Along with seatbelts, the airbag has also saved countless lives around the world. The Supplementary Restraint Systems (SRS) – so-called because they should be used with seatbelts – have been around since the 1970s and are installed in virtually all modern cars.
Airbag systems initially began as just a bag inflating to provide a cushioning effect and prevent the head of the driver or front passenger from hitting the steering wheel or windscreen, reducing the risk of serious head injuries. But researchers have constantly tried to make airbags more effective in various ways and to provide cushioning and protection in a greater number of conditions.
Honda R&D has been hard at work for decades to make airbags better and developed a ground-breaking front passenger airbag design some years back. The airbag technology is designed to better manage lateral collision forces that can cause an occupant’s head to rotate severely at high velocity and slide off a conventional airbag, increasing the chance of serious injury.
China’s auto industry goes back many decades but it was only in the 1980s, as the country’s economy opened up, that the industry began to expand. Numerous new car companies were established, largely with government support to help them get going, and apart from joint-ventures with foreign carmakers, there were also many that developed on their own.
In the auto industry, the name of the game is numbers – to achieve the biggest volumes possible so that economies of scale can push production costs down. To build up to the critical levels, aspects like quality and safety may not be as high a priority as producing as many vehicles as possible. It’s a normal evolutionary process in the auto industry and once the critical annual volume is reached, then attention can be given to other areas as increasing profits provide the financial resources for more R&D.
So it’s not unusual that the early cars from Chinese companies had low quality and it should be remembered that the Japanese and Koreans also went through that phase. In the 1960s, when the Japanese cars started to sell in noticeable numbers in Malaysia, they were considered fragile and thought to be ‘made from Milo tin can materials’, which was really a myth. But in time, they improved quality and moved so far ahead as to lead the industry in that aspect.
For the Chinese carmakers, the 2000s were a time of rapid growth and getting into world markets. While their vehicles were selling well in China and there was then little emphasis on safety, the same was not the case in other countries. Safety standards were well established and independent organizations like Euro NCAP and Germany’s TUV and ADAC conducted assessments on new vehicles which included crashing them.
The severely damaged Landwind X6 tested by Germany’s ADAC in 2005 increased the negative perception of the passive safety of Chinese vehicles.
The early Chinese cars exported to Europe had poor ratings then, and a SUV model called the Landwind X6 showed a shocking result in Euro NCAP’s crash test in 2005 when it was so severely damaged that it got zero stars. Though testing by some other organizations suggested that it was not all that bad, the negative publicity became associated with cars from China.
The need for better engineered cars with better protection for occupants saw the establishment of safety standards by the China Automotive Technology Research Centre in 2006. This was the start of C-NCAP (China’s New Car Assessment Program) which would eventually adopt international standards typically led by Euro NCAP. There is now a Global NCAP organization which coordinates and assists national and regional organizations in this field.
NCAP tests are not required by law in any country, but their results are of interest to car-buyers who will be better informed of the level of safety a model offers. Manufacturers therefore aim to achieve the best result – 5 stars – for their new models. During development, they are made aware of the various requirements in the tests and engineer their vehicles to meet or even exceed those requirements.
Many new models nowadays can score the maximum of 5 stars but some get less either because of their design or because they may not have sufficient protective capability or features. In some cases, reduced equipment may also mean a lower score, but the vehicle will also cost less. So it is up to the buyers to decide whether they value their lives enough to pay the extra for better safety or settle for a less safe car and save money instead.
The NCAP requirements or protocols are constantly evolving and are periodically updated with tougher requirements as new technologies become available and also to push manufacturers to make their cars safer. Thus a model which may have scored well in 2003 might not achieve the same result today because the requirements have become tougher. For example, in 2008, Euro NCAP (and other NCAPs followed later) made it a requirement that Electronic Stability Control (ESC) must be present to be able to get 5 stars. If a model scored well in all areas but had no ESC, it would get only 4 stars. This basically forced the industry to make ESC a standard feature before long, providing motorists with better active safety.
Another example is the provision of airbags for both front occupants. This was promoted by ASEAN NCAP for models sold in the region and before long, manufacturers made dual front airbags standard across the range.
