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Roll Over Test
Roll Over Test
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Article in Proceedings of the Institution of Mechanical Engineers Part D Journal of Automobile Engineering · November 2006
DOI: 10.1243/09544070JAUTO360
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Clive Neal-Sturgess
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The manuscript was received on 12 May 2006 and was accepted after revision for publication on 21 July 2006.
DOI: 10.1243/09544070JAUTO360
Abstract: The paper provides a method to simulate the vehicle kinematics in rollover tests.
There are several rollover tests in use: SAE J2114 dolly rollover, ditch rollover, corkscrew,
curb trip, and soil trip. Sensors located on board the vehicle record the various accelerations
and make it possible to reconstruct the whole event with high accuracy, which is difficult in
real-world accidents.
Euler parameters, as a useful method to describe the orientation of a rigid body, have been
widely used in three-dimensional multi-body and rollover crash simulations. A method based
on the Euler parameters derived from the test data is used to simulate the vehicle rollover
kinematics in a SAE J2114 dolly rollover test. The detailed procedure from the raw data to the
Euler parameters is described and the influence of gravity included in the test data is removed
by projecting to a local vehicle reference system.
The method is validated by simulating the dolly rollover test in MADYMO, using a simple
rigid body model to represent the vehicle. Good agreement is obtained from the comparison
between the simulated vehicle orientation and the test video, and the comparison between
simulated displacements and calculated displacements using the recorded test accelerations
at the same points. This demonstrated that the method proposed is a useful and effective
method for simulating vehicle kinematics in rollover tests.
JAUTO360 © IMechE 2006 Proc. IMechE Vol. 220 Part D: J. Automobile Engineering
1504 Y Hu, C E Neal-Sturgess, and A M Hassan
2 TESTS AND SIMULATIONS 3. Corkscrew tollover test. The corkscrew rollover test
shown in Fig. 3 uses a ramp to lift one side of the
To date, there have been several real-world rollover vehicle with a certain speed to generate a rollover.
tests. The purpose of this test is to assess the strength
and integrity of the occupant compartment. Such
1. The SAE J2114 dolly rollover test. A dolly rollover
a test is useful for scenarios with slow-roll motion
test was described in the Society of Automotive
around the longitudinal axes of the car [2].
Engineers (SAE) Recommended Practice J2114
4. Curb trip rollover test. The vehicle is towed side-
shown in Fig. 1 as a method of evaluating the per-
ways on a moving fixture towards a stationary
formance of a vehicles’ crashworthiness during
curb. The moving fixture is decelerated at a known
rollover. The test consists of positioning a vehicle
rate, releasing the vehicle. As the vehicle moves
on a dolly fixture, which is inclined at 23° to
laterally, the tyres contact the curb shown in Fig. 4,
the horizontal. The fixture is towed at 48 km/h
(30 miles/h) and stopped suddenly to generate
the vehicle rollover. The number of rolls can vary
from one to three or more under the same initial
conditions depending on the vehicle tested.
2. Ditch rollover test. This slow-speed ditch test
emulates a real-world fall-over accident. When a
vehicle is tipped by a slope and its centre of mass
is outboard of its wheels, a fall-over happens. This
is an important test since, based on the field data
analysis, fall-over accounts for about 13 per cent
of all passenger vehicle rollover accidents [1].
Figure 2 shows a diagram of the ditch test. Fig. 3 Corkscrew rollover test
Fig. 1 SAE J2114 dolly rollover test Fig. 4 Curb trip rollover test
Proc. IMechE Vol. 220 Part D: J. Automobile Engineering JAUTO360 © IMechE 2006
Simulation of vehicle kinematics in rollover tests with quaternions 1505
AB
a
vehicle model including inertial properties, tyre q =cos
0 2
model, and crush strength, to simulate a rollover test
AB
and real-world accidents. The simulations were all a
matched successfully with real test data. q =−cos b sin
1 1 2
The rollover simulations quoted above are all
AB
based on kinetic models, which are concerned with a
q =−cos b sin
the effects of forces on the motion of a body or 2 2 2
system of bodies, and so the accuracy depends on
AB
a
the initial conditions, the vehicle model properties, q =−cos b sin
3 3 2
the suspension model, the tyre model, and the con-
tact between the vehicle and ground. Usually, such (1)
models are useful to reconstruct accidents with a
where the parameters are defined in Appendix 1.
