Periodic Reporting for period 1 - SALIENT (Novel Concepts for Safer, Lighter, Circular and Smarter Vehicle Structure Design forEnhanced Crashworthiness and Higher Compatibility)
Período documentado: 2022-09-01 hasta 2024-02-29
The long-term aim for SALIENT is to make our roads safer and reduce serious injuries and fatalities. To fulfil this ambition, SALIENT has presented novel structural and vehicle concepts that are safer, lighter, circular, and smarter, which can be adapted to accommodate different crash scenarios. Since the beginning of SALIENT, the focus has been on developing innovative technologies to demonstrate and validate the effectiveness of light front-end structure (FES), considering eco-design and circular economy principles, to enhance vehicle safety. SALIENT has made significant progress in identifying full technical and performance requirements and future crash scenarios as well as developing and adapting a comprehensive eco-design strategy, advanced materials, and computational and simulation tools. In this regard, SALIENT has investigated innovative circular design and emerging active safety technologies to develop a smart front-end structure (FES) with high energy absorption capability, which will be adapted (prior crash events) to future mixed traffic scenarios to meet or exceed future vehicle demands in terms of safety, structural integrity, crashworthiness, and compatibility.
SALIENT pathway to impact will focus on developing safer but also lighter and circular vehicle structures and advanced vehicle concepts with higher compatibility between vehicles of different sizes/masses-dissimilar crashes as well as novel structural designs tolerant to a wider set of crash angles. SALIENT impact scale and significance covers: Scientific Impact (creating high-quality new knowledge, Strengthening human capital in R&I, and fostering diffusion of knowledge and open science); Economic Impact (key technological trends, increased attractiveness of the vehicles market, economic viability and technological feasibility, and increased competitiveness, and growth of EU companies); and Social Impact (quality of life with safe and environmentally friendly technologies, enhanced consumer experiences by extended lifetime of components, and increased public awareness and acceptance).
Sciences and Humanities (SSH) in SALIENT has a strong role covering a wide portfolio of actions: Socio-economic assessment of the SALIENT solutions through LCA, and Life cycle cost analysis (LCCA); Business strategy for the exploitation and future market uptake of the project outcome, including market and competitor research and business modelling; and a carefully designed societal outreach campaign.
SALIENT pathway to impact will focus on developing safer but also lighter and circular vehicle structures and advanced vehicle concepts with higher compatibility between vehicles of different sizes/masses-dissimilar crashes as well as novel structural designs tolerant to a wider set of crash angles. SALIENT impact scale and significance covers: Scientific Impact (creating high-quality new knowledge, Strengthening human capital in R&I, and fostering diffusion of knowledge and open science); Economic Impact (key technological trends, increased attractiveness of the vehicles market, economic viability and technological feasibility, and increased competitiveness, and growth of EU companies); and Social Impact (quality of life with safe and environmentally friendly technologies, enhanced consumer experiences by extended lifetime of components, and increased public awareness and acceptance).
Sciences and Humanities (SSH) in SALIENT has a strong role covering a wide portfolio of actions: Socio-economic assessment of the SALIENT solutions through LCA, and Life cycle cost analysis (LCCA); Business strategy for the exploitation and future market uptake of the project outcome, including market and competitor research and business modelling; and a carefully designed societal outreach campaign.
The following technical activities have been carried out:
1. Full understanding of technical requirements and future accident scenarios involving light vehicles (A comprehensive set of new crash scenarios defining the impact parameters (e.g. speed, angle, energy, geometry); Identification of semi-automated (SAV) and automated vehicles (AV) traffic penetration rates (and accompanying roll-out strategies) with the potential to better predict future traffic accidents). Examined how the introduction of driving automation affected traffic safety in mixed traffic scenarios.
2. Develop innovative and circular conceptual design of vehicle’s FES, considering future accident scenarios (A detailed eco-design strategy has been developed and has been used for innovative design of both base crashworthiness FES design concept (BCFES) and active front-end structure (ACFES). Different BCFES and ACFES designs have been developed and are currently being optimized).
3. Develop and validate highly innovative and sustainable materials for new scalable structure concepts (Materials development and preparation of coupon samples for testing as well potential optimization of materials compositions have been developed and optimized).
4. Optimize high-throughput low-cost manufacturing technologies and processes (Manufacturing technologies and processes investigation and optimization work have been conducted and are being finalized).
5. Develop ADAS sensing system algorithm for critical incident detection with optimized integration to BCFES (The ADAS sensing system and triggering response of ACFES has been prepared and a model algorithm with sufficient fidelity has been developed).
6. Advance simulation and virtual testing capabilities for crash and compatibility analysis.
1. Full understanding of technical requirements and future accident scenarios involving light vehicles (A comprehensive set of new crash scenarios defining the impact parameters (e.g. speed, angle, energy, geometry); Identification of semi-automated (SAV) and automated vehicles (AV) traffic penetration rates (and accompanying roll-out strategies) with the potential to better predict future traffic accidents). Examined how the introduction of driving automation affected traffic safety in mixed traffic scenarios.