The upgrading of protocols is done in discussion with the industry to ensure that sufficient time is given for carmakers to improve their engineering or further develop technologies that will make it possible to meet new tests. There is also the cost factor as imposition of new technology too fast can make cars more expensive.
In the case of China, C-NCAP (which set standards) was behind the global NCAP standards at the start. However, by 2012, the protocols were upgraded to become close to what Euro NCAP had. For example, the main frontal offset impact speed was increased from 56 km/h to 64 km/h, and there was a general increase in the thresholds for injury scores of the dummies.
By 2018, the vehicles that were made in China and also the regulations set by the authorities were comparable to those in Europe. This meant that Chinese vehicles had safety standards that could be considered as world-class, with most of the models sold globally being able to match those from other makes.
A recent example of this achievement is with the latest HAVAL H6 from GWM (Great Wall Motors). The new SUV was given a 5-star rating by ANCAP, the NCAP organization for the Australasian region. Even more impressive was that the model had met ANCAP’s latest 2022 protocols which are tougher.
“This is GWM’s first new HAVAL SUV model to the Australasian market for a number of years. Delivering a 5-star vehicle to the market – against ANCAP’s latest 2022 protocols – demonstrates the brand has kept pace with the latest ANCAP safety standards and consumer safety expectations,” said ANCAP’s CEO, Carla Hoorweg.
The H6 achieved excellent results in 4 aspects – Adult Occupant Protection (AOP), Child Occupant Protection (COP), Safety Assist and Vulnerable Road-User Protection, with scores of 90%, 88%, 81% and 73%, respectively.
Details of the results showed that the H6 got a ‘GOOD’ grade in AOP. It has got a full score in tests such as side impact, oblique pole, whiplash protection, and rescue and extrication. In addition to the 70%+ high-strength steel vehicle frame, the vehicle is also equipped with an omnidirectional airbag that can effectively protect front and rear passengers from injury during a crash.
In terms of COP, the H6 also did very well. It received a full score in dynamic test (side) due to the lower ISOFIX anchorages and top tether anchorages installed in the rear seat. These further strengthen the connection between the childseat and the vehicle body, thus providing better safety protection for children.
Vulnerable Road User Protection is something which GWM would have given attention to earlier because C-NCAP had already been looking into it for some years now. The China In-Depth Accident Study (CIDAS) which was developed like Germany’s GIDAS identified that around 22% of serious crashes involved pedestrians. This led C-NCAP to also evaluate vehicles to rate how well pedestrians were protected in a collision.
The H6 also performed well in this aspect, thanks to features like an energy-absorbing space in the front bumper. Also, the Automatic Emergency Braking (AEB) system can detect pedestrians and cyclists ahead and automatically brake the car if the driver does not take action to prevent it.
There is a scientific theory that a ‘Big Bang’ occurred at the beginning of the universe. Likewise, it was many ‘bangs’ which were at the beginning of a development in the automobile’s history which would save thousands of lives. These were the tests conducted by the engineers at Mercedes-Benz in the 1960s to develop the airbag system which almost every car sold today must have.
“We used missile technology,” Helmut Patzelt, one of the founding fathers of the airbag and an expert in pyrotechnics, remembered. “A missile receives its thrust from discharged gas, and we applied this very principle. The only difference is that we trapped the gas – inside an airbag.”
At the moment of a frontal collision, the airbag starts to inflate at over 300 km/h and immediately after it is fully inflated, the pressure is released to have an absorbing effect. The entire process takes place in the blink of an eye and is certainly much quicker than what this animation shows.
It was with this type of triggering test that Mercedes-Benz began to develop the idea of the airbag in 1967, prompted by two developments which affected automobile design: the rapidly spiralling number of accidents during the 1960s and a resultant series of new laws in the USA, one of which required an ‘automatic occupant protection system’ for every car in the USA from 1969 onwards. “We can no longer tolerate unsafe automobiles,” declared Lyndon B. Johnson, the President of the USA then.
And so it was that previously ignored inventions – for which patent applications had been submitted by German Walter Linderer and American John W. Hedrik as early as 1953 – suddenly took on a whole new meaning. “A folded, deployable receptacle which inflates automatically in the event of danger” was a fascinating idea; yet, at that time, the technology required to make it happen simply did not exist. This was the cue for the automotive engineers to commence their explosive experiments.
