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MADYMO – UPDATES AND OUTLOOK Dr.ir. Martin Tijssens TASS International

September 27, 2016

Confidential

Model update Hybrid-III 50th ellipsoid model d_hyb350el_Q_[usr|inc].xml (v1.5-rc1– R75+)

Model improvement motivation

• Increase correlation level in customer’s data set towards requested 70% combined Wifac score

3-10-2016 2

Models & Applications – Frontal Dummy

Confidential 3-10-2016 3

Model Update THOR-M ellipsoid model d_thor50el_[usr|inc].xml (v2.0 – R76)

Upper arm geometry update including upper arm load cell

Model improvement motivation

• Design updated with CAD data provided by NHTSA

SD3-shoulder Iliac load cell geometry update for better interaction with lap belt

Thorax [Up|Low] and Abdomen IR-TRACC: exact (non-zeroed) IR-TRACC length and angle added

Confidential

THOR-M v2.0 ellipsoid

Model Validation

face impact neck torsion low thorax impact knee impact ankle flexion

Neck flexion ribcage impact upper abdomen impact

• Certification • Updates needed to comply with latest certification requirements as defined in Qualification Manual from October

19, 2015

• Model meets most certification requirements for head, neck, thorax, abdomen and legs (still under development)

• Additionally, component validation is done in certification-like tests where experimental data is available

• No data available for the specific validation of the SD3-shoulder model; characteristics based on engineering judgement

• Full dummy applications • Validation of model performance and model robustness done in sled tests and in full interior vehicle applications

• Several configurations including sled and full vehicle, frontal and oblique, low and high severity

3-10-2016 4

Confidential

Correlating MADYMO model to dimensions of Ford Taurus

NHTSA Oblique impact test

8-3-2016 5

Confidential

• Correlate dimensions of model to real-world data (Top view)

• Validate motion of MADYMO vehicle model to test video

NHTSA Oblique impact test

8-3-2016 6

Confidential

t = 140 ms

NHTSA Oblique impact test

8-3-2016 7

Confidential

NHTSA-OI Demo model: 2013 Ford Taurus

NHTSA Oblique impact test

8-3-2016 8

• Airbag timing derived from test video results

• Performance of dummy model response improved by tuning of restraint system parameters. (No detailed data available)

THOR Occupant kinematics comparison

Confidential

Injury levels

Ford Taurus

Dummy injury results IARV Driver Passenger

Reference (#8087) Simulation

Reference (#8087) Simulation

Head BRIC 1 1.41 1.42 1.31 1.42 HIC15 700 584 479 158 241 3ms Res. (g) 80 93.7 69.7 47.7 57.9 Neck Neck Tension (kN) 2.52 2.01 3.03 1.21 2.47 Neck Compression (kN) 3.6 0.04 0.52 0.02 0.73 Flexion at OC (Nm) 48 5.6 21.5 18.0 19.9 Extension at OC (Nm) 72 3.9 6.9 3.2 14.3 Chest Upr Rt - Disp (mm) NA 31.7 28.9 27.6 17.8 Upr Lt - Disp (mm) NA 11.1 19.7 32.0 15.2 Lwr Rt - Disp (mm) NA 45.1 30.4 11.8 19.4 Lwr Lt - Disp (mm) NA 13.4 13.9 32.2 30.8 Max. Displacement (mm) NA 45.1 30.4 32.2 30.8 3ms Chest Gs (g) 60 47.7 78.5 39.8 50.6 Abdomen Displacement (mm) 111 69.7 59.1 67.3 65.2 Acetabulum Rt Res. Force (kN) 3.5 1.95 2.38 4.28 4.19 Lt Res. Force (kN) 3.5 2.09 2.66 7.55 7.75 Femur Rt - Fz (kN) 10 4.07 3.53 3.42 3.84 Lt - Fz (kN) 10 2.69 3.94 2.47 4.79 Tibia Rt Upr Tibia Index 1.16 1.57 3.07 Rt Lwr Tibia Index 1.16 1.09 1.72 Lt Upr Tibia Index 1.16 1.53 1.73 Lt Lwr Tibia Index 1.16 1.34 1.45

NHTSA Oblique impact test

8-3-2016 9

Confidential

Model update Hybrid-III 05th ellipsoid model d_hyb305el_Q_[usr|inc].xml

Model improvement motivation

• Predict the onset of submarining in Euro NCAPs FWFI test

3-10-2016 10

Models & Applications – Frontal Dummy

V2.0 V1.5

V2.0 V1.5

Confidential

New Feature

Simulation Generator Use Case • Create and submit multiple DEFINE-based model

variants from one base model

MADYMO Workspace 7.6.1 – XMADgic

Features • Wizard for setting up parameter studies

• Generate Simulation Files

• Submit Files to MADYMO

• Show Run Details

• Option ‘Generate unique filenames’

• Option to set sleep interval after each run submission

3-10-2016 11

Confidential

New Feature

Scaling an Airbag Use Case • Apply individual scaling steps to shrink an existing airbag from its reference

(inflated) state to the initial state, where it fits inside its cover.

