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4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/J2926_201707 SURFACE VEHICLE INFORMATION REPORT J2926 JUL2017 Issued 2011-08 Revised 2017-07 Su
5、perseding J2926 AUG2011 Rollover Testing Methods 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
6、evaluation of rollover protection systems at the vehicle and component levels. This update provides printing of color images in the document. TABLE OF CONTENTS 1. SCOPE 4 2. REFERENCES 4 3. DEFINITIONS . 4 4. TEST METHODS FOR FULL VEHICLE TESTING 5 4.1 Dolly Rollover Test Procedure 5 4.1.1 Backgroun
7、d . 5 4.1.2 Test Procedure 6 4.2 Rollover Impact Test Systems Designed for Initial Impact Control . 7 4.2.1 Controlled Rollover Impact System (CRIS) Test 7 4.2.2 Jordan Rollover System (JRS) 8 4.3 Ramped Rollover Tests. 9 4.3.1 Background . 9 4.4 Curb Trip Methodologies . 12 4.4.1 Critical Sliding V
8、elocity Mode 12 4.4.2 Lateral Curb Tripping 13 4.4.3 Oblique Curb Trip 14 4.5 Deceleration Rollover Sleds 14 4.6 Ditch/Embankment 16 4.7 Soil Trip Testing 18 4.7.1 Roller Coaster Dolly (RCD) . 19 4.8 Maneuver Induced Rollover Testing . 19 5. COMPONENT TEST METHODOLOGIES 20 5.1 Rollover Restraint Tes
9、ter (RRT) . 20 5.2 Key Safety Inc. Device 21 5.3 Rotational Test Benches . 21 5.4 Dynamic Rollover Fixture (DRF) . 22 5.5 Rollover Component Sled (ROCS) Fixture . 23 5.6 Lateral Rollover Simulator (LRS) 24 SAE INTERNATIONAL J2926 JUL2017 Page 2 of 47 5.7 Spin Fixture Testing 25 5.8 Linear Impactor T
10、esting 25 5.9 Vehicle Roof Strength Test Procedure . 26 5.10 Inverted Drop Test 26 6. CAE TESTING METHODS . 26 6.1 Rigid Body Based Simulations (e.g., MADYMO, ATB, DYNAMAN) . 27 6.2 Finite Element Methods (e.g., LS-DYNA, RADIOSS, PAMCRASH) 28 6.3 Test Conditions Selection and Adjustment . 29 6.4 Sen
11、sor Testing 29 6.5 Restraint and Structure Development . 30 6.6 Impact Conditions and Roof Structure 31 6.7 Vehicle Rollover Sequence Modeling Including the Effects of the Suspension 32 6.8 Restraint Evaluation 34 6.9 Bus Rollover Simulations 35 6.10 Curb and Soil Trip Rollover . 36 6.11 Side Curtai
12、n Development 37 6.12 Mining Vehicle Protection Systems . 38 6.13 Heavy Trucks in Rollovers 39 6.14 Padding Effects on Human Neck Injury 39 6.15 Drop Testing 40 7. DISCUSSION 40 8. NOTES 40 8.1 Revision Indicator 40 APPENDIX A REFERENCE MATERIALS 41 SAE INTERNATIONAL J2926 JUL2017 Page 3 of 47 INTRO
13、DUCTION 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 utilized for rollover crashworthiness evaluation, as well as references for additional follow-up. The material
14、s 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 the literature created by Chou, McCoy and Leigh at Ford Motor Company, who graciously have provided thei
15、r 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 the previous authors for sharing their document, which allowed us to expand upon their initial work. The
16、 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 particular methodology should not be construed as invalidating any work not included, nor is the inclusion
17、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 that the current document provides some additional insight into the current state of methods available for
18、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-Mitchell (2007) reported that more than 60% of rollover initiations were tripped as shown in Figure A and
19、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) reported on a breakdown of test types and their relationship with rollover crashes as shown in Figure B
20、. 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 perspective on the relevant rollover crashes. As shown in Figure B, nine laboratory tests cover 93% of the
21、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 in the paper by Parenteau et al. (2001a). The data shown in Figure B involve three columns of frequency pe
22、rcentages. 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 considered. The analysis method determined the fraction of real-world rollovers that would be addressed b
23、y 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 of belted occupants. The results have been updated with newer NASS-CDS data, but the main conclusion was that a series of ro
24、llover tests is needed to cover the majority of real-world injuries in field rollover crashes. SAE INTERNATIONAL J2926 JUL2017 Page 4 of 47 Figure B - Analysis of test types with rollover crash types for passenger cars and LTVs Numerous papers exist with regard to rollover crash characterization whe
25、re examination of various aspects of interest has been conducted. 1. SCOPE The scope of this document is to 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 comprehens
26、ive literature review, but rather illustrates the techniques that are in use or have been used to evaluate rollover crashworthiness-related issues. 2. REFERENCES Appendix A contains a list of references and other literature on the subject. 3. DEFINITIONS For ease of discussion the following terms ar
