

directory and Target point CSV file

Generates results which can be

reviewed in HV and HG clients

Automatically generates a power point

report

Results at different points can be

appended, overlaid and/or replaced

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An Automated Head Impact Process

Automation of Post Processing ( Available in 14.0)

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An Automated Head Impact Process

Benefits of the HF Automated Process

It is more efficient process with significant time saving

The time saving help CKNA CAE group to evaluate IP head impact faster

and reducing the engineering development costs.

Automation process helps analysts to complete more projects.

It Helps to reduce the possibility of error that may occurs on manual

setup.

It has significant impact on the division or work group benefits.

The automated process reduces the head form setup for 30 points from 8

hours to 30 minutes.

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An Automated Head Impact Process

Acknowledgements

We would like to thank Shawn Ryan, manager of Design CAD Group, at

Calsonic Kansei for his support and valuable information regarding this

project.

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An Automated Head Impact Process

Thank You!

&

Q?