By 1970, the pressure on the developers increased when the newly-formed US highway safety authority (NHTSA) stipulated that driver airbags would be a legal requirement for all new cars – starting as early as January 1, 1973. No sooner had it been made a requirement than the airbag became the subject of a long-running dispute. “The airbag will kill more people than it saves,” claimed critical voices that joined the debate in the USA.
As a consequence, the introduction date was changed to 1976. And even after that, the production launch had to be postponed on several other occasions. Alarmist statements and uncertainties had people wondering if the airbag was just ‘a lot of hot air’. Hansjurgen Scholz, who was then project manager for passive restraint systems at Mercedes-Benz, remembered that period only too well: “When a fatal accident involving an airbag occurred in the USA in 1974, most of those involved deserted the project like a sinking ship!” All of a sudden, the development team at Mercedes-Benz found that they were left on their own, without any outside support. Other German manufacturers also failed to see the potential of the life-saving airbag at the time.
But the team of engineers was not ready to give up. “We had recognised the enormous potential of the air cushion. And we were not going to throw away our trump card,” said Professor Guntram Huber, a former director of development for passenger car bodywork at the German carmaker. He would later be awarded the ‘Safety Trophy’ by the American Department of Transportation for his role in the introduction of the airbag.
The inside of a steering wheel with an airbag system. The white section is the folded airbag and below it are the pellets which reaction to generate a gas that inflates the airbag at very high speed – like the firing of a rocket exhaust.
And so it was that, in 1974, Mercedes-Benz decided to go ahead and put the airbag into production, regardless of the seeming negative sentiment in the US market concerning airbags. What’s more, the idea was to offer the safety device in the world market and not just the US alone.
The technological challenges that had to be overcome when developing this innovation, which finally led to the unveiling of the world’s first driver airbag in December 1980, were immense. A new product had to be created entirely from scratch. Problems that required solutions included the sensor-triggered deployment mechanism, the gas generation process, the tear-resistance of the airbag fabric, the effects on health and hearing, functional reliability and the crucial issue of how to prevent unintentional activation. Given the intrepid test methods employed – they were, after all, based on missile technology – the authorities were quick to offer resistance, at first putting the triggering mechanism used to inflate the airbag in the same category as fireworks. In Malaysia too, early perception of airbag systems by the authorities was similar and required companies to have rooms akin to bomb shelters to store airbag systems! For this reason, all those involved in the development of the airbag had to attend an explosives course. Following initial tests with liquid gas cylinders, the breakthrough was finally achieved by using a solid fuel for firing the airbag.
Toxicologists also had their say, querying the emissions left behind inside the car after deployment of the airbag. But the developers were able to allay these fears as well, since the solid fuel pressed into tablet form – consisting of sodium azide, calcium nitrate and sand – left behind predominantly non-hazardous nitrogen gas and small quantities of hydrogen and oxygen. It did, however, get smoky inside the cabin, leading people to sometimes fear that a fire had started.
In their efforts to overcome the technical hurdles before them, many of the ideas the engineers came up with were highly unconventional. Since the sound of the deploying airbag was above the pain barrier but only lasted for 10 milliseconds, the effect on the eardrums could not be clearly ascertained at first. The engineers therefore installed a cage containing 15 canaries in a test car to determine the harmful effects of the noise, gas emissions and air pressure during deployment of the airbag. Not only did all the canaries survive the test, they also remained their usual lively selves…
Testing airbags under development in 1969.
Some 250 crash tests on complete vehicles, around 2,500 sled tests and thousands of component tests provided the airbag pioneers with invaluable knowledge to help the airbag on its way to full series production. The primary concern in all the tests was stopping the car airbag from deploying unintentionally – a horror scenario for the developers. In early tests, the airbag would sometimes go off even when the vehicle was at a standstill, meaning that the engineers also had to develop the electronic system from scratch. The sensor only had a few milliseconds in which to deploy the airbag – still very much a fanciful idea in those days. As if that were not enough, the sensor had to be able to function reliably for several years at extremely low or very high temperatures with constant fluctuations in humidity, depending on the country.
