Systems Engineering Approach in Development of Delphi Driver Protection Module (DDPM) by Virtual Engineering

In this paper, the design and development of the Delphi Driver Protection Module (DDPM) using a systems and virtual engineering approach is presented. LS-DYNA software tool was used in virtual prototype studies. The DDPM consists of driver side energy absorbing components. The components included in this module are 1) an adaptive Energy Absorbing (EA) steering column, 2) driver air bag, 3) steering wheel, 4) energy absorbing knee bolster, and 5) adjustable pedals. Each individual component was designed virtually and the virtual design was validated with limited test results. Further, a sub-system mini-sled model using a Blak Tuffy dynamic test was developed to study the functioning of the module due to upper torso loading during a crash. The results of this mini sled model were correlated with actual physical tests. For system level response study, a full finite element sled model was developed. The results of these studies using virtual engineering approach are presented.