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1、FINITE ELEMENT ANALYSIS OF AUTOMOBILECRASH SENSORS FOR AIRBAG SYSTEMSABSTRACTAutomobile spring bias crash sensor design time can be significantly reduced by using finite element analysis as a predictive engineering tool.
2、The sensors consist of a ball and springs cased in a plastic housing.Two important factors in the design of crash sensors are the force-displacement response of the sensor and stresses in the sensor springs. In the past,
3、sensors were designed by building and testing prototype hardware until the force-displacement requirements were met. Prototype springs need to be designed well below the elastic limit of the material.Using finite element
4、 analysis, sensors can be designed to meet forcedisplacement requirements with acceptable stress levels. The analysis procedure discussed in this paper has demonstrated the ability to eliminate months of prototyping effo
5、rt.MSC/ABAQUS has been used to analyze and design airbag crash sensors.The analysis was geometrically nonlinear due to the large deflections of the springs and the contact between the ball and springs. Bezier 3-D rigid s
6、urface elements along with rigid surface interface (IRS) elements were used to model ball-to-spring contact.Slideline elements were used with parallel slideline interface (ISL) elements for spring-to-spring contact.Finit
7、e element analysis results for the force-displacement response of the sensor were in excellent agreement with experimental results.INTRODUCTIONAn important component of an automotive airbag system is the crash sensor. Va
8、rious types of crash sensors are used in airbag systems including mechanical, electro-mechanical, and electronic sensors. An electro-mechanical sensor (see Figure 1) consisting of a ball and two springs cased in a plasti
9、c housing is discussed in this to as the x-direction (see the global coordinate system shown in Figure 2) in this paper. Once enough acceleration in the x-direction is applied to overcome the preload on spring1, the ball
10、 displaces the spring. As the acceleration applied continues to increase, spring1 is displaced until it is in contact with spring2. OnceFigure 1. Electro-mechanical automobile crash sensor.contact is made between spring1
11、 and spring2, an electric circuit is completed allowing the sensor to perform its function within the airbag system.FINITE ELEMENT ANALYSIS METHODOLOGYWhen creating a finite element representation of the sensor, the foll
12、owing simplifications can be made. The two springs can be fully restrained at their bases implying a perfectly rigid plastic housing. This is a good assumption when comparing the flexibility of the thin springs to the st
13、iff plastic housing. The ball can be represented by a rigid surface since it too is very stiff as compared to the springs. Rather than modeling the contact between the plastic housing and the ball, all rotations and tran
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