Some 600 test cars took part in road tests, off-road trials and rally events, clocking up in excess of 7 million kilometres, in order to ensure that the sensor could perform its vital, life-saving function. In addition, the engineers, technical experts and office staff had to literally put themselves in the firing line. They sat at the steering wheel to gauge the effects of the airbag as it deployed in an emergency, all under the watchful eye of the project team who recorded the results.
Last but not least, another issue which had to be resolved before the first airbag was allowed to be installed a production car in December 1980. Even 40 years ago, Mercedes-Benz was thinking of the environment and had to consider disposal of airbags; in other words what to do with the airbag when the car reached the end of its life or after it actually did its life-saving work.
Following the world premiere of the driver’s airbag in a W126 S-Class in 1980 (above), the specialists in the safety development department set about building upon their lead, using their know-how to further develop the safety system. This led to the installing a second airbag for the front passenger which was introduced in 1988. Then, in 1992, all Mercedes-Benz models were fitted with a driver’s airbag as standard globally, with the passenger airbag eventually becoming standard as well in 1994.
A further milestone in passenger car safety was achieved in 1995 when the side airbag made its debut in the E-Class following a development period of around 10 years. The side airbag against each front door presented new challenges for the developers as it only had 20 milliseconds in which to deploy following a crash. In contrast, the front airbag enjoyed the comparative ‘luxury’ of around 40 milliseconds (a millisecond is one-thousandth of a second… quicker than even a blink of an eye).
Today, most Mercedes-Benz models have multiple airbags systems around the cabin to provide maximum protection during an accident, even from collisions against the sides.
The next milestone in airbag history – the windowbag – came in 1998. In the event of a side impact, it inflates across the side windows to form a curtain, its large dimensions providing a wide area to protect the heads of both the front occupants and the rear passengers. Windowbags can prevent the head from hitting the side window, roof pillars or roof frame and are also capable of catching any fragments of glass or other objects propelled into the interior following a collision or subsequent roll-over, which constitute an additional injury hazard. They can also prevent people from being ejected during a violent impact.
An early concern was the presence of a childseat on the front seat – a very dangerous situation which manufacturers warn drivers of. The powerful impact of a deploying airbag can force the childseat against the backrest and cause serious injury to the child in it and it will be lethal if the child is facing forward. For this reason, Mercedes-Benz engineers developed automatic child-seat and front-passenger recognition systems which enable the ideal airbag response given the situation in hand. Similarly, the front airbag, sidebag and belt tensioner on the front passenger side are deactivated when the seat is not occupied.
The development of airbag systems has not stopped at Mercedes-Benz. On the contrary, new technologies have improved performance and functions. Today, the airbag has evolved into a highly complex and sensitive electronic system – a high-tech product that adapts to suit the seat occupant and the accident situation, responding accordingly before the driver has even had time to fully register any precarious accident situation. This lightning-fast reaction time is down to electronic triggering sensors and gas generators which allow the front airbags to deploy in stages, depending on the severity of the accident.
The life-saving air cushion will continue to be a vital component at the heart of the safety equipment package for all Mercedes-Benz vehicles. And apart from regulatory requirements, which Mercedes-Benz has always met or exceeded, many future features and improvements will also be guided by what happens in real-life accidents. For the engineers, this means making airbags effective enough to cover a wide range of accident scenarios and ensuring that they can be deployed in accordance with the severity of the accident.
For many who have been in a car when it has been involved in a serious accident, the safety features that they may thank for having saved their lives would likely be the seatbelt and perhaps the airbag as well. There’s no doubt that these two safety features have saved tens of thousands of lives and reduced the severity of injuries for many thousand more.
However, just as vital to preventing deaths and reducing injuries has been the structure of the car itself. This is what has first contact with another object – a vehicle, a tree, a lamp post or even a building – and it receives the enormous forces of impacts. These forces are transmitted through the body and each the cabin where they can cause injuries as various parts are smashed into humans.
