1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
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4、SA) Fax: 724-776-0790 Email: CustomerServicesae.orgSAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/J2926_201108SURFACEVEHICLEINFORMATIONREPORTJ2926 AUG2011 Issued 2011-08 Rollover Testing Methods
5、 RATIONALE Inquiries from industry have been received requesting information on rollover testing procedures and approaches that have been utilized. This document provides background as to the techniques that have been utilized for rollover testing and evaluation of rollover protection systems at the
6、 vehicle and component levels. TABLE OF CONTENTS 1. SCOPE 52. REFERENCES 53. TEST METHODS FOR FULL VEHICLE TESTING 53.1 Dolly Rollover Test Procedure 53.1.1 Background . 53.1.2 Test Procedure 63.2 Rollover Impact Test Systems Designed for Initial Impact Control . 73.2.1 Controlled Rollover Impact Sy
7、stem (CRIS) Test 73.2.2 Jordan Rollover System (JRS) 83.3 Ramped Rollover Tests . 93.3.1 Background . 93.4 Curb Trip Methodologies . 123.4.1 Critical Sliding Velocity Mode 123.4.2 Lateral Curb Tripping 133.4.3 Oblique Curb Trip 143.5 Deceleration Rollover Sleds 143.6 Ditch/Embankment 163.7 Soil Trip
8、 Testing 183.7.1 Roller Coaster Dolly (RCD) . 203.8 Maneuver Induced Rollover Testing . 204. COMPONENT TEST METHODOLOGIES 214.1 Rollover Restraint Tester (RRT) . 214.2 Key Safety Inc. Device 224.3 Rotational Test Benches . 224.4 Dynamic Rollover Fixture (DRF) . 234.5 Rollover Component Sled (ROCS) F
9、ixture . 244.6 Lateral Rollover Simulator (LRS) 254.7 Spin Fixture Testing 254.8 Linear Impactor Testing 264.9 Vehicle Roof Strength Test Procedure . 274.10 Inverted Drop Test 27Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted wi
10、thout license from IHS-,-,-SAE J2926 Issued AUG2011 Page 2 of 48 5. CAE TESTING METHODS . 275.1 Rigid Body Based Simulations (e.g. MADYMO, ATB, DYNAMAN) 285.2 Finite Element Methods (e.g. LS-DYNA, RADIOSS, PAMCRASH) . 295.3 Test Conditions Selection and Adjustment . 305.4 Sensor Testing 305.5 Restra
11、int and Structure Development . 315.6 Impact Conditions and Roof Structure 325.7 Vehicle Rollover Sequence Modeling Including the Effects of the Suspension . 335.8 Restraint Evaluation 355.9 Bus Rollover Simulations 365.10 Curb and Soil Trip Rollover . 375.11 Side Curtain Development 385.12 Mining V
12、ehicle Protection Systems . 395.13 Heavy Trucks in Rollovers 405.14 Padding Effects on Human Neck Injury 405.15 Drop Testing 416. DISCUSSION 417. NOTES 417.1 Marginal Indicia . 41APPENDIX A REFERENCE MATERIALS 42 Copyright SAE International Provided by IHS under license with SAENot for ResaleNo repr
13、oduction or networking permitted without license from IHS-,-,-SAE J2926 Issued AUG2011 Page 3 of 48 INTRODUCTION At SAE there have been inquiries regarding the common techniques being used for evaluation of rollover crashworthiness. This report contains a brief description of the methods being utili
14、zed for rollover crashworthiness evaluation, as well as references for additional follow-up. The materials are organized to reflect: Full vehicle testing methods (Section 3) Component testing methods (Section 4) Computer Aided Engineering (CAE) testing methods (Section 5) Our work was facilitated by
15、 the literature created by Chou, McCoy and Leigh at Ford Motor Company, who graciously have provided their work to us (Chou, 2005b). The literature has been revised to reflect information that has been published or become available since that time. The authors wish to acknowledge our appreciation to
16、 the previous authors for sharing their document, which allowed us to expand upon their initial work. The present document cannot include all test methodologies that have been used in the past and does not refer to all published papers that have been written on the subject. Omission of a paper or pa
17、rticular methodology should not be construed as invalidating any work not included, nor is the inclusion of a method intended to endorse or authenticate the use of any particular method. This document is intended to be a living document that evolves as new methodologies are developed. It is hoped th
18、at the current document provides some additional insight into the current state of methods available for use in the development of improved vehicle rollover crashworthiness. By way of background, there are numerous rollover configurations that occur in the accident environment. For example, Obrien-M
