modeFRONTIER as a Platform for Innovation in Automotive FMVSS 201u Design Robustness Automation

During product development of a passenger vehicle, occupant protection is one of the most important aspects. National Highway Traffic Safety Administration (NHTSA) established the Federal Motor Vehicle Safety Standard 201u regarding upper interior head impact (FMVSS 201U). In a self-certification letter sent to NTHSA, the OEM documents the status of each vehicle to be sold in the U.S. market.

Ford has generated a modeFRONTIER innovative solution to increase the Interior design robustness for FMVSS 201u regulation using a novel, integrated, automated tool.

modeFRONTIER stands as a multi cross functional software and scripting platform in order to automatically process a large number of head form target points combining locations and head form horizontal angles to identify the worst case in a significant time reduction. FMVSS 201u is designed with the purpose of evaluating the interaction of an occupant in a roll over accident hitting the interior trim when he/she is unbelted, NHTSA have designed a test procedure to calculate impact target point locations based on probabilistic studies.

New trends to include a lower roof panel due to styling and fuel efficiency proposes additional interior room, this reduces the packaging space for including head impact absorption energy countermeasures, while maintaining opposite upper body structural stiffness for roof crush requirement.

Initial targeting is defined in accordance with the FMVSS regulation, this can be run automatically using the developed tool, nevertheless there are target points that could be relocated since the head form might not be positioned due to complex geometry. In this case modeFRONTIER allows to create as many extra target points as needed in order to relocate the original target points in a reduced time of 90%. FMVSS 201u virtual verification runs on cross functional software tools to reach the point where analysis and conclusions can be made. Ansa Scripting generates the target points, and positions the head form. Head impact simulation is performed by LS Dyna solver. The results are processed in Meta Post to evaluate Head Injury Criterion (HIC) and automate the impact animation.