Oasys LS-DYNA 11th Annual Update Meetings in India

Pune – 24th April 2018

Bangalore – 26th April 2018

Introducing JFOLD - a Simulation based

Airbag Folding System for LS-DYNA

Shinya Hayashi Richard Taylor

JSOL Corporation Arup
 Introduction
Airbag safety system requirements
Fast virtual design
• In-position occupant injury prediction
Realistic gas flow
• Out-of-position occupant injury prediction
• Component performance issues
– Trim and module fracture prediction
– Airbag hang-ups Detect and solve problems
during the early design
– Incorrect deployment direction phases using simulation

 We need more accurate finite element airbag models

Copyright © 2018 JSOL Corporation All Rights Reserved 2

 Introduction
Demand for improved airbag model performance

Airbag CAE models must accurately simulate the same

deployment shape, timing and power as the real device.

In particular, we need…
• Good model of the gas dynamics  CPM
• Realistic folded condition  JFOLD
• Correct fabric behaviour  FORM=14
• Robust contacts 
• Good trim material failure models 
• … etc.

Copyright © 2018 JSOL Corporation All Rights Reserved 3

 Introducing JFOLD
JFOLD is a software tool that helps the user do simulation based airbag folding.

Development driven by experience of

folding airbags for customers.
JFOLD runs inside PRIMER and uses
LS-DYNA to simulate each folding step.
Easy-to-use tool for non-expert users:
• Access to pre-processing functions
like MEASURE & CUT-SECTIONS.
• Internal checking & fixing avoids
calculation errors.
Windows & Linux supported 
Constantly improved to make folding
quicker and easier.

Copyright © 2018 JSOL Corporation All Rights Reserved 4

 How JFOLD works

Copyright © 2018 JSOL Corporation All Rights Reserved 5

 Process Management Panel

Folding pattern A

“Root” “Parent step” “Child step” Folding pattern B

Folding pattern C

LS-DYNA
analysis

LS-DYNA
analysis

Copyright © 2018 JSOL Corporation All Rights Reserved 6

 Project Sharing Capability

Request new airbag OOP studies

development Trim breakout studies
Full vehicle injury studies

Car maker
Request new
folding pattern
Costs
and
Folded airbag model
delays!

Supplier Develop prototypes

Refold airbag model Refold airbag
& folded CAE
models

Copyright © 2018 JSOL Corporation All Rights Reserved 7

 Project Sharing Capability

Request new airbag OOP studies

development Trim breakout studies
Full vehicle injury studies

Car maker Car maker can

easily modify fold
pattern using
Shared JFOLD project data JFOLD 

Supplier Develop prototypes Final design updates

Fold using JFOLD using JFOLD

Copyright © 2018 JSOL Corporation All Rights Reserved 8

 Six Free Example Projects including Two Tutorials

3D Passenger airbag

Driver’s airbag

Also: curtain
airbag

Side airbag

Copyright © 2018 JSOL Corporation All Rights Reserved 9

 Example of Built-in Tool Assembly
Thin Folds were made using the built-in Fold Tool assembly:

4 tools  1 assembly

Copyright © 2018 JSOL Corporation All Rights Reserved 10

 Example of Built-in Tool Assembly
Example of how to set up the Folding Tool

Import from library

Scale to correct size

Copyright © 2018 JSOL Corporation All Rights Reserved 11

 Example of Built-in Tool Assembly
The Auto-Move function positions all plates just slightly away from
the airbag fabric automatically

Copyright © 2018 JSOL Corporation All Rights Reserved 12

 Example of Built-in Tool Assembly

Preview function animates the tool motion

Copyright © 2018 JSOL Corporation All Rights Reserved 13

 Example of Built-in Tool Assembly
In this example, two folding assemblies were used: the left folds over the right.