19、itchell (2007) reported that more than 60% of rollover initiations were tripped as shown in Figure A and Digges (1991) reported that more than 90% of vehicle rollovers occur about the vehicle longitudinal axis. FIGURE A - DISTRIBUTION OF ROLLOVER INITIATION TYPE IN THE 2001-2005 NASS-CDS Viano (2004
20、) reported on a breakdown of test types and their relationship with rollover crashes as shown in Figure B. The study of field crashes involved analysis of databases from crashes in the United States, United Kingdom, Australia and Germany (Parenteau et al. 2001a, 2003). This work provided a global pe
21、rspective on the relevant rollover crashes. As shown in Figure B, nine laboratory tests cover 93% of the field incidence of rollover crashes for passenger cars and 89% for LTVs. This addressed 84% of serious injury rollovers. Details on the methodology used to determine these fractions are covered i
22、n the paper by Parenteau et al. (2001a). The data shown in Figure B involve three columns of frequency percentages. The left represents the NASS-CDS rollover categories used to classify rollover crashes and their field prevalence. The middle column represents the type of laboratory rollover crashes
23、considered. The analysis method determined the fraction of real-world rollovers that would be addressed by these laboratory tests. The right column is the final fraction of field relevance of the laboratory tests. This includes the frequency of rollover crashes and serious injury ofbelted occupants.
24、 The results have been updated with newer NASS-CDS data, but the main conclusion was that a series of rollover tests is needed to cover the majority of real-world injuries in field rollover crashes. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or ne
25、tworking permitted without license from IHS-,-,-SAE J2926 Issued AUG2011 Page 4 of 48 FIGURE B - ANALYSIS OF TEST TYPES WITH ROLLOVER CRASH TYPES FOR PASSENGER CARS AND LTVS Numerous papers exist with regard to rollover crash characterization where examination of various aspects of interest has been
26、 conducted. DEFINITIONS For ease of discussion the following terms are identified in terms of general usage and in the context of rollover testing: Leading Side (sometimes referred to as Near Side) - The side of the vehicle that is initially going into the roll; so a driver side leading roll describ
27、es an orientation that in the initial part of the rollover the driver side is starting to move toward theground (while the passenger side would be moving upward). Trailing Side (sometimes referred to as Far Side) - The side of the vehicle that is following the leading side going into the roll; so in
28、 driver side leading roll the passenger side would be the trailing side. Curb Trip - A rollover that occurs when a vehicle moving laterally slides into a length of raised curb; the rollover is initiated by the impact of the wheels with a raised curb. Pitch-over - An end-over-end type of rollover, su
29、ch as might occur when a vehicle with a longitudinal velocity goes over a drop off.Soil Trip - A rollover that initiates as a result of the furrowing forces from the buildup of soil by the wheels as the vehiclemoves laterally on a dirt surface. On-road Rollover - A rollover that initiates on the roa
30、d surface. Un-tripped Rollover - A rollover that initiates on the road surface as a result of friction forces between the tires and the road surface. Corkscrew - A rollover test where the rollover motion is initiated by a vehicle moving with one side of its wheels on an inclined ramp, resulting in a
31、 spiraling-type motion during the rollover. Trip-over - When the lateral motion of the vehicle is suddenly slowed or stopped inducing a rollover. The opposing force may be produced by a curb, pothole or pavement that the vehicle wheels dig into. Turn-over - When centrifugal forces from a sharp turn
32、or vehicle rotation are resisted by normal surface friction (most common for vehicle with higher cg). The surface includes pavement surface and gravel, grass, dirt and there is no furrowing, gouging at the point of impact. If rotation and/or surface friction causes a trip, the rollover is classified
33、 as a turn-over.Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2926 Issued AUG2011 Page 5 of 48 Fall-over - When the surface on which the vehicle is traveling slopes downward in the direction o
