Development, Optimization, and Design for Robustness of a Novel FMVSS 201U Energy Absorber

In order to streamline the product development process, the design space for FMVSS 201U impact performance of a steel mechanical energy absorber assembly was investigated by means of LS-DYNA 970 explicit finite element simulation methods in conjunction with statistical analytical procedures. A sequence of response surfaces, based on various levels of design parameters, was developed and used to determine minimal stopping distance for which it would be possible to achieve acceptable impact attenuation performance under various impact loading conditions given a worst case assumption of rigid vehicle interior body panels. A model was also developed, based on the variation of deterministic variables, in order to estimate and minimize, by means of a robustness analysis, the range of deviation of product response that would be expected as a result of variability in manufacturing and installation processes.