Thanks to pioneering work by a Daimler Benz engineer in the late 1940s, modern car structures have been engineered in such a way as to diminish the impact forces so they do not cause great harm. The engineer was Béla Barényi and his innovation – called the passenger car safety cell – is a fundamental feature of passive automotive safety to this day. It was patented in Germany by Daimler-Benz and described as ‘a passenger car body with a passenger safety cell’. The Patent No. 845 157, which also identified Barényi as the inventor, had the title ‘Motor vehicle, specifically for personal transport’.
The engineer was fortunate to work at Daimler-Benz which was just as passionate about safety as he was. There were other carmakers at that time who carefully avoided topics about crash safety; particularly in the post-war period, nobody wanted to be reminded about the dangers of driving. The topic was viewed as a sales killer right up to the 1970s.
Barényi’s innovation had completely changed how vehicle construction should be with regard to occupant protection. For decades, engineers had taken the approach that the more rigid the body could be made, the better the protection would be during an accident. So a tank would have been very safe – but rather impractical on public roads.
Barényi’s studies showed that that the forces generated during an impact were transferred to the occupants with hardly any prior absorption. And with no seatbelts to retrain them (airbags would come 30 years later), they would also be thrown about the cabin, if not out of it.
These findings led Barényi to find a way to have absorb the kinetic energy built up during a collision. He came up with an overall vehicle concept which consisted of three cells: the safety cell in the middle where the occupants were seated, and cells at the front and rear which were connected to it. This concept was developed some years earlier when Barényi did his own ‘Terracruiser’ and ‘Concadoro’ studies, and when he joined Daimler-Benz, he was able to realise them.
The text of the patent application explained the purpose of this design as follows: “The forces generated during a collision are […] absorbed by the [front or rear] cell section.” Later on, a catchy expression was coined for these areas of controlled deformation: crumple-zones. The safety cell that encircled the occupants and protected them from the impact forces acting on the vehicle structure also came to be referred to as a ‘safety cage’.
The 1959 Mercedes-Benz W 111 model (referred to as ‘Fintail’) was the first car to have the safety cell concept in its design.
In 1959, the safety body with its rigid passenger cell was used for the first time in a production model – the Mercedes-Benz W 111 series which had the distinctive ‘fintail’. Mercedes-Benz also increased the awareness of developers where automotive safety in general was concerned. The W 111 model also had a new safety steering wheel (also developed by Barényi) with a large impact plate and a deformable connecting piece between the plate and the end of the steering column, which was moved forward.
With new technologies, especially computer-aided engineering, the concept of the safety cell has evolved further. The impact forces are not just absorbed but also dissipated by carefully designed structural members to provide ‘paths’ around the cabin area. Nevertheless, the fundamental objective remains and that is to prevent or minimize the forces that reach the occupants. Béla Barényi received more than 2,500 patents for his inventions, most of which related to automotive innovations and enhancements.
Today’s cars have even better protection all round, not just at the front and back, but Barényi’s fundamental idea of having a strong safety cell around the occupants remains.
Vaccination does not make you immune to COVID-19 infection. You can still get infected and although you may not show symptoms, you may be spreading spread the coronavirus to others. Do not stop taking protective measures such as wearing a facemask, washing hands frequently and social distancing.
It is well known that a Swedish engineer, Nils Ivar Bohlin, who joined Volvo from the aircraft industry developed the 3-point safety belt that is common in every car today. And, though patented, Volvo generously allowed everyone else to follow the same design without any charge. It was a ‘gift to the world’ as Volvo hoped such a move would get the seatbelt adopted widely and quickly. And it was, saving hundreds of thousands of lives worldwide. Bohlin’s invention appeared in the late 1950s and of course, Volvo led the way by installing it in its cars as standard.
An idea from aircraft
However, the seatbelt was around for some time before Bohlin’s invention. The idea came from aircraft and early automotive inventors considered it to provide a form of restraint in the event the driver was thrown forward. In France, for example, Gustave-Desire Leveau registered a concept in 1903, which was for a complex 4-point seatbelt for the driver as well as the passengers.
Before the 1960s, seatbelts that were provided were the 2-point lap type that went only around the waist (left). Nils Bohlin’s invention added a third strap coming down from the top across the chest (right).