34、f vehicle movement so that the center of gravity (cg) becomes outboard of its wheels. The distinction between this code and turn-over is a negative slope. Flip-over - When a vehicle is rotated around its longitudinal axis by a ramp-like object such as a turned-down guardrail or the back slope of a d
35、itch. The vehicle may be in yaw when it comes in contact with a ramp-like object. Bounce-over - When a vehicle rebounds off of a fixed object and overturns as a consequence. The rollover must occur in close proximity to the object from which it is deflected. 1. SCOPE The scope of this document is to
36、 provide an overview of the techniques found in the published literature for rollover testing and rollover crashworthiness evaluation at the vehicle and component levels. It is not a comprehensive literature review, but rather illustrates the techniques that are in use or have been used to evaluate
37、rollover crashworthiness-related issues. 2. REFERENCES Appendix A contains a list of references and other literature on the subject. 3. TEST METHODS FOR FULL VEHICLE TESTING 3.1 Dolly Rollover Test Procedure 3.1.1 Background According to Wilson and Gannon (1972), the Dolly Rollover Test Procedure wa
38、s introduced by Mercedes-Benz in a presentation to the SAE Impact and Rollover Subcommittee in 1970. The dolly rollover test was incorporated into FMVSS 208 in 1971. SAE Recommended Practice SAE J2114 “Dolly Test Procedure” was adopted in 1993. The SAE J2114 rollover test procedure is shown in Figur
39、e 1. A close up of the dolly fixture is shown in Figure 1A. Based on literature review SAE J2114 has been used in evaluation of the following: Restraint system performance Rollover occupant protection system performance Occupant kinematics and ejection Vehicle structural integrity such as roof crush
40、 performance Vehicle rollover kinematics Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2926 Issued AUG2011 Page 6 of 48 FIGURE 1 - SAE J2114 ROLLOVER TEST MODE (COURTESY OF AUTOLIV)FIGURE 1A -
41、 CLOSE UP OF J2114 DOLLY ROLLOVER FIXTURE (COURTESY OF EXPONENT)James et al. (1997) reported that the SAE J2114 rollover test procedure is one of the most widely used rollover test methodologies because it provides a measure of control over the trip location and the vehicle roll direction. In spite
42、of a measure of control over the trip location and vehicle roll direction, they noted that the timing and location of specific vehicle/ground contacts and the resulting roll motion of the vehicle during staged testing are not repeatable. According to James et al., the procedure also does not appear
43、to simulate the occupant motion prior to and during the trip phase. 3.1.2 Test Procedure The test vehicle is oriented laterally on a rolling cart with a platform at a roll angle of 23 degrees from the horizontal and with the leading side tires against a 4-in (10.16-cm) high rigid flange. The lower-s
44、ide tires are to be 9 in (22.86 cm) above the ground. The vehicle and rolling cart are accelerated to a constant velocity (30 mph is given as an example in the SAE J2114 procedure, but is required in FMVSS 208) and the cart then is stopped at a distance of not more than 3 ft (0.914 m) without transv
45、erse or rotational movement of the platform during its deceleration. The cart deceleration must be at least 20 gs for a minimum of 40 ms. The tire support flange will induce an initial roll velocity of the vehicle, and the leading sidetires will most likely impact the ground first, after which the v
46、ehicle will continue to roll. This test procedure was used by NHTSA during the early 1980s for testing numerous passenger cars and trucks, and evaluated by many researchers from the 1970s to the present (Ennos, 1971; Segal and Kamhilz, 1983; Wilson and Gannon, 1972; Cooperrider, 1990). The specified
47、 test conditions of 23 degree angle and 30 mph velocity were chosen to ensure that most vehicles would roll on concrete roadways subjected to the aforementioned deceleration pulses. It also has been used for developing, testing and evaluating rollover occupant protection systems. This test method ha
48、s been used to research rollover mechanics on surfaces other than concrete, including dirt (Croteau 2010). Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2926 Issued AUG2011 Page 7 of 48 3.2 Rollover Impact Test Systems Designed for Initial Impact Control There are at least two rollover test systems designed to control initial impact conditions. The CRIS (Controlled Rollover Impact System) test device utilizes a semi-trailer to deliver a rotating and transl
