Comparative biofidelity of the Hybrid III and THOR 50th male ATDs under three restraint conditions during frontal sled tests.

OBJECTIVE: The purpose of this study was to provide a whole-body biofidelity assessment of the Hybrid III (HIII) and THOR 50th percentile male anthropomorphic test devices (ATDs) during frontal sled tests, incorporating data from kinematics, chest deflection, and test buck reaction load cells. Additionally, the accuracy of the injury risk prediction capabilities for each ATD was evaluated against injuries observed in matched postmortem human surrogate (PMHS) tests. METHODS: Sled tests, designed to simulate a United States New Car Assessment Program (US-NCAP) frontal test, were conducted using the HIII, THOR, and 8 approximately 50th percentile male PMHS under 3 restraint conditions. The test buck was instrumented with load cells on the steering column, knee bolster supports, and foot supports. ATD and PMHS reaction force-time histories were quantitatively compared using the ISO/TS-18571 objective rating metric. Previously published biofidelity analyses of kinematic and chest deflection data from the same tests were combined with the reaction force analyses to perform an overall assessment of the comparative biofidelity of each ATD. Injury risk predictions from existing HIII and proposed THOR injury risk curves for the US-NCAP were compared to observed injuries. RESULTS: For the reaction forces, the HIII and THOR had similar levels of biofidelity on average, except for 2 locations. The HIII produced more biofidelic knee bolster support forces, and the THOR lap belt forces were more biofidelic. The comparative biofidelity of the ATDs also varied by body region. The THOR head response was more biofidelic, whereas the HIII thorax and lower extremity responses had higher biofidelity. When all body regions were pooled, the HIII was more biofidelic, but differences between ATDs were generally small. Both ATDs were able to predict the observed injuries, except for the HIII chest, HIII neck, and THOR neck, all of which underpredicted PMHS injury outcomes. CONCLUSIONS: This study revealed that biofidelity assessed through response time histories and accuracy of injury risk predictions do not always align. Specifically, the HIII had marginally better time history biofidelity, whereas the THOR had better injury prediction. However, not all THOR responses could be fully assessed, so more work is needed to assess the THOR in complex loading environments.

Evaluation of Hybrid III and THOR-M neck kinetics and injury risk under various restraint conditions during full-scale frontal sled tests.

OBJECTIVE: The objective of this research was to compare the kinetics and predicted injury risks of the Hybrid III (HIII) and Test device for Human Occupant Restraint (THOR)-M necks during full-scale frontal sled tests under 3 safety restraint conditions: knee bolster (KB), knee bolster and steering wheel airbag (KB/SWAB), and knee bolster airbag and steering wheel airbag (KBAB/SWAB). METHODS: Twelve sled tests were performed for the HIII and THOR-M, and 8 matched sled tests were performed using postmortem human surrogates (PMHSs). The tests were designed to match the 2012 Toyota Camry New Car Assessment Program (NCAP) full-scale crash test. Upper and lower neck forces and moments were collected from the HIII and THOR-M load cells. Inverse dynamics was used to calculate PMHS upper neck forces and moments from acceleration data until the time of head contact. The PMHSs experienced head contact with the SWAB before appreciable neck loading occurred. Therefore, PMHS neck forces and moments were only compared to the HIII and THOR-M for the KB condition. Neck injury risks were calculated for the HIII and THOR-M and were compared to the injuries observed for the PMHSs. RESULTS: The HIII had greater upper and lower neck shear forces than the THOR-M, whereas both surrogates had similar upper and lower neck axial forces. The HIII also experienced greater peak upper neck bending moments than the THOR-M, which experienced negligible upper neck bending moments. Before head contact, the PMHSs experienced upper neck flexion, and the HIII experienced extension. The HIII and THOR-M injury risk curves predicted less than a 50% risk of an Abbreviated Injury Scale (AIS) 3+ injury. No AIS 3+ neck injuries were observed for the PMHS tests, but at least one AIS 2 injury was observed per condition. CONCLUSIONS: The results of this study showed that the HIII and THOR-M had different neck kinetics for these restraint conditions. In particular, the THOR-M experienced lower upper neck shear forces and bending moments. These differences are likely due to the very different neck designs of the anthropomorphic test dummies (ATDs), particularly the increased compliance of the THOR-M neck. Despite these differences, both ATDs still predicted a similar risk of AIS 3+ neck injury.