In Germany, Daimler Benz introduced a seatbelt in its Mercedes-Benz 300 SL Roadster (W 198) in 1957. The 2-point seatbelt, essentially like what was found in commercial aircraft, was an option in the open-top supersports car and the owner could have it installed on one or both seats.
Racing cars get seatbelts
From the 1950s onwards, an increasing number of cars racing in motorsport were also fitted with a seatbelt. It was a logical thing to do as speeds rose, and drivers could be flung out or hit the steering wheel in a crash. Over time, safety systems in racing cars have advanced and those used by drivers in Formula 1 cars are extremely sophisticated, providing head-and-neck support to reduce the dangerous acceleration of the head during a collision.
The most advanced seatbelt systems are probably the ones in F1 racing cars which must restrain the drivers who can crash at very high speeds.
In 1958, Mercedes-Benz started to offer the 2-point seatbelt as optional equipment for the entire range of passenger cars with individual seats in the front. By the end of the same year, lap belts in the rear seats were also optionally available. Konrad Adenauer, the first Chancellor of the Federal Republic of Germany, was convinced by the system and his official car was equipped with a lap belt in the rear.
Enhanced operation for convenience
As mentioned earlier, Volvo made the 3-point seatbelt concept freely available to the industry and Mercedes-Benz adopted the idea in the 1960s. It combined the benefits of a lap belt and shoulder belt – just like Bohlin had described it in 1958 – and included a reeling mechanism, which was initially like a ‘luxury’ feature. Mercedes-Benz introduced the seatbelt with the automatic reeling mechanism as standard equipment in front seats in 1973, and later as standard equipment in rear seats.
The W 126 Mercedes-Benz S-Class came with a seatbelt and tensioner for more effective restraint, as well as an airbag for the driver.
It is not just the way the seatbelt wraps around the body which is critical, but also how it is attached. The company delivered the R 107 model series SL (in 1971) with a seatbelt anchored to the bottom of the seat as standard equipment.
Seatbelt becomes compulsory
The value of seatbelts was very quickly noted by safety authorities, supported by accident research data. Manufacturers were asked to provide them as standard, at least for the front occupants, but not everyone wanted to use them. So laws were introduced to make usage compulsory, at least for the front occupants. Later on, the laws would be revised to include rear passengers as well.
Such laws initially met with plenty of resistance as they seemed to cause inconvenience and imagined discomfort. In Switzerland, for example, the protests were strong enough that the requirement was suspended some time and a referendum carried out before the law was accepted in 1981.
Mercedes-Benz continuously did R&D on all types of passive safety systems, which included seatbelts. As part of the Experimental Safety Vehicle (ESV) programme, automatically engaging seatbelts for the front seats were tested back in 1972 in the ESV 13 experimental safety vehicle. ESV 22, developed in 1973, served as a platform to test 3-point seatbelts featuring 3 seatbelt force-limiters and seatbelt tensioners as well as the driver airbag. By 1981, the driver airbag in conjunction with a seatbelt with a tensioner system was ready for introduction in the S-Class (W 126), providing the driver with even better protection during frontal collisions.
The quest to give better protection to the occupants of a motor vehicle continues, with various systems working together to provide the best protection when a car is involved in an accident. Advances are being made in the structure and new types of restraint systems are being developed although the primary one will still be the seatbelt.
Car-buyers all over the world are always concerned about the safety standards of the car they are interested in getting. After all, they will be using it daily and while no one wants to have an accident, it can happen unexpectedly and when it does, that’s when the protective systems and engineering become vital in minimising injuries.
Today, buyers can be better informed about how safe a model is, thanks to the New Car Assessment Programme (NCAP) which started in the European car industry 24 years ago. The program, conducted by the independent Euro NCAP organisation, involved crash tests and other assessments of new vehicles which were analysed and star ratings would be awarded, depending on the performance in the tests.
NCAP for ASEAN region
Since then, as awareness grew in other parts of the world, including Malaysia, regional NCAPs were established. This was an important move as there would be some models which might be sold or developed for specific regions. In ASEAN, the Malaysian Institute of Road Safety Research (MIROS), an agency under the Transport Ministry, was instrumental in starting a NCAP for the region. The ASEAN NCAP is recognised and part of the Global NCAP organisation which shares information and discusses matters relating to motor vehicle safety standards.