27、e identified in terms of general usage and in the context of rollover testing: 3.1 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 describes an orientation that in the initial part of the rollover the driv
28、er side is starting to move toward the ground (while the passenger side would be moving upward). 3.2 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 driver side leading roll the passenger side would be the traili
29、ng side. 3.3 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. 3.4 PITCH-OVER An end-over-end type of rollover, such as might occur when a vehicle with a longitudinal velocit
30、y goes over a drop off. 3.5 SOIL TRIP A rollover that initiates as a result of the furrowing forces from the buildup of soil by the wheels as the vehicle moves laterally on a dirt surface. SAE INTERNATIONAL J2926 JUL2017 Page 5 of 47 3.6 ON-ROAD ROLLOVER A rollover that initiates on the road surface
31、. 3.7 UN-TRIPPED ROLLOVER A rollover that initiates on the road surface as a result of friction forces between the tires and the road surface. 3.8 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 spir
32、aling-type motion during the rollover. 3.9 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. 3.10 TURN-OVER When centrifugal forces from a sharp turn
33、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
34、 as a turn-over. 3.11 FALL-OVER When the surface on which the vehicle is traveling slopes downward in the direction of 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. 3.12 FLIP-OVER When a vehicl
35、e is rotated around its longitudinal axis by a ramp-like object such as a turned-down guardrail or the back slope of a ditch. The vehicle may be in yaw when it comes in contact with a ramp-like object. 3.13 BOUNCE-OVER When a vehicle rebounds off of a fixed object and overturns as a consequence. The
36、 rollover must occur in close proximity to the object from which it is deflected. 4. TEST METHODS FOR FULL VEHICLE TESTING 4.1 Dolly Rollover Test Procedure 4.1.1 Background According to Wilson and Gannon (1972), the Dolly Rollover Test Procedure was introduced by Mercedes-Benz in a presentation to
37、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 Figure 1. A close up of the dolly fixture is shown in Fi
38、gure 1A. Based on literature review SAE J2114 has been used in evaluation of the following: Restraint system performance Rollover occupant protection system performance SAE INTERNATIONAL J2926 JUL2017 Page 6 of 47 Occupant kinematics and ejection Vehicle structural integrity such as roof crush perfo
39、rmance Vehicle rollover kinematics Figure 1 - SAE J2114 Rollover test mode (courtesy of Autoliv) Figure 1A - 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 methodolog
40、ies because it provides a measure of control over the trip location and the vehicle roll direction. In spite 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 veh
41、icle during staged testing are not repeatable. According to James et al., the procedure also does not appear to simulate the occupant motion prior to and during the trip phase. 4.1.2 Test Procedure The test vehicle is oriented laterally on a rolling cart with a platform at a roll angle of 23 degrees
42、 from the horizontal and with the leading side tires against a 4-in (10.16-cm) high rigid flange. The lower-side 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 req
43、uired in FMVSS 208) and the cart then is stopped at a distance of not more than 3 ft (0.914 m) without transverse 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 v
44、elocity of the vehicle, and the leading side tires will most likely impact the ground first, after which the vehicle will continue to roll. SAE INTERNATIONAL J2926 JUL2017 Page 7 of 47 This test procedure was used by NHTSA during the early 1980s for testing numerous passenger cars and trucks, and ev
45、aluated by many researchers from the 1970s to the present (Ennos, 1971; Segal and Kamhilz, 1983; Wilson and Gannon, 1972; Cooperrider, 1990). The specified 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
46、 aforementioned deceleration pulses. It also has been used for developing, testing and evaluating rollover occupant protection systems. This test method has been used to research rollover mechanics on surfaces other than concrete, including dirt (Croteau 2010). 4.2 Rollover Impact Test Systems Desig
47、ned 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 translating test vehicle onto an outdoor test surface. The JRS (Jordan
48、 Rollover System) test device enables control of the vehicle initial rollover impact conditions and the number of impacts with a moving impact surface driven by a pneumatic sled system. The JRS rollover system is suitable for use in a laboratory setting. These systems are described in 3.2.1 (CRIS) a
49、nd 3.2.2 (JRS). 4.2.1 Controlled Rollover Impact System (CRIS) Test Cooper et al. (2001) reported on a dynamic rollover test procedure with controlled roof impact, thus the method is referred to as the Controlled Rollover Impact System (CRIS) and is covered by US Patent 6,651,482 assigned to Exponent, Inc. (Moffatt, 2003). This test method releases a rotating vehicle onto the ground from the back of a moving semi-trailer