MADYMO Workspace 7.7 – XMADgic

Features • Position the airbag such that its supported nodes coincide with the cover.

• Any number of scaling steps can be added to shrink the airbag by moving a subset of its

nodes towards a plane.

3-10-2016 12

Confidential

PreScan & MADYMO Active Human in Pre Crash Braking scenario

MADYMO for Integrated Safety

3-10-2016 13

Confidential

Occupant and Pedestrian

Human model is designed to represent an average human under conditions characteristic for automotive safety.

High biofidelity

Parameters representing different occupant awareness and relaxation states:

Muscle activation (PMHS test, activation off)

Muscle co-contraction

Muscle reaction time

Validation (Kinematics) in frontal, lateral, rear, oblique and vertical impact for low to high severity impacts.

High biofidelity in both pre- and in-crash

Active Human Model

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Confidential

Setup Pre-crash loading

Frontal 3-point belt 1g, 3.8g

Frontal 5-point belt 0.4g, 0.7g, 15g

Lateral 5-point belt 0.5g, 7g

Rear 5-point belt 3.6g

Vertical 6g, 10g

Setup Blunt impact loading

Frontal Head 2-5.5m/s; 23.4kg

Frontal Thorax 3.3-9.9m/s; 23.4kg

Frontal Abdomen 6.9m/s, 31.4kg; 9.4m/s 61kg

Lateral Shoulder 4.5-5.5m/s; 23.4kg

Lateral Thorax 3.3- 5.9m/s; 23.4kg

Lateral Abdomen 4.43, 6.26m/s drop test

Lateral Pelvis 3.46m/s, 6.66m/s 23kg

Setup Sled loading

Frontal 3-point belt 14g peak

Lateral 6.25, 8.65 m/s

active human reaction – testing with volunteers

passive human reaction – PMHS blunt testing

passive human reaction – PMHS full scale

Active Human Model validation

3-10-2016 15

Confidential

Enables immediate use of AHM in ready-made occupant application

Demonstrates best-practice engineering MADYMO techniques

Measures the effect of pre-crash events on occupant safety in in-crash

MADYMO V7.6

AHM Application Model – update v2.0

• Application Model adapted for new release of AHM v2.0

• New pre-defined functionality built-in:

• Pre-crash braking and evasive maneuvers (motion based)

• Both driver or passenger occupant

• Parametrized geometry of driver compartment

• Optimized Motorized Seat Belt

Application Model v2.0 More functions, driver & passenger, evasive

& braking

updates v1.0 => v2.0

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Confidential

Active Human Model Examples Pre-crash braking followed by rear impact

3-10-2016 19

Confidential

Whiplash tool Injury identification

• A general consensus is building in the scientific community that the complex kinematics of the head and neck in a rear impact result in distortions of the neck.

• These distortions may be different in the three phases of neck motion in a rear impact.

• Therefore, each phase may have different injury mechanisms.

• They may even be different per occupant, depending on size, gender, age, awareness, muscle tension, etc.

• So, a whiplash is not just one kind of injury, but can be one of the neck injuries (related to muscles, ligaments, facet joint, vertebral discs or nerve tissue) that are believed to cause the whiplash symptoms or even a combination of neck injuries.

3-10-2016 20

Confidential

Whiplash tool From injury identification to whiplash probability

Injury Risk %

Occupant in correct position

Occupant bend forward

Occupant bend backward

Headrest Nominal 2 4 1

Headrest High 2 4 2

Headrest Low 2 5 1 3-10-2016 21

Confidential

Workflow

ΔV

MTarget

MBullet

Average damage

Whiplash injury probability xx%

1. Gather accident data

2. Determine average impact pulse

3. Determine occupant parameters

Head rest position Occupant gender Occupant position Seat inclination Seat NCAP rating

4. Simulate physics of whiplash case

Average pulse

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Confidential

EXAMPLE CALCULATION RESULTS

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Upper neck Fx backward [N]

NKm

Whip lash %

Confidential 3-10-2016 24