reasonable accuracy; however, to obtain an accurate
The parameters are not independent, but must
simulation of the vehicle kinematics in rollover tests,
satisfy the constraint
it is preferable to use the test data (accelerations or
displacements). q2 +q2 +q2 +q2 =1 (2)
0 1 2 3
The four Euler parameters represent the orientation
of the vehicle. In fact, the Euler angles q, c, and Q
can also be expressed by the Euler parameters
according to
sin q=2(q q −q q )
1 2 0 3
cos q sin c=−2(q q +q q )
2 3 0 1
cos q cos c=q2 −q2 +q2 −q2
0 1 2 3
2(q q +q q )
tan Q=− 1 3 0 2
q2 +q2 −q2 −q2
0 1 2 3
Fig. 5 Soil trip rollover test (3)
JAUTO360 © IMechE 2006 Proc. IMechE Vol. 220 Part D: J. Automobile Engineering
1506 Y Hu, C E Neal-Sturgess, and A M Hassan
Also, there is a relationship between the angular Software such as MADYMO provides the interface for
rates and the Euler parameters of the body in a fixed the Euler parameters but, starting from the raw
reference frame relative to an inertial reference accelerometer data to obtain the Euler parameters,
frame, which is given by there are some practical factors to consider. The
following section provides the detailed procedure.
CD C DC D
q̇ +q
+q +q
0 1 2 3 v
q̇ −q −q +q x
1 =1 0 3 2 v (4) 3.2.1 Gravity effect removal
q̇ 2 +q −q −q y
2 3 0 1 v Usually an accelerometer placed in a stationary
q̇ −q +q −q z manner on the Earth with its sensitive axis pointing
3 2 1 0
To solve equation (4), there are a number of numerical vertically will give an output signal equivalent to 1G,
methods available including Taylor series expansion, assuming that it responds to static acceleration
the rotation vector concept, Runge–Kutta algorithms, inputs. However, when the body is moving, accelero-
and the state transition matrix [9]. In this paper, the meters measure accelerations, which represent the
fourth-order Runge–Kutta method is chosen as it is actual dynamics of a moving body but may also
reasonably simple and robust, and this method is be contaminated by components of the Earth’s
given by gravitational field, which may also be sensed. For
example, if such an accelerometer is left stationary
1 with its sensitive axis pointing parallel to the surface
q(t+h)=q(t)+ (k +2k +2k +k )
6 1 2 3 4 of the Earth, it will produce an output signal
k =hq(t)v(t) equivalent to 0G.
1 In a rollover event, accelerometers record inertial
k =h[q(t)+0.5k ]v(t+0.5h) and gravitational accelerations at the same time,
2 1
k =h[q(t)+0.5k ]v(t+0.5h) owing to the change in orientation of the vehicle.
3 2 The recorded acceleration is equal to the sum of the
k =h[q(t)+k ]v(t+h) inertial and gravitational acceleration according to
4 3
(5) A =A +A (7)
r i g
where
As a rollover is a long-duration event, because of
q(t)=[q (t) q (t) q (t) q (t)]T accumulated errors, the influence of gravity on the
0 1 2 3
accelerometer data may be large. In the method
and v(t)=[v (t) v (t) v (t)]T.
x y z employed in this paper, if the gravity is not removed,
When the four Euler parameters are available, the
after the coordinate transformation using the Euler
orientation of the vehicle is completely determined,
parameters, the a and a values are the same, but
and the coordinate transformation can be expressed x y
the a value would shift 1G between the cases with
as z
and without gravity. The difference in acceleration
CD
x and velocity for the Z direction only is shown in the
b
y Figs 6 and 7.
b It can be seen from the above that, to obtain
z accurate estimates of the position, it is necessary to
b
remove the gravity effect before the double integration
C D
q2+q2−q2−q2 2(q q −q q ) 2(q q +q q )
0 1 2 3 1 2 0 3 1 3 0 2 of the acceleration. In general, the gravity and inertial
= 2(q q +q q ) q2−q2+q2−q2 2(q q −q q ) accelerations cannot be completely separated with-
1 2 0 3 0 1 2 3 2 3 0 1
2(q q −q q ) 2(q q +q q ) q2−q2−q2+q2 out information about the vehicle orientation [7].
