Updated review of potential test procedures for FMVSS no.208

Gabler, Hampton C.; Hackney, James R.; Hollowell, William T.; Stucki, Sheldon L.; Summers, Stephen · 1999 · ROSA P / United States. Department of Transportation. National Highway Traffic Safety Administration

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Summary

This 1999 report by the National Highway Traffic Safety Administration (NHTSA) evaluates potential test procedures for Federal Motor Vehicle Safety Standard (FMVSS) No. 208, which governs occupant crash protection. The study was motivated by the need to replace a temporary "generic sled test" protocol, adopted in 1997 to address airbag-related injuries to children and out-of-position adults, with a more robust procedure that accurately evaluates full vehicle system performance. The primary objective was to identify test methods that effectively measure occupant protection against deceleration severity and compartment intrusion while ensuring vehicle crash compatibility with other vehicles. The researchers analyzed seven candidate test procedures: full frontal fixed rigid barrier, oblique frontal fixed rigid barrier, generic sled, frontal fixed offset deformable barrier, perpendicular moving deformable barrier (MDB), oblique MDB, and full frontal fixed deformable barrier. The methodology combined crash test data, computer simulations, and an analysis of National Automotive Sampling System (NASS) crash data from 1988–1997. Crash responses were categorized as "stiff" (short duration, high acceleration) or "soft" (longer duration, lower acceleration), and intrusion levels were assessed. The NASS analysis, covering approximately 3,770 vehicles, estimated target populations for each test configuration based on real-world frontal crash exposure and injury severity. Key findings indicated that the generic sled test fails to replicate actual vehicle crash pulses, airbag deployment timing, or intrusion, and addresses a significantly smaller target population than other options. The MDB-to-vehicle test, particularly in offset configurations, addressed the largest target population, covering approximately 64% of drivers exposed to frontal crashes and 59% of those sustaining serious or fatal injuries. In contrast, the rigid barrier test addressed about 44% of drivers. The report found that "soft" pulses generally resulted in lower injury levels than "stiff" pulses. Crucially, the study highlighted that tests producing neither high intrusion nor high deceleration, such as the sled test or full frontal fixed deformable barrier, offer no constraint on front structure stiffness, potentially leading to the manufacture of overly stiff, incompatible vehicles. The report recommends eliminating the sled test procedure and considering four options for future rulemaking. Option 1 combines perpendicular and oblique rigid barrier tests. Option 2 combines the rigid barrier with an offset-barrier test. Option 3 utilizes the MDB-to-vehicle test, which requires a 2–3 year lead time for development. Option 4 combines the rigid barrier and MDB tests, offering the largest target population coverage and incentives for improved compatibility, particularly for lighter vehicles. The authors conclude that the ideal test procedure must balance the need to soften front structures for deceleration control while strengthening the occupant compartment to prevent intrusion.

Key finding

A moving deformable barrier-to-vehicle test addresses the largest target population of drivers exposed to frontal crashes, covering approximately 64 percent of drivers and 59 percent of those receiving serious to fatal injuries.

Methodology

dataset

Sample size: 3770

Provenance

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Topics

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• naturalistic crash near crash

Information type

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• Applied Guidance: standards test procedures
• Empirical Findings: crash risk outcomes