Robust design optimization of frontal structures for minimizing injury risks of Flex Pedestrian Legform Impactor

The Flexible Pedestrian Legform Impactor (Flex-PLI) consisting of a flexible femur and tibia will be tested for pedestrian protection by Euro NCAP within the next couple of years as a potential replacement for the Transport Research Laboratory (TRL) legform impactor. The injury risks that are measured when using Flex-PLI are the elongation of the anterior/posterior cruciate ligament (A/PCL), elongation of the medial collateral ligament (MCL), and tibia bending moment (TBM). In this study, we used a correlated computer-aided engineering (CAE) model to conduct a contribution analysis of each injury with regard to the changes in the location of the frontal structures based on the results of a design of experiments (DOE) and analysis of variance (ANOVA). The frontal structures that were selected as control factors were the energy absorber (EA), lower bumper stiffener (LBS), and hood angle. A kriging interpolation model was developed using the DOE results, and its results were compared with those of the CAE model. Furthermore, for robust design optimization, the speed and height of Flex-PLI were used as the noise factors. Finally, a robust design optimization was carried out using the optimal combination of the discrete control factors for minimizing MCL elongation.