1 3 0 2 2 3 0 1 0 1 2 3 Praxl [10] mentioned that there were some extra
CD
x calculations to consider the gravity in the coordinate
a
× y (6) data transformation, but he did not provide a
a detailed process. Takagi et al. [11] applied angular
z acceleration and linear accelerations to remove the
a
gravity effect. The angular acceleration was deter-
3.2 Practical factors
mined by taking the derivative of the angular rate
The Euler parameters, as a useful method to describe data. This method is sensitive to the angular rate data;
the orientation of a rigid body, have been widely it is easy to induce a derivative error and requires a
used in three-dimensional multi-body simulations. high-precision angular velocity sensor. In fact, by
Proc. IMechE Vol. 220 Part D: J. Automobile Engineering JAUTO360 © IMechE 2006
Simulation of vehicle kinematics in rollover tests with quaternions 1507
using equation (6) to remove the effect of gravity, the the vehicle is equal to G cos 23°. For this reason, it is
process is simplified. The gravitational acceleration important to analyse the vehicle orientation and
can be projected on to the local vehicle coordinate gravity effect during the offset correction. The offset
system and removed from the accelerometer output, correction can use an averaging algorithm, which
to obtain the inertial accelerations along the local assumes that the signal is corrected by subtracting a
vehicle coordinate system. Alternatively, after the bias from each point on the signal.
raw accelerations are transformed to the inertial Based on the current National Highway Traffic
reference, the effect of gravity can be removed by Safety Administration (NHTSA) filtering standard SAE
subtracting the gravitational acceleration from the J211-1, the CFC60 cut-off frequencies are applied
vertical direction. to acceleration data, whereas the CFC1000 cut-off
frequencies are applied to the angular rate data.
3.2.2 Offset correction and filters
3.3 Method
Owing to offset, drift, noise, and sensitivity errors,
there will always be errors arising in the output from The total procedure used can be divided into three
any sensor. For this reason, offset correction or bias steps.
removal, and some filters, need to be applied to the Step 1. The raw test data, including the acceleration
raw sensor signals. and angular rate of the centre of gravity (CG) of the
As mentioned above, because of the gravity effect, vehicle, were adjusted for any offset and filtered,
the recorded acceleration is not zero even when the by using signal analysis software for Microsoft
vehicle is stationary. For example, when the vehicle Windows, which can be found at http://www-
is on the dolly in a SAE J2114 dolly rollover test, the nrd.nhtsa.dot.gov/software/signal-analysis/
output of the accelerometer along the vertical axis of downloads.html.
JAUTO360 © IMechE 2006 Proc. IMechE Vol. 220 Part D: J. Automobile Engineering
1508 Y Hu, C E Neal-Sturgess, and A M Hassan
Step 2. To find the orientation of the vehicle, The kinematics during the first 3 s represent the
quaternions can be obtained by solving equation most severe portion of the rollover in terms of injury
(4) using offset-corrected and filtered angle rates causation, as the highest head, neck, and chest
from Step 1. The numerical integration used a accelerations of dummies happen in this period.
fourth-order Runge–Kutta method. Then, the Also, as there was little roof crush in the first 3 s of
gravity components are available by projecting the the test, and the vehicle rollover can be simulated as
gravity on to the vehicle-fixed coordinate system a rigid body.
using equation (6). These are then subtracted from The rigid body shown in Fig. 9 is used to represent
the acceleration data, determined in Step 1, to the test vehicle with a similar geometry, and the
obtain the inertial accelerations in the vehicle- same dimensions, moments of inertia, mass, initial
fixed coordinate system. After projecting on to the velocity, and position. For the test vehicle, two
inertial or Earth coordinate system, the inertial ellipsoids are shaped to give the vehicle figuration,
accelerations are available. The main program and four cylinders represented the tyres, which are
code in Visual Basic is provided in Appendix 2. for visual aid only, as they are not included in the
computations and do not have any functional con-
Step 3. The displacements of the CG of the vehicle
tact interaction. In this model, the vehicle kinematics
are calculated by double integration of the inertial
are prescribed by specifying the motion for all
accelerations obtained in Step 2. The displacement
degrees of freedom of a free joint and determined
and Euler parameters were then used as the input
by the data collected at the vehicle’s CG. This can,
for the MADYMO model in the global coordinate
within limits, accurately model the kinematics of the
system. The detailed flow chart of data process is
vehicle without the complications of modelling
shown in Fig. 8.
the vehicle suspension and tyre characteristics,
which are difficult to model accurately.
Figure 10 shows the displacements of the CG of the
4 RESULTS
vehicle in the inertial reference system calculated by
the method outlined above, and Fig. 11 shows the
To verify the method, a SAE J2114 dolly rollover
four Euler parameters representing the orientation
test was chosen. The test was performed by the
of the vehicle. The vehicle motion is shown in Fig. 12.
