Report 106310 Concept Design of a Crash Management System for ...

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3 Crash Management System 12 Fig. 3-7: Intrusions into the car’s firewall after the Euro NCAP offset crash Acceleration [g] 200 175 150 125 100 75 50 25 0 Max = 370 mm Intrusion [mm] 200 150 100 50 0 Rear seat left side Rear seat right side 0 20 40 60 80 100 120 140 160 Time [ms] Fig. 3-8: Acceleration at the car’s rear seats during the Euro NCAP offset crash
3 Crash Management System 13 Energy [kJ] 200 160 120 80 40 0 0 20 40 60 80 100 120 140 160 Fig. 3-9: Energy absorption behaviour in Euro NCAP offset crash 3.2 Concept Design Time [ms] Compared to mild steel, extrusion-based aluminium bumper systems offer approximately 45- 50 % weight saving with similar or better crash performance [WEL06]. But aluminium crash management systems also compare very well with crash management systems made using modern high strength steel grades because of the significantly higher specific energy absorption capacity of aluminium alloys specifically developed for optimum crash performance. For this reason, aluminium is widely used for crash structures in passenger cars. The application of extruded crash bumpers with crash boxes is a common way to realise such systems. Fig. 3-10 shows an example. These systems are characterised by their high effectiveness and low complexity. Fig. 3-10: Extruded bumper beam with crash boxes [GIL04] Total amount of absorbed energy Energy absorbed by car Energy absorbed by barrier To further increase the effectiveness of crash management systems honeycomb structures as shown in Fig. 3-11 can be used. The energy absorption potential of these structures is higher than that of simple extrusion profiles. The disadvantages regarding the manufacturing and joining complexity, however, avoid a higher market penetration of this technology.
Page 1 and 2: Concept Design of a Crash Managemen
Page 3 and 4: Contents 3 Contents 1 Introduction
Page 5 and 6: 2 Truck Models 5 2 Truck Models The
Page 7 and 8: 2 Truck Models 7 Fig. 2-4: Advanced
Page 9 and 10: 3 Crash Management System 9 1000 mm
Page 11: 3 Crash Management System 11 Peak I
Page 15 and 16: 3 Crash Management System 15 To ass
Page 17 and 18: 3 Crash Management System 17 Fig. 3
Page 19 and 20: 3 Crash Management System 19 Crash
Page 21 and 22: 3 Crash Management System 21 Volvo
Page 23 and 24: 3 Crash Management System 23 The co
Page 25 and 26: 3 Crash Management System 25 Force
Page 27 and 28: 3 Crash Management System 27 maximu
Page 29 and 30: 3 Crash Management System 29 is imp
Page 31 and 32: 3 Crash Management System 31 3.6 We
Page 33 and 34: 5 Literature 33 5 Literature [ADA95
Page 35 and 36: 5 Literature 35 [VTN09] N. N. Truck
Page 37 and 38: 6 Appendix 37 Acceleration [g] 250
Page 39 and 40: 6 Appendix 39 Energy [kJ] 225 Total
Page 41 and 42: 6 Appendix 41 Fig. 6-9: Intrusions
Page 43 and 44: 6 Appendix 43 Force [kN] 150 100 50

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