Calsonic Kansei developed an automated head impact process using HyperMesh to position virtual head forms on instrument panels for crash simulation. The new process automates tasks that were previously done manually, reducing setup time from 8 hours to 30 minutes. Key benefits include improved efficiency, reduced errors, and the ability for engineers to complete more design projects within time and budget constraints. The automation helps Calsonic Kansei evaluate head impact performance faster and reduce vehicle development costs.

1. Calsonic Kansei North America (CKNA)
27000 Hills Tech Court,
Farmington Hills, MI 48331
Vali Farahani – Technical Specialist
Mark Corritore – Senior CAE Engineer
Sal Maaita – Senior CAE Group Manager
Altair Engineering, Inc.
Altair Engineering Inc.
Aditya Jayanthi – Application Engineer
Shan Bala – Project manager
An Automated Head Impact Process Setup
for Automobile Instrument Panel (IP)
Application

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An Automated Head Impact Process
Presentation Outline
• Objective
• CalsonicKansei Corporation Background
• Head Impact Overview
• FMVSS201 Regulations
• Introduction
• HF Positioning Manual Process
• HF Positioning Automation Process
• Automated Results Versus Manual
• Automation of Post Processing (Available V14.0)
• Benefits
• HF Automation Demo
• Acknowledgements

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An Automated Head Impact Process
Objective:
 To develop an advanced script algorithm to automate
the HF positioning on instrument panel (IP) for head
impact crash application using current commercial
available software HyperMesh®.
 To enhance the script on HM-V14.0 for post processing
to generate final report automatically in power point
format.

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CalsonicKansei Production and Development Operations
 CalsonicKansei is a Tier-I auto supplier and established in August 25, 1938
 Global headquarters in Saitama-City, Japan
 It operates a global network across the world
 Global Consolidated number of employees are about 24,000

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CalsonicKansei Major Client Base

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CalsonicKansei Major Products/Commodities
Center Console Box
HVAC Systems Electronic Systems
AC Compressors
Cockpit Module Systems Exhaust Systems
Front End Module
Meter HVAC Control Switches
ABCU
BCM ODS
HCCOND
EVAP
Motor/Fan
FLEX Pipe
Manifold/CC
EXST Assy
Motor Fan Assy
Radiator Assy
AC Condenser
RCS
HVAC Unit
CPM

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An Automated Head Impact Process
head impact Overview
 When a car is accelerated and crushed into another vehicle or
any rigid object , the occupant’s head impacts
CPM/Instrument Panel.
INST
Vehicle Speed
 The purpose of Head Impact analysis is to protect occupant’s
head during the vehicle crash from fatal injury.
 Head Impact simulation is a part of early stage of the IP
design development and it is commonly done in automotive
industry to meet FMVSS201 Regulations.

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An Automated Head Impact Process
FMVSS201 Regulations
FMVSS201 Regulations state that when a target point on Instrument
Panel within “Head Impact Zone” is impacted by:
 A 6.8 kg (15 lb.), 165 mm (6.5 in) diameter Head Form (HF)
 at a velocity of 14.7±0.2 MPH
 with the pendulum adjustable length of 29 to 33 inches,
The deceleration of HF shall not exceed 80g continuously for more
than 3 milliseconds.
HF
HF Pivot Point
Adjustable Length
IP

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An Automated Head Impact Process
Introduction
 In the past, to asses the head impact performance of IP, CKNA CAE group
had to perform a lengthy manual process to position each HF within IP
impact zone. As a part of manual process, analyst assigns initial velocity
to HF, define contacts between HF and IP, create input/output control
cards and export LS-DYNA input data.
 In order to simplify the HF positioning and developing a more efficient
process, CalsonicKansei North America (CKNA) CAE group decided to
work with Altair Engineering Inc. to develop an advance algorithm to
automate the HF setup using current commercial available software
HyperMesh®.
 script will automatically position HF from a user prepared input excel file
in .csv format based on a selected seating reference point. The script
calculates the impact angle for each point automatically and positions the
HF at the impact point. The surface contacts between HF and IP are
created automatically for all positioned Head Forms.

