Use of Madymo for Simulations of Helicopter Crash Scenarios within the HeliSafe TA Project M. Blundell., Bastien C., S. Vadlamudi and Y. Zhang Coventry University 6 th European Madymo Users meeting, Berlin 2007 1
HELISAFE TA Project Helisafe TA (Helicopter Occupant Safety Technology Application) is an EU funded 6 th Framework Specific Targeted Research Project that aims to develop improved levels of occupant crash protection for civil helicopters The project involves 12 European partner companies and institutions 2
Main Activities A major feature of the project is an integrated programme of : Full scale helicopter crash tests Developing occupant protection concepts Crash test dummy development Laboratory based cabin/cockpit mock-up sled tests Supporting computer simulation 3
Helisafe TA Partners AUTOFLUG (D) The project co-ordinator CIDAUT (ES) CIRA (I) DLR (D) EUROCOPTER-SAS (F) EUROCOPTER (D, a subsidiary of EUROCOPTER-SAS) POLITECNICO DI MILANO (I) PZL Swidnik S.A. (PL) TNO Automotive, Safety R&D (NL) SRS (D, a subsidiary of SIEMENS) COVENTRY UNIVERSITY (UK) UNIVERSITY DELFT (NL) 4
Main Activities 5
Overall Simulation Activity Helisafe TA AFG Reference Scenario EC-SAS SAMCEF EC Model EC-SAS Finite Element Simulations DLR DRI-KRASH Simulations CU Madymo/ADAMS Simulations Computer Simulations 1 st Baseline Drop Test Roll Over Case Real World Scenarios (influence of surface, crash angles ) Secondary and Multiple Impacts 6
Full Helicopter Model Data Management at CU EC-SAS SAMCEF data set CU Data translation programs FORTRAN, MATLAB, EXCEL Madymo Models 7
Overall Simulation Activity in Helisafe TA Computer Simulations 1 st Baseline Drop Test Roll Over Case Real World Scenarios (influence of surface, crash angles ) Secondary and Multiple Impacts 8
Simulation work at Coventry To develop multi-body based simulation models in Madymo that could be used to simulate full helicopter crash scenarios To develop subsystem cockpit/cabin models for more detailed investigation of occupant protection systems 9
Madymo Models including Occupant NLG Left MLG Right MLG 10
Helicopter Rollover Helicopter Occupants are at risk of several Post- Crash Risk Hazards including fire, smoke and ditching in open water. Preventing injury is essential to aid escape. Rollover is significant and can injure and trap occupants (Survey of 92 NTSB Crash Cases) Post Crash Risk Cases Occupants Fatalities Major Injuries Minor Injuries No Injuries No. % No. % No. % No. % No. % Fire 6 7 17 9 53 1 6 5 29 2 12 Water 5 5 22 11 50 0 0 1 9 10 45 Remote Location 5 5 16 5 31 2 13 1 6 8 50 Rollover 20 22 46 2 4 0 0 12 26 32 70 11
Full Helicopter with Occupant (Madymo) Straight Drop - 5m/s Acceleration plot 12
Full Helicopter Roll Over (Madymo) Landing on uneven ground with occupant 13
Full Scale Crash Test at CIRA The first of a series of full scale drop test has been completed at CIRA. The tests will be performed to match a chosen reference scenario. Base line tests will provide local input crash pulse data for the simulation models Impact velocity 15.05m/s (Vx=12.8m/s, Vy=7.9m/s), pitch angle 5 nose up 14
Full Scale Crash Test at CIRA A final test will evaluate new safety concepts developed using computer simulation and a series of laboratory sled (inertial) tests with dummies and cockpit/cabin mock-up tests. The sled tests will be performed at CIDAUT and SRS (Siemens) 15
Full Scale Crash Test at CIRA 16
Cockpit and Cabin Modelling 17
Madymo Modelling 18
Model integration 19
Dummy Responses & Safety Systems Model acts as a rigid inertia rig with local acceleration pulses applied to dummies and seats Model allows testing of new safety concepts (harnesses/airbags) Model could be used to simulate full-scale or sled tests Potential to vary layouts and investigate crash pulses for further scenarios 20
Typical Measured Response Upper lumbar spinal forces of pilot and forward-faced dummies obtained from Madymo Simulations of fullscale drop test with the Bell UH-1D cabin/cockpit model 21
Development of new Harness Design Concepts Body centred harness 3/4 point harness 3 point harness X-harness 4-point harness Triangle harness 22
Sled test (HS1 pulse) 100 50 Acceleration (m/s^2) 0 0.00 0.10 0.20 0.30 0.40 0.50-50 -100-150 -200 x direction z direction -250 Time (s) 23
Frontal Impact Simulation HS1 horizontal pulse 24
Harness Design Concepts for front Seated Occupants HS1 loading is applied 25
Side impact Simulation 26
Harness Design Concepts for Side Seated Occupants HS1 loading is applied 27
Investigation of Airbag position 15 Z=872mm 28
Comparison of Dummy movements With and without airbag for HS1 and DT1 pulse 29
Conclusions A generic helicopter has been modelled in both Madymo The capability to include a model of the seat, dummy, restraint system and airbag in a full Madymo helicopter model has been demonstrated 30
Conclusions A subsystem cabin/cockpit model has been developed for the test helicopter and can be used for the evaluation of new occupant protection design concepts The models have been demonstrated as capable of: Simulating the evolution of a roll over event Sled tests Full scale crash tests 31
Conclusions In frontal cases, 4 point harness has given the best injury results for HS1 pulse In side impact, body centered harness has given the best injury results for HS1 pulse The position of the airbag has been determined and will be used in the final drop test 32