2. Develop innovative and circular conceptual design of vehicle’s FES, considering future accident scenarios (A detailed eco-design strategy has been developed and has been used for innovative design of both base crashworthiness FES design concept (BCFES) and active front-end structure (ACFES). Different BCFES and ACFES designs have been developed and are currently being optimized).
3. Develop and validate highly innovative and sustainable materials for new scalable structure concepts (Materials development and preparation of coupon samples for testing as well potential optimization of materials compositions have been developed and optimized).
4. Optimize high-throughput low-cost manufacturing technologies and processes (Manufacturing technologies and processes investigation and optimization work have been conducted and are being finalized).
5. Develop ADAS sensing system algorithm for critical incident detection with optimized integration to BCFES (The ADAS sensing system and triggering response of ACFES has been prepared and a model algorithm with sufficient fidelity has been developed).
6. Advance simulation and virtual testing capabilities for crash and compatibility analysis.
1. A comprehensive set of new crash scenarios defining the impact parameters (e.g. speed, angle, energy, geometry); Identification of SAV and AV traffic penetration rates (and accompanying roll-out strategies) with the potential to better predict future traffic accidents.
2. A new Base Crashworthiness FES design concept (BCFES) with improved multi-angle crashworthiness; three promising Adaptive Crashworthiness FES (ACFES) concept solutions: AC1. Adaptable materials stiffness; AC2. Control crash load paths; and AC3. Inflatable/pressurized structural elements (Al). These designs are targeted to have a significant weight reduction (WR) at demo level ~ 42.7% (primary weight saving). The improvement in the stiffness and reliability concept of the SALIENT BCFES can be transferred/integrated to the vehicle’s Body in White (BiW) leading to a more sustainable and safer BiW with additional WR on average ~11.6% ( Being Optimized).
3. Development of 3 lightweight and multi-functional materials with high recyclability (6063 Al Alloy; TP- CFRP; and optimized hybrids - Al/TP-CFRP based on intelligent local reinforcement with unidirectional CF tapes); Innovative materials meet cost, performance, quality and recyclability targets; Improved process, functionally and productivity; Automated joining process for hybrid materials).
4. Improved forming technology; Optimized TP-CFRPs and hybrid materials production processes; Maintain or improve the cost of manufacture and operation; High production rates via faster process; >25% saving in energy; >20% reduction in production time; 10% saving in production cost; <5% waste (Being Optimized).
5. A reliable novel advanced driver assistance systems (ADAS) sensing algorithm capable of detecting and communication the specific details of an impending and likely crash; A capable triggering mechanism (TrM) to activate ACFES based on signal received prior to the crash events.
6. Innovative MSE platform; >10% increase of correlation factor between test and simulation results; > 30% increase the number of considered aspects and perspectives at a concept decision in the automated simulation process by increase the amount of numerical simulation in decision making 10%; >20% efficiency increase due to the use of the MSE to solve simulation; CAE test correlations status based on component level tests at ≥80%; Full set of crash analysis for future accidents (Being Optimized).
2. A new Base Crashworthiness FES design concept (BCFES) with improved multi-angle crashworthiness; three promising Adaptive Crashworthiness FES (ACFES) concept solutions: AC1. Adaptable materials stiffness; AC2. Control crash load paths; and AC3. Inflatable/pressurized structural elements (Al). These designs are targeted to have a significant weight reduction (WR) at demo level ~ 42.7% (primary weight saving). The improvement in the stiffness and reliability concept of the SALIENT BCFES can be transferred/integrated to the vehicle’s Body in White (BiW) leading to a more sustainable and safer BiW with additional WR on average ~11.6% ( Being Optimized).
3. Development of 3 lightweight and multi-functional materials with high recyclability (6063 Al Alloy; TP- CFRP; and optimized hybrids - Al/TP-CFRP based on intelligent local reinforcement with unidirectional CF tapes); Innovative materials meet cost, performance, quality and recyclability targets; Improved process, functionally and productivity; Automated joining process for hybrid materials).
4. Improved forming technology; Optimized TP-CFRPs and hybrid materials production processes; Maintain or improve the cost of manufacture and operation; High production rates via faster process; >25% saving in energy; >20% reduction in production time; 10% saving in production cost; <5% waste (Being Optimized).
5. A reliable novel advanced driver assistance systems (ADAS) sensing algorithm capable of detecting and communication the specific details of an impending and likely crash; A capable triggering mechanism (TrM) to activate ACFES based on signal received prior to the crash events.
6. Innovative MSE platform; >10% increase of correlation factor between test and simulation results; > 30% increase the number of considered aspects and perspectives at a concept decision in the automated simulation process by increase the amount of numerical simulation in decision making 10%; >20% efficiency increase due to the use of the MSE to solve simulation; CAE test correlations status based on component level tests at ≥80%; Full set of crash analysis for future accidents (Being Optimized).