Occupant kinematics of the Hybrid III, THOR-M, and postmortem human surrogates under various restraint conditions in full-scale frontal sled tests.

OBJECTIVE: The objective of this research was to compare the occupant kinematics of the Hybrid III (HIII), THOR-M, and postmortem human surrogates (PMHS) during full-scale frontal sled tests under 3 safety restraint conditions: knee bolster (KB), knee bolster and steering wheel airbag (KB/SWAB), and knee bolster airbag and steering wheel airbag (KBAB/SWAB). METHODS: A total of 20 frontal sled tests were performed with at least 2 tests performed per restraint condition per surrogate. The tests were designed to match the 2012 Toyota Camry New Car Assessment Program (NCAP) full-scale crash test. Rigid polyurethane foam surrogates with compressive strength ratings of 65 and 19 psi were used to simulate the KB and KBAB, respectively. The excursions of the head, shoulders, hips, knees, and ankles were collected using motion capture. Linear acceleration and angular velocity data were also collected from the head, thorax, and pelvis of each surrogate. Time histories were compared between surrogates and restraint conditions using ISO/TS 18571. RESULTS: All surrogates showed some degree of sensitivity to changes in restraint condition. For example, the use of a KBAB decreased the pelvis accelerations and the forward excursions of the knees and hips for all surrogates. However, these trends were not observed for the thorax, shoulders, and head, which showed more sensitivity to the presence of a SWAB. The average scores computed using ISO/TS 18571 for the HIII/PMHS and THOR-M/PMHS comparisons were 0.527 and 0.518, respectively. The HIII had slightly higher scores than the THOR-M for the excursions (HIII average = 0.574; THOR average = 0.520). However, the THOR-M had slightly higher scores for the accelerations and angular rates (HIII average = 0.471; THOR average = 0.516). CONCLUSIONS: The data from the current study showed that both KBABs and SWABs affected the kinematics of all surrogates during frontal sled tests. The results of the objective rating analysis indicated that the HIII and THOR-M had comparable overall biofidelity scores. The THOR-M slightly outperformed the HIII for the acceleration and angular velocity data. However, the HIII scored slightly better than the THOR-M for the excursion data. The most notable difference in biofidelity was for the knee excursions, where the HIII had a much higher average ISO score. Only the biofidelity of the HIII and THOR-M with regard to occupant kinematics was evaluated in this study; therefore, future work will evaluate the biofidelity of the ATDs in terms of lower extremity loading, thoracic response, and neck loading.

Assessment of Thoracic Response and Injury Risk Using the Hybrid III, THOR-M, and Post-Mortem Human Surrogates under Various Restraint Conditions in Full-Scale Frontal Sled Tests.

A total of 20 full-scale frontal sled tests were conducted using the Hybrid III (HIII), THOR-M and post-mortem human surrogates (PMHSs) to evaluate the thoracic biofidelity of the HIII and THOR-M under various belted restraint conditions. Each surrogate was tested under three belted restraint conditions: knee bolster, knee bolster and steering wheel airbag, and knee bolster airbag and steering wheel airbag. In order to assess the relative biofidelity of each ATD, external thoracic deflections were quantitatively compared between the ATDs and PMHSs using an objective rating metric. The HIII had slightly higher biofidelity than the THOR-M for the external thoracic deflections. Specifically, the THOR-M lower chest was more compliant compared to the other surrogates. However, the THOR-M exhibited expansion of the lower chest opposite belt loading, which was also observed to some degree in the PMHSs. The efficacy of the current injury risk prediction instrumentation and criteria were also evaluated for each surrogate. The THOR-M and its proposed injury risk criteria predicted the injuries observed in the PMHS tests better than the HIII. The PMHS injury criteria over-predicted the amount of chest deflection necessary to produce a severe injury and, consequently, under-predicted injury risk. The results of this study indicate that further testing should be performed to evaluate the biofidelity of the THOR-M thorax under more conditions. Furthermore, current thoracic injury risk criteria, which were developed using censored data, may not be effective at predicting injuries for all restraints and experimental conditions.

Neck forces and moments of human volunteers and post mortem human surrogates in low-speed frontal sled tests.

