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Preservation of passenger compartment space during a frontal vehicle-to-vehicle collision is extremely significant for the self-protection of small cars. It is well known that crash speed, mass, stiffness and geometric interaction ail have an influence on the intrusion of the passenger compartment in a frontal impact between vehicles. This paper reports on a new enhanced body structure to reduce passenger compartment intrusion in a crash between large and small cars. The test discussed in this report set the crash speed of both cars at 50kph, the mass of the large car at almost twice that of the small car, and the small car over lap at 50%. The proposed innovative body structure for the front end of small cars achieved a previously unavailable level of efficiency of energy absorption and was able to maintain cabin integrity.

CAE technology has been applied for the crash safety design of vehicles, however, the optimum design has not been completed for the crash behavior of the vehicles. The authors have proposed a Statistical Design Support System (SDSS), and brought forward that the SDSS is one of the available optimal approaches for the nonlinear and dynamic phenomena. In this study, the SDSS was applied for the multi-objective optimization design of the reinforced members of a vehicle, where the weight, cabin deformation, and collision acceleration were chosen as the objective functions, and the simultaneous optimization for the functions was carried out. It was shown that the SDSS could be used as a practical multi-objective optimization tool for the crash safety design of vehicles.