Development of A New Dynamic Rollover Test Methodology for Heavy Vehicles

Paper #:
  • 2017-01-1457

  • 2017-03-28
Among all the vehicle rollover test procedures (SAE J2114 dolly, curb-trip, corkscrew ramp, ditch/embankment, soil trip, etc.), the dolly rollover test is the most widely used. However, it requires the test vehicle to be seated on a dolly with a 23° initial angle, which prevents a vehicle over 5,000 kg to be tested, and repeatability is often a concern. In the current study, we developed and implemented a new dynamic rollover test methodology focused on evaluating crashworthiness and occupant protection that does not require an initial vehicle angle. To do that, a custom cart was designed to carry the test vehicle laterally down a track. The cart incorporates two ramps under the testing vehicle’s trailing-side tires. In a test, the cart with the vehicle travels at the desired test speed and is stopped by a track-mounted curb. The cart stopping pulse is modulated using two honeycomb blocks. While the cart is being stopped, the vehicle slides laterally from the cart with the far-side wheels sliding up the ramps, which generates the desired lateral roll rate. The vehicle near-side wheels slide onto a high-friction surface, such as rake-finished concrete, which generates an additional strong roll moment around the vehicle center of gravity. To design the testing procedure, finite element simulations were conducted to select values for several testing parameters, including ramp height, ramp length, ground surface friction, vehicle traveling speed, cart height and stopping distance. The goal of the simulations is to ensure that the vehicle would roll with the desired roll rate, so that the desired number of quarter turns would be produced. Two physical tests using two armored military vehicles were conducted using the procedure. Both tests resulted in the desired 5-6 quarter-turns of the vehicle with a repeatable initial roll rate. The tests demonstrated that the newly-designed rollover procedure is suitable for vehicles that are generally too large/heavy for using other dynamic rollover tests, and may also be useful for lighter vehicles when a well-controlled, directly lateral roll is desired.
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