OBJECTIVE: The objective of this study was to quantify the effects of active muscles (e.g. conscious bracing, resting tone, and reflex response) and acceleration severity on the neck forces and moments generated during low-speed frontal sled tests with adult male human volunteers and post mortem human surrogates (PMHSs). METHODS: A total of 24 frontal sled tests were analyzed including male volunteers of approximately 50th percentile height and weight (n = 5) and PMHSs (n = 2). The tests were performed at two acceleration severities: low (∼2.5 g, Δv ≈ 5 kph) and medium (∼5.0 g, Δv ≈ 10 kph). Each volunteer was exposed to two impulses at each severity, one relaxed and one braced, while each PMHS was exposed to one impulse at each severity. Linear acceleration and angular velocity of the head were measured at a sampling rate of 20kHz, then filtered using SAE Channel Frequency Class 180 and 60, respectively, and transformed to the head center of gravity (CG). The location of the head CG, external auditory meatus, and occipital condyle (OC) were approximated using pretest photos and literature values. Neck forces (Fx and Fz) and sagittal plane moments (My) were calculated at the OC by applying the equations of dynamic equilibrium to the head. RESULTS: Peak Fx, Fz, and My increased significantly with increasing acceleration severity (p < 0.1). Minimal differences were observed between the magnitudes of the peak forces and moments for each subject type. Qualitatively, differences in the timing of peak neck forces and moments and the overall shape of the time histories were evident. Maximum Fx, Fz, and My occurred earliest in the event for the braced volunteers and latest for the PMHSs. However, these differences were not supported statistically for the volunteers (p > 0.05). The timing of neck loading was visibly augmented by the increased stiffness of the volunteer necks as a result of muscle activation. Although differences were observed between the volunteer muscle conditions, the volunteer subsets were more similar to each other than the PMHSs. CONCLUSIONS: This study examined the effects of active muscles, in the form of conscious and reflexive muscle activity, on the biomechanical response of occupants in low-speed frontal sled tests. Although active bracing did not result in significantly different peak neck loads or moments, the timing of these peak values were affected by muscle condition. The findings of this study provide insight to the kinetics experienced during low-speed sled tests and are important to consider when refining and validating computational models and ATDs used to assess injury risk in automotive collisions.

Non-censored rib fracture data during frontal PMHS sled tests.

OBJECTIVE: The purpose of this study was to obtain non-censored rib fracture data due to three-point belt loading during dynamic frontal post-mortem human surrogate (PMHS) sled tests. The PMHS responses were then compared to matched tests performed using the Hybrid-III 50(th) percentile male ATD. METHODS: Matched dynamic frontal sled tests were performed on two male PMHSs, which were approximately 50(th) percentile height and weight, and the Hybrid-III 50(th) percentile male ATD. The sled pulse was designed to match the vehicle acceleration of a standard sedan during a FMVSS-208 40 kph test. Each subject was restrained with a 4 kN load limiting, driver-side, three-point seatbelt. A 59-channel chestband, aligned at the nipple line, was used to quantify the chest contour, anterior-posterior sternum deflection, and maximum anterior-posterior chest deflection for all test subjects. The internal sternum deflection of the ATD was quantified with the sternum potentiometer. For the PMHS tests, a total of 23 single-axis strain gages were attached to the bony structures of the thorax, including the ribs, sternum, and clavicle. In order to create a non-censored data set, the time history of each strain gage was analyzed to determine the timing of each rib fracture and corresponding timing of each AIS level (AIS = 1, 2, 3, etc.) with respect to chest deflection. RESULTS: Peak sternum deflection for PMHS 1 and PMHS 2 were 48.7 mm (19.0%) and 36.7 mm (12.2%), respectively. The peak sternum deflection for the ATD was 20.8 mm when measured by the chest potentiometer and 34.4 mm (12.0%) when measured by the chestband. Although the measured ATD sternum deflections were found to be well below the current thoracic injury criterion (63 mm) specified for the ATD in FMVSS-208, both PMHSs sustained AIS 3+ thoracic injuries. For all subjects, the maximum chest deflection measured by the chestband occurred to the right of the sternum and was found to be 83.0 mm (36.0%) for PMHS 1, 60.6 mm (23.9%) for PMHS 2, and 56.3 mm (20.0%) for the ATD. The non-censored rib fracture data in the current study (n = 2 PMHS) in conjunction with the non-censored rib fracture data from two previous table-top studies (n = 4 PMHS) show that AIS 3+ injury timing occurs prior to peak sternum compression, prior to peak maximum chest compression, and at lower compressions than might be suggested by current PMHS thoracic injury criteria developed using censored rib fracture data. In addition, the maximum chest deflection results showed a more reasonable correlation between deflection, rib fracture timing, and injury severity than sternum deflection. CONCLUSIONS: Overall, these data provide compelling empirical evidence that suggests a more conservative thoracic injury criterion could potentially be developed based on non-censored rib fracture data with additional testing performed over a wider range of subjects and loading conditions.