Zanita Zaunuddin, Head of the Safety and Intelligent Drive team at Proton which engineered the X50 to score 5 stars.
While consumers have come to know about ASEAN NCAP ratings as they are publicised in articles as well as advertisements, the ratings are not mandatory for Type Approval of a vehicle to be permitted for sale in Malaysia. Nevertheless, because NCAP ratings are easy to understand and provide consumers with useful information on how safe a model is, manufacturers strive to achieve the best results and get a 5-star rating, the maximum currently awarded.
Adapted from Geely Binyue
For this reason, when the Proton X50 began development, its performance in the ASEAN NCAP was targeted to be no less than 5 stars. The X50, being adapted from Geely’s Binyue SUV model, already had sound engineering but it was not as straightforward as simply changing the badge and making styling changes here and there. To become a Proton model required a new engineering programme which included meeting the highest ASEAN NCAP standards.
The task fell to the Safety and Intelligent Drive team at Proton, headed by Zanita Zainuddin. To ensure a 5-star rating, crucial, yet subtle changes had to be made, involving performance tuning, material replacement and parts repositioning. One crucial change made was on the bodyshell of the X50. In initial frontal collision tests during development, the front floorboard often experienced tearing, certainly unacceptable by any standard. To overcome this, the engineers had to reinforce the area with ultra-high-strength steel, thereby shifting the force of impact to other areas that do not present any threat to occupant safety. Overall, 40% of the body, including the front, side and back, was made using a combination of high-strength steel variants.
It’s not a straightforward matter to convert from the lefthand drive Geely Binyue (above) to the righthand drive Proton X50 (below).
Another change was on the driver’s footrest, next to the accelerator and brake pedals. It was not a simple matter converting from the lefthand drive of the Binyue to the righthand drive for the X50. In fact, Geely had not developed a righthand drive variant so Proton would have to re-engineer certain areas for the conversion.
The engine is always placed under the bonnet towards the right side of the vehicle, regardless of the driving side. Therefore, during a collision, the driver of a righthand-drive Proton X50 would be more vulnerable to foot injury as compared to the driver of a lefthand drive Geely Binyue. To safeguard the driver’s resting foot from such harm, the footrest for the X50 had to be modified to ensure that the foot remains on the footrest by reducing slippage.
Improving for ASEAN NCAP from C-NCAP
Being a model primarily for the China market, the Binyue was developed to meet the requirements of C-NCAP, which is the NCAP for that country. Although there are common criteria among all the NCAPs, there are also some differences with ASEAN NCAP.
One example is the curtain airbags. ASEAN NCAP emphasizes that the static deployment of curtain airbags covers a range of body types for the different people that may be in the vehicle. Therefore, the curtain airbags for the X50 had to be adjusted to provide additional cushioning to the head area during impact, primarily during side collisions. Since this greatly improves occupants’ safety, it was highly recommended that the additional provision be incorporated in future Geely models.
Child Occupant Protection
C-NAP is also less focussed on the issue of compatible seats for child occupants, which is an important area in ASEAN NCAP referred to as Child Occupant Protection (COP) and contributory to the overall assessment. Zanita’s team made a changes which included lengthening the hook on the ISOFIX attachment point for compatible childseats. This not only made it easier to install the seat but also to readjust its angle to ensure secure positioning. The work done by Proton in such areas has been shared with Geely and will help it to be ready for such requirements if introduced by C-NAP in 2021.
Results of ASEAN NCAP’s assessment of Child Occupant Protection for the X50.
Benefits of being in the Geely Group
Geely and Proton have both benefited from each brand being subjected to different safety and market standards. The best practices are being gathered and shared, ultimately benefitting consumers who get to enjoy not only a comfortable ride but also a very safe one. Additionally, having Volvo – widely acknowledged as the world leader in automotive safety – as part of the group means being able to get assistance in advancing safety technologies.