NHTSA in 1997. The accelerations a , a , and a
cgx cgy cgz
of the CG of the vehicle and the angular velocities
4.1 Validation
v , v , and v , along the longitudinal, lateral, and
x y z
vertical axes respectively of the vehicle were recorded. To validate the simulation, two comparisons were
The test duration was approximately 6 s. In this conducted. One was a visual comparison between
paper, because of the accumulated errors and com- the orientation of the vehicle in the simulation and
putational constraints, only the first 3 s are simulated that shown by the film of the test. Figure 13 shows
with the MADYMO software (TNO automotive). the comparison at some key orientations. From this
comparison, it can be seen that the simulation pro-
vided good agreement with the vehicle orientation
from the test, except for a slight error at 1.05 s, which
may be due to suspenion effects.
Proc. IMechE Vol. 220 Part D: J. Automobile Engineering JAUTO360 © IMechE 2006
Simulation of vehicle kinematics in rollover tests with quaternions 1509
The other comparison is between the simulated v around the roll axis is not sufficiently accurate,
y
displacements of a point on the test vehicle where because some data are lost in the test, and the vehicle
an accelerometer was attached, and the calculated is not a rigid body in the real test, which can also
displacements from the accelerations recorded by have a small effect on the displacements along the
that accelerometer. Figures 14 to 16 show the roll and pitch directions.
results. About after 1.5 s, the displacements in the In particular the suspension and tyres are modelled
longitudinal direction shown in Fig. 14 began to as rigid bodies for convenience, which will affect the
show discrepancies. This is because the angular rate kinematics in this mode. Figures 15 and 16 show
JAUTO360 © IMechE 2006 Proc. IMechE Vol. 220 Part D: J. Automobile Engineering
1510 Y Hu, C E Neal-Sturgess, and A M Hassan
Proc. IMechE Vol. 220 Part D: J. Automobile Engineering JAUTO360 © IMechE 2006
Simulation of vehicle kinematics in rollover tests with quaternions 1511
much better accuracy; overall it is reasonable to accelerations, which can also be used for other
conclude that the simulation is successful and applications that need gravity effect removal.
demonstrates the usefulness of the model. This method avoids the complication of vehicle
suspension and tyres and ignores the contact between
the vehicle and ground, which greatly simplify the
5 DISCUSSION AND CONCLUSIONS simulation. However, it also means that there are
some limitations. For the parts of the vehicle close
The simulation showed good agreement between the to the CG, the simulation is of good accuracy but,
test and simulation, it showed that using the Euler for other parts remote from the CG, the accuracy
parameters to reconstruct the vehicle kinematics in decreases slightly; this is because of the simplification
rollover tests is an effective and useful method. The of modelling the suspension and tyres. Thus this
reasons are as follows. method can give good accuracy for simulating
occupant protection research where the occupants
1. Only products exist in the Euler parameters
are near to the CG of the vehicle [12].
defining the kinematic differential equations.
2. Using only the angular rate sensor rather than
linear accelerations to solve the orientation ACKNOWLEDGEMENTS
decreases the errors in the numerical solution.
3. As the measurements are related to the CG, then This work is financially supported by the Overseas
there is only one point at which the accelerations Research Students Award Scheme (2003–2006), UK,
of the CG and the angular velocities along the and the University of Birmingham.
longitudinal, lateral, and vertical axes are recorded.
This means that the method developed is suitable
for all rollover tests where the accelerations and REFERENCES
angular rates are available.
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and injury mechanisms. Once the vehicle mechanics crash tests. Int. J. Crashworthiness, 2002, l7(4),
have been established, a compartment model can be 487–498.
constructed in which the occupant model can be 3 Cheng, H., Rizer, A. L., and Obergefell, L. A. Pickup
truck rollover accident reconstruction using the ATB
described. Different interior designs with respect to
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the occupant and restraint system can be evaluated 4 Steffan, H., Geigl, B. C., and Moser, A. A new
without having to repeat the real-world test, as it is approach to occupant simulation through the
simple to add or change constraints or objects. It also coupling of PC-Crash and MADYMO. SAE paper
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Simulation of vehicle kinematics in rollover tests with quaternions 1513
JAUTO360 © IMechE 2006 Proc. IMechE Vol. 220 Part D: J. Automobile Engineering