Quantification of toy sword kinematics with male pediatric volunteers.

While extensive research in toy safety has been performed, data is unavailable with regard to the kinematics of toy swords. To improve upon design criteria, knowledge of a child’s physical capacity is essential. The purpose of this study was to quantify the linear and angular velocities generated by children swinging toy swords. A total of 36 male subjects, ages 4-14 years old, each participated in one trial. Subjects were instructed to swing a toy sword as fast and hard as possible for ~10 seconds. A Vicon motion analysis system was used to capture subject and sword kinematics. Peak linear and angular sword velocities were calculated. A strong correlation was identified between age and velocity. The 8-14 year old males were not significantly different. The 4 year old males generated significantly lower velocities than the 8-14 year old males. The 6 year old males produced significantly lower velocities than the 10- 14 year old males. It was concluded that age had a significant effect on the linear and angular velocities generated by children. The trends observed within this study likely result from typical pediatric and adolescent development. By accounting for the physical capabilities of a specific population, toys can be designed with decreased inherent risks of injury.

Human occupants in low-speed frontal sled tests: effects of pre-impact bracing on chest compression, reaction forces, and subject acceleration.

OBJECTIVES: The purpose of this study was to investigate the effects of pre-impact bracing on the chest compression, reaction forces, and accelerations experienced by human occupants during low-speed frontal sled tests. METHODS: A total of twenty low-speed frontal sled tests, ten low severity (∼2.5g, Δv=5 kph) and ten medium severity (∼5g, Δv=10 kph), were performed on five 50th-percentile male human volunteers. Each volunteer was exposed to two impulses at each severity, one relaxed and the other braced prior to the impulse. A 59-channel chestband, aligned at the nipple line, was used to quantify the chest contour and anterior-posterior sternum deflection. Three-axis accelerometer cubes were attached to the sternum, 7th cervical vertebra, and sacrum of each subject. In addition, three linear accelerometers and a three-axis angular rate sensor were mounted to a metal mouthpiece worn by each subject. Seatbelt tension load cells were attached to the retractor, shoulder, and lap portions of the standard three-point driver-side seatbelt. In addition, multi-axis load cells were mounted to each interface between the subject and the test buck to quantify reaction forces. RESULTS: For relaxed tests, the higher test severity resulted in significantly larger peak values for all resultant accelerations, all belt forces, and three resultant reaction forces (right foot, seatpan, and seatback). For braced tests, the higher test severity resulted in significantly larger peak values for all resultant accelerations, and two resultant reaction forces (right foot and seatpan). Bracing did not have a significant effect on the occupant accelerations during the low severity tests, but did result in a significant decrease in peak resultant sacrum linear acceleration during the medium severity tests. Bracing was also found to significantly reduce peak shoulder and retractor belt forces for both test severities, and peak lap belt force for the medium test severity. In contrast, bracing resulted in a significant increase in the peak resultant reaction force for the right foot and steering column at both test severities. Chest compression due to belt loading was observed for all relaxed subjects at both test severities, and was found to increase significantly with increasing severity. Conversely, chest compression due to belt loading was essentially eliminated during the braced tests for all but one subject, who sustained minor chest compression due to belt loading during the medium severity braced test. CONCLUSIONS: Overall, the data from this study illustrate that muscle activation has a significant effect on the biomechanical response of human occupants in low-speed frontal impacts.

Kinetic and kinematic responses of post mortem human surrogates and the Hybrid III ATD in high-speed frontal sled tests.