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An Automated Head Impact Process
HF Manual Process Flow Chart for Head Impact Setup
Positioned
HF
HF Pivot
Point
Calculate HF
Angle of Rotation
Start
Process In CAD
System By DE
Determine HI
Marking Zone
Define HF
Target points
Determine HF
Center of Rotation
Position HF for Each Target Point
Assign Initial Velocity to HF
Define constraint for HF
Create Contacts Between HF & IP
Create Input/Output Control Cards
Assign Mass Moment of Inertia to HF
Define Surface contacts for CPM
Export out the data for LS-Dyna
Analyst Receives Setup info From DE
Passenger
Zone
Driver
Zone

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An Automated Head Impact Process
Head Form (HF) Manual With Post Processing Plots
Acceleration
3ms-G

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An Automated Head Impact Process
HF Positioning on IP Automation Process

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An Automated Head Impact Process
HF Automation Template Flow Chart Structure
Load IP Head Impact Template
Import IP (CPM)
Import HF
Specify SgR Point
Position HF
Define Contacts
Export out Decks
GUI Description
Process Manager
Launch HyperMesh
Select User Profile Crash
Radios
LsDyna
PamCrash
Solver Options
START

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An Automated Head Impact Process
Process for Importing IP and HF FE Models
GUI Description (IP FEM)
GUI Description (HF FEM)
File Type
LsDyna
HyperMesh
HF FEM ApplySelect HF with
Lin/rot Velocity
2
File Type
LsDyna
HyperMesh
IP FEM Apply1
File Format
Imported IP Assembly & HF
HF
IP

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An Automated Head Impact Process
Positioned HF for Selected Target Points
Specify
SgRP
By Node
By Coordinates
Specify Direction
of Vehicle Motion
Apply3
User Options
GUI Description
Specify HF Zone
Marking on IP
By Node
Position
HF’s
Apply4
Remove
Penetration
Specify
HF
Target
or pivot
.CSV File GUI Description
Angle of Rotations are calculated
automatically for each target point

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An Automated Head Impact Process
Define Contacts and Export out the Decks for Solver
Define Automatic Single
Surface Contact
Apply to Save
Surface Contact
5
6
Create output Directory
Export out decks for
Selected Target Points
Master
File
IP File HF File
Target
File
Submit Master
File to Server
GUI Description
GUI Description

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An Automated Head Impact Process
Automation Results Versus Manual

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An Automated Head Impact Process
Automation Results Versus Manual

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An Automated Head Impact Process
Automation of Post Processing ( Available in HM V14.0)
 Load Vehicle Safety Tools preference file.
 Available for Radioss and Dyna results
 Input vehicle direction, Clip Threshold,
SAE filter
 Load Defaults file which points to IP deck
directory and Target point CSV file
 Generates results which can be
reviewed in HV and HG clients
 Automatically generates a power point
report
 Results at different points can be
appended, overlaid and/or replaced

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An Automated Head Impact Process
Automation of Post Processing ( Available in 14.0)

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An Automated Head Impact Process
Benefits of the HF Automated Process
 It is more efficient process with significant time saving
 The time saving help CKNA CAE group to evaluate IP head impact faster
and reducing the engineering development costs.
 Automation process helps analysts to complete more projects.
 It Helps to reduce the possibility of error that may occurs on manual
setup.
 It has significant impact on the division or work group benefits.
 The automated process reduces the head form setup for 30 points from 8
hours to 30 minutes.

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An Automated Head Impact Process
Acknowledgements
 We would like to thank Shawn Ryan, manager of Design CAD Group, at
Calsonic Kansei for his support and valuable information regarding this
project.

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An Automated Head Impact Process
Thank You!
&
Q?