Q10 EURO NCAP 2020 HARDWARE & FE MODEL UPDATES - Jerry Wang (Ph. D) & Fuchun Zhu - Humanetics
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Q10 EURO NCAP 2020 HARDWARE & FE MODEL UPDATES Jerry Wang (Ph. D) & Fuchun Zhu
2 Contents • Part One – Brief of Q10 Euro NCAP 2020 upgrade kit • Part Two – Q10 Euro NCAP 2020 FE model updates ©2019 Confidential & Proprietary
3
Overview time line of Q10 developments
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
EU funded project Euro NCAP
EPOCh initiative
Requirements Feedback Abdomen Requirements Q10 2020
Design and Prototyping Design updates pressure sensor Validation
FE supported Trade off study
Validation and Evaluation Production integration Evaluation
Design and Prototyping
Q10 2020
Final design
Production
Hip liner
ASIS Load Cell
UNECE Regulation 129 Future harmonization
with Euro NCAP?
©2019 Confidential & Proprietary
4
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
©2019 Confidential & Proprietary
5
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
©2019 Confidential & Proprietary
6
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)
©2019 Confidential & Proprietary
Part Two: Q10 Euro NCAP 2020 FE Models
Development
MK-FO-00036C, Rev A
8
Q10 Dummy Model Development History/Status
2015 2016 2017 2018 2019
March 2018: Based on evaluation results,
Euro NCAP CWG decided for limited update
by restoring some original Q10 parts
Hardware Status
• Validation/Testing
New Q10 • Third Party Evaluation
Euro NCAP 2020
Reports to Euro NCAP, Advisory Board and Conferences Design. FE model FE model release 3rdQ 2019
available for evaluation
Q10 2020 V1.0 Concept Model V1.0 Full Prototype 2017 V1.1 V1.2
Design/FE analysis loop done in all stages of development-concept to launch!
©2019 Confidential & Proprietary
9
Q10 Euro NCAP 2020 Dummy Model v1.1
• 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)
©2019 Confidential & Proprietary
10 Q10 Euro NCAP 2020 Dummy Model v1.1 • 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 ©2019 Confidential & Proprietary
11 Q10 Euro NCAP 2020 SK Dummy Model v1.1 • 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 ©2019 Confidential & Proprietary
New Validation Tests for v1.2 Model
Planned Release Date: 9/2019
• Neck mini sled tests
• Lumbar spine mini sled tests
• Abdomen foam drop tests
• APTS pendulum impact tests
MK-FO-00036C, Rev A13
Neck Mini Sled Tests
• 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.
Neck1 (EJ8877) Neck 2 (EJ6567)
Impact
velocity With Without With cable Without
cable cable cable
Test 1 √ √ √ √
2 m/s
Test 2 √ √ √ √
Test 1 √ √ √ √
3 m/s
Test 2 √ √ √ √
Test 1 √ √ √ √
4 m/s
Test 2 √ √ √ √
Test 1 √ √ √ √
5 m/s
Test 2 √ √ √ √
Test 1 √ √ √ √
6 m/s
Test 2 √ √ √ √
©2019 Confidential & Proprietary14
Neck Mini Sled Tests
• Neck kinematics to replicate loading level seen in a vehicle test.
a
• Initial Position reference for FEA established via Laser scanning.
• Validation based on 3 independent sets of signals.
a. Ballast Acceleration & Angular velocity outputs. b
b. Upper Neck Loadcell Forces & Moments.
c
c. Lower Neck Loadcell Forces & Moments.
©2019 Confidential & Proprietary15
Neck Mini Sled Tests
Upper Neck Loads: 6 m/s (with Cable)
Test
V1.1
V1.2
• Focused on Upper Neck Loadcell signals - important for EuroNCAP injury rating.
©2019 Confidential & Proprietary16
Neck Mini Sled Tests
Lower Neck Loads: 6 m/s (with Cable)
Test
V1.1
V1.2
©2019 Confidential & Proprietary17
Neck Mini Sled Tests
Ballast Kinematics angular velocity: 6 m/s (with Cable)
Test
V1.1
V1.2
©2019 Confidential & Proprietary18
Lumbar Spine Mini Sled Tests
• 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.
Lumbar 1 (EJ2521) Lumbar 2 (EJ5778)
Impact
velocity With Without With cable Without cable
cable cable
Test 1 √ √ √ √
3 m/s
Test 2 √ √ √ √
Test 1 √ √ √ √
4 m/s
Test 2 √ √ √ √
Test 1 √ √ √ √
5 m/s
Test 2 √ √ √ √
Test 1 √ √ √ √
6 m/s
Test 2 √ √ √ √
©2019 Confidential & Proprietary19
Lumbar Spine Mini Sled Tests
• Lumbar kinematics to replicate loading level seen in a vehicle test
a
• 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. b
©2019 Confidential & Proprietary20
Lumbar Spine Mini Sled Tests
Ballast Kinematics angular velocity: 6 m/s (with Cable)
Test
V1.2
©2019 Confidential & Proprietary21
Lumbar Spine Mini Sled Tests
Loadcell loads: 6 m/s (with Cable)
Test
V1.2
©2019 Confidential & Proprietary22
Abdomen Foam Drop Tests
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.
Upper Neck Force-Z
Stiffer Abdomen
Tuned (softer) Abdomen
Abdomen Insert
©2019 Confidential & Proprietary23
Abdomen Foam Drop Tests
• Component level tests with isolated the abdomen;
• Total of 27 tests were executed at multiple speeds;
• Hardware variability-three test subjects.
Impact Abdomen 1 Abdomen 2 Abdomen 3
velocity (EJ4177) (DY 7779) (Q10-10001)
Test 1 √ √ √
1.55 m/s Test 2 √ √ √
Test 3 √ √ √
Test 1 √ √ √
2.51 m/s Test 2 √ √ √
Test 3 √ √ √
Test 1 √ √ √
3.38 m/s Test 2 √ √ √
Test 3 √ √ √
Drop Tower Setup
©2019 Confidential & Proprietary24
Abdomen Foam Drop Tests (without skin)
Drop speed:
1.55m/s Test
2.51 m/s V1.1
3.38 m/s V1.2
©2019 Confidential & Proprietary25
Abdomen Foam Drop Tests (with skin)
Drop speed:
1.55m/s Test
2.51 m/s V1.1
3.38 m/s V1.2
©2019 Confidential & Proprietary26 APTS sensor FE model development • 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 ©2019 Confidential & Proprietary
27
APTS sensor FE model development
• Sensor validation based on Component Tests – multiple speeds
APTS 50 mm
test @ 0.74 m/s
test @ 1.13 m/s
FE in Red
• Peak pressure (bar) values/timing profile of the sensor
match with the validation domain of the ECE-R129
legislation requirements.
©2019 Confidential & Proprietary28
Full Dummy Validations: Thorax Frontal 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
Tilt sensor outputs
©2019 Confidential & Proprietary29
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
Tilt sensor outputs
©2019 Confidential & Proprietary30
Full Dummy Validations: Pelvis Lateral Impact
• FE data validation based on
o Pelvis 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 alignment of pendulum
Tilt sensor outputs
©2019 Confidential & Proprietary31
In Summary
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/APTS
Full body validations – Thorax/Pelvis/Abdomen/Femur
Address customer feedbacks
Meet Euro NCAP 2020 specifications
©2019 Confidential & ProprietaryThank you for your attention
Acknowledges: Q10 Euro NCAP 2020 FE model
development team members
Renuka Jagadish
Vinit Manjarekar
Apoorva Lakshminarayana
MK-FO-00036C, Rev AYou can also read