Despite improvements in vehicle design and safety technologies, frontal automotive collisions continue to result in a substantial number of injuries and fatalities each year. Although a considerable amount of research has been performed on PMHSs and ATDs, matched dynamic whole-body frontal testing with PMHSs and the current ATD aimed at quantifying both kinetic and kinematic data in a single controlled study is lacking in the literature. Therefore, a total of 4 dynamic matched frontal sled tests were performed with three male PMHSs and a Hybrid III 50th percentile male ATD (28.6g, Δv=40 kph). Each subject was restrained using a 4 kN load limiting, driver-side, 3-point seatbelt. Belt force was measured for the lap belt and shoulder belt. Reaction forces were measured at the seat pan, seat back, independent foot plates, and steering column. Linear head acceleration, angular head acceleration, and pelvic acceleration were measured for all subjects. Acceleration of C7, T7, T12, both femurs, and both tibias were also measured for the PMHSs. A Vicon motion analysis system, consisting of 12 MX-T20 2 megapixel cameras, was used to quantify subject 3D motion (±1 mm) at a rate of 1 kHz. Excursions of select anatomical regions were normalized to their respective initial positions and compared by test condition and between subject types. Notable discrepancies were observed in the responses of the PMHSs and the ATD. The reaction forces and belt loading for the ATD, particularly foot plate, seat back, steering column, and lap belt forces, were not in agreement with those of the PMHSs. The forward excursions of the ATD were consistently within those of the PMHSs with the exception of the left upper extremity. This could potentially be due to the known limitations of the Hybrid III ATD shoulder and chest. The results presented herein demonstrate that there are some limitations to the current Hybrid III ATD under the loading conditions evaluated in the current study. Overall, this study presents a comprehensive data set of belt forces, reaction forces, accelerations, and bilateral displacement data that can be used to evaluate the performance of ATDs and validate computational models.

Occupant kinematics in low-speed frontal sled tests: Human volunteers, Hybrid III ATD, and PMHS.

A total of 34 dynamic matched frontal sled tests were performed, 17 low (2.5g, Δv=4.8kph) and 17 medium (5.0g, Δv=9.7kph), with five male human volunteers of approximately 50th percentile height and weight, a Hybrid III 50th percentile male ATD, and three male PMHS. Each volunteer was exposed to two impulses at each severity, one relaxed and one braced prior to the impulse. A total of four tests were performed at each severity with the ATD and one trial was performed at each severity with each PMHS. A Vicon motion analysis system, 12 MX-T20 2 megapixel cameras, was used to quantify subject 3D kinematics (±1mm) (1kHz). Excursions of select anatomical regions were normalized to their respective initial positions and compared by test condition and between subject types. The forward excursions of the select anatomical regions generally increased with increasing severity. The forward excursions of relaxed human volunteers were significantly larger than those of the ATD for nearly every region at both severities. The forward excursions of the upper body regions of the braced volunteers were generally significantly smaller than those of the ATD at both severities. Forward excursions of the relaxed human volunteers and PMHSs were fairly similar except the head CG response at both severities and the right knee and C7 at the medium severity. The forward excursions of the upper body of the PMHS were generally significantly larger than those of the braced volunteers at both severities. Forward excursions of the PMHSs exceeded those of the ATD for all regions at both severities with significant differences within the upper body regions. Overall human volunteers, ATD, and PMHSs do not have identical biomechanical responses in low-speed frontal sled tests but all contribute valuable data that can be used to refine and validate computational models and ATDs used to assess injury risk in automotive collisions.

Effects of bracing on human kinematics in low-speed frontal sled tests.

Continued development of computational models and biofidelic anthropomorphic test devices (ATDs) necessitates further analysis of the effects of bracing on an occupant's biomechanical response in automobile collisions. A total of 20 dynamic sled tests were performed, 10 low (2.5 g, Δv = 4.8 kph) and 10 medium severity (5.0 g, Δv = 9.7 kph), with five male human volunteers of approximately 50th percentile male height and weight. Each volunteer was exposed to two impulses at each severity, one relaxed and one braced prior to the impulse. A Vicon motion analysis system, 12 MX-T20 2 megapixel cameras, was used to quantify subject 3D kinematics (±1 mm) (1 kHz). Excursions of select anatomical regions were normalized to their respective initial positions and compared by test condition. At the low severity, bracing significantly reduced (p < 0.05) the forward excursion of the knees, hips, elbows, shoulders, and head (average 35-70%). At the medium severity, bracing significantly reduced (p < 0.05) the forward excursion of the elbows, shoulders, and head (average 36-69%). Although not significant, bracing at the medium severity considerably reduced the forward excursion of the knees and hips (average 18-26%). This study illustrates that bracing has a significant influence on the biomechanical response of human occupants in frontal sled tests and provides novel biomechanical data that can be used to refine and validate computational models and ATDs used to assess injury risk in automotive collisions.