Calspan/Chrysler Research Safety Vehicle Phase III Final Technical Report: Volume I: Technical Report

Fabian, G. J.; Frig, G. E. · 1979 · ROSA P / United States. Department of Transportation. National Highway Traffic Safety Administration

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Summary

This report documents the final design of the Calspan/Chrysler Research Safety Vehicle (RSV) Phase III, a project funded by the National Highway Traffic Safety Administration (NHTSA) to develop automotive safety technologies applicable to the mid-1980s. The research was motivated by the need to address rising highway injuries and fatalities while simultaneously meeting constraints related to fuel economy, material conservation, and mass producibility. The program aimed to demonstrate that significant safety improvements could be integrated into a vehicle design without excessive cost or weight penalties, moving beyond safety as an "add-on" to an integrated system approach. The RSV was based on the Simca 1308, a lightweight, front-wheel-drive vehicle selected for its adaptability to a five-passenger configuration and its weight under 2,500 lbs. The design process involved extensive trade-off analyses, static crush tests, dynamic impact tests, and computer simulations using the Calspan crash victim simulation program. The engineering team modified the base vehicle to incorporate a three-zone crash energy management structure: Zone I featured soft-face bumpers for pedestrian protection and low-speed damage resistance; Zone II provided energy dissipation for intervehicular collisions; and Zone III absorbed energy during severe frontal impacts. The design also prioritized material recyclability, limiting aluminum use to prevent contamination during steel reclamation, and utilized recycled plastics where possible. Key findings and design features included the integration of advanced occupant restraint systems. The final vehicles were equipped with a driver air bag and a passenger automatic inflatable air belt, supplemented by knee blockers, energy-absorbing door trim, and crushable padding on pillars. The chassis modifications included flatproof tires to eliminate roadside repair risks and increase cargo capacity, an anti-skid braking system, and flatproof tire warning systems. The structural redesign ensured that the passenger compartment maintained integrity with limited intrusion (up to 150 mm) during crashes. The report details the specific engineering of components such as the front longitudinal rails, side sills, and roof structures, supported by a comprehensive bill of materials and component drawings. The significance of this work lies in its demonstration that a family car could achieve high levels of crashworthiness, pedestrian safety, and occupant protection while remaining compatible with mass production techniques and future resource constraints. The RSV served as a proof-of-concept for integrating passive restraints and structural energy management into a lightweight vehicle platform. The documentation provides a complete technical record of the design decisions, component specifications, and analytical methods used, offering a foundation for future automotive safety standards and vehicle design philosophies focused on holistic safety integration rather than isolated feature additions.

Key finding

The RSV design successfully integrated a three-zone structural energy management system, flatproof tires, and advanced passive restraints to achieve improved crashworthiness and pedestrian safety without compromising fuel economy or mass production feasibility.

Methodology

modeling

Provenance

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Topics

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• vehicle conspicuity