“Proton has always emphasized safety as one of its unique selling points, unbiased to any country or platform. It is not surprising then that we continue to challenge ourselves so that this DNA is inherent throughout our range of models, be it our locally produced car or the current joint development with our partner Geely,” said Zanita.
Safety is an important factor that car-buyers consider when shopping today. There is an expectation that occupants will be well protected in the event of an accident and avoid serious injuries. At the same time, with advanced technologies, electronic systems can help a driver avoid an accident.
Organisations such as Euro NCAP and ASEAN NCAP regularly evaluate new models in the market, going to the extent of crashing and ramming them to simulate accidents. Their findings provide car-buyers with independent assessments to make more informed decisions when choosing their next car.
Renault Captur crash test by Euro NCAP.
Core competence since 1920s
For Renault, the subject of safety has been a core competence for a very long time. In fact, as far back as 100 years ago, the company already installed active safety systems in its cars which today are commonplace. In 1922, for example, the company was one of the first manufacturers in the world to equip its 6-cylinder models – the 18 CV and 40 CV – with additional front wheel brakes. At that time, braking was typically at the rear wheels. In addition, Renault offered a patented brake booster for the powerful 40 CV with 9.1-litre engine.
Renault 40 CV (left) and Juvaquatre
From 1937 onwards, the introduction of independent wheel suspension in place of the rigid axle also brought a significant increase in safety reserves. That same year, the Juvaquatre compact car was the first Renault model to have the modern chassis design on the front axle.
The Juvaquatre, produced between 1937 and 1960, was also the first Renault model with a self-supporting body. It was lighter than the frame construction that was dominant at the time and offered higher impact safety. Some of the principles of its construction would be followed in later years in all car bodies.
Accident research
As far back as 1954, Renault was already studying the effects of vehicle accidents in order to make safer cars. This was done at a centre for accident research located in the Paris area. It became the place where every new Renault model would be thoroughly tested, including crash-testing, heralding the era of modern, systematic safety and accident research.
A crash test in the 1950s
Back then, the crash tests were quite ‘basic’ and compared to today’s high-tech tests, the procedures would even be considered ‘archaic’. The Renault researchers simply sent cars crashing into trucks and then examined the outcome on different areas of the car. There were no sensor-equipped crash test dummies back then so a lot relied on visual examination and analysis.
Destroying a car was also significantly more expensive than it is today. This is why, in the 5 years between 1955 and 1960, Renault only crashed around 100 vehicles. In comparison, the company conducts up to 400 crash tests a year today and 10 times more in computer simulations.
Another facility that Renault established in the 1950s was the Laboratory for Physiology and Biomechanics. This institution was under the direction of a physician and its role was to support the development departments in designing safer and more comfortable vehicles.
Today, Renault conducts up to 400 crash tests a year and 10 times more using computer simulations.
In 1969, the laboratory’s name was changed to reflect its expanded function – the Laboratory for Accident Research, Biomechanics and Studies of Human Behaviour. Its task was to investigate real-world accidents with scientific methods and use the findings to further improve safety standards in Renault vehicles.
Safety vehicle prototypes
Renault’s basic research in the field of passive safety culminated in 1974 in the BRV (Basic Research Vehicle) prototype. In addition to a crash-optimized structure with an energy-absorbing crumple zone at the front and a fixed safety cell for the passengers, the vehicle had 3-point seatbelts for all seats, including the rear. The inclusion of seatbelts was significant because at that time, seatbelts were compulsory only in France and only outside of towns.
The BRV (left) and EPURE safety vehicles
In 1979, the EPURE concept vehicle took up the body concept of the BRV, supplemented by reinforced side members and padding in the doors as protection in the event of a side impact. For the first time, there were also precautions for pedestrian protection and gas generators that would tighten the seatbelts in the event of a crash. This was the birth of the pyrotechnic belt-tensioner, which Renault introduced in 1993 and was one of the first carmakers to do so.
Automotive safety will continue to be a central part of all product development at Renault. Drawing on multiple resources, it constantly develops new technologies, some of which are pioneering, that raise levels of occupant protection. Today, the brand has one of the safest model ranges in Europe, with vehicles across all classes – from the compact Captur to the Koleos – able to score the maximum of 5 stars in Euro NCAP’s evaluations.
