Crashworthiness optimisation of a coach under frontal impact conditions

Purpose Identifying weak points in a structure that compromise its proper functioning is a crucial step for optimising its design. Providing a structure capable of absorbing these weaknesses is essential to ensure proper operation and safety, especially in the automotive industry. This manuscript proposes solutions to increase the driver’s residual volume, ensuring compliance with the regulation ECE R29. Adjusting the stiffness/plastic joints of side profiles allows the internal volume to be optimised for the driver's survival at the same impact energy. Previous topology optimisation algorithms were applied to enhance crash box crashworthiness, and the optimised model integrates the model. Design/methodology/approach Preliminary studies revealed that coaches do not comply with ECE R29 regulation during a frontal impact, necessitating evaluating previous results and identifying critical points for structural optimisation. Findings An iterative redesign ensured compliance with ECE R29 regulations by incorporating reinforcements at identified critical points and strengthening plastic joints. Various parts were monitored for deformation and displacement, with results compared to original structure data. The steering wheel was monitored to prevent driver collisions during crash tests, ensuring regulation compliance and increased driver safety. Originality/value This approach successfully tested the original coach vehicle according to an adaptation of the ECE R29 regulation, offering a solution to improve passive safety for future products, leading to a new generation of safer coaches.