Rotator height adjusted for a thicker fold

Timing offset to avoid collision

Copyright © 2018 JSOL Corporation All Rights Reserved 14
 Analysis Submission
JFOLD can submit LS-DYNA on local processors
(Remote & batch submission under development)

Edit mode
Colour of buttons
shows run status  Running (JFOLD submit)

Running (user submit)

Updates automatically
when finished. Finished : Normal termination

Finished : Error termination

Copyright © 2018 JSOL Corporation All Rights Reserved 15

 Side Airbag Example

Copyright © 2018 JSOL Corporation All Rights Reserved 16

 Side Airbag Folding and Deployment Study
Study Objectives:
1. Demonstrate JFOLD using a simple airbag and common folding techniques
2. Compare deployment performance of each design using CPM in LS-DYNA
JFOLD data created in this study will be made freely available to JFOLD customers

Make various folding

patterns using JFOLD
Example side airbag

Assess performance

Inflator

Package space

Copyright © 2018 JSOL Corporation All Rights Reserved 17

 Side Airbag Folding and Deployment Study

Tuck Folding Inflator fitting

Zig-Zag Folding Roll Folding

Copyright © 2018 JSOL Corporation All Rights Reserved 18

 Side Airbag Folding and Deployment Study

Lift Folding
Wrapper Fitting

Thick Folding

Copyright © 2018 JSOL Corporation All Rights Reserved 19

 Copying Tools to A New Step

Copying tools saves preparation time!

NEW NEW COPIED

Copyright © 2018 JSOL Corporation All Rights Reserved 20

 Copying Tools to A New Step

Copying tools saves preparation time!

NEW
COPIED

NEW
Mostly COPIED
Copyright © 2018 JSOL Corporation All Rights Reserved 21
 Final Mods for CPM Deployment Analysis
Wrapper elements deleted to create a perforated tear line.

Copyright © 2018 JSOL Corporation All Rights Reserved 22

 Impactor Deployment Results
Tuck  Zig-zag Fold  Zig-zag Zig-zag  bend

ZIGZAG = FASTER ZIGZAG + BEND = FASTEST

ROLL = SLOWER

Tuck  Roll Fold  Roll Roll  bend

Copyright © 2018 JSOL Corporation All Rights Reserved 23

 Curtain Airbag Example

Copyright © 2018 JSOL Corporation All Rights Reserved 24

 Curtain Airbag Example
Typical design,
demonstration model

Free examples show easiest &

quickest ways to make different
fold types.

Roll  Fold

Copyright © 2018 JSOL Corporation All Rights Reserved 25

 Curtain Airbag Example
Free examples show easiest &
quickest ways to make
different fold types. Fit cover - keeps
Inflator fitted into pocket. the airbag together.
It rips off during
deployment.

Rolled airbag is pulled into design

package position using quick and easy
methods Cut section through
final model 

Copyright © 2018 JSOL Corporation All Rights Reserved 26

 CPM Deployment: Visualisation - D3PLOT
Particle mapping can roughly visualise pressure field 

Copyright © 2018 JSOL Corporation All Rights Reserved 27

 Driver’s Airbag Example

Copyright © 2018 JSOL Corporation All Rights Reserved 28

 Roll Folding using JFOLD

Copyright © 2018 JSOL Corporation All Rights Reserved 29

 Zig-Zag Folding using JFOLD

JFOLD’s Z-Fold Tool assy. used to create accordion pattern

Again, rods used to fold thicker sections

Copyright © 2018 JSOL Corporation All Rights Reserved 30

 Wrapper & Case Fitting

Wrapper Fitting Case Fitting

Copyright © 2018 JSOL Corporation All Rights Reserved 31

 Passenger Airbag Example

Copyright © 2018 JSOL Corporation All Rights Reserved 32

 Passenger Airbag Example

Free examples show easiest & Stitch

Wrap quickest ways to make
different fold types.

Fold Collapse
inner

Copyright © 2018 JSOL Corporation All Rights Reserved 33

 Passenger Airbag Example

Roll

Wrap Relax

Copyright © 2018 JSOL Corporation All Rights Reserved 34

 PAB Deployment Analysis: CPM in LS-DYNA

Copyright © 2018 JSOL Corporation All Rights Reserved 35

 New Morphing Function

Copyright © 2018 JSOL Corporation All Rights Reserved 36

 Shape Morphing – 3 step process:
1. Morph the inflated bag to roughly desired shape
– Interactive morphing to change size and shape
– JFOLD reports volume, distance to occupant etc.

Target inflated volume: 90 litres 

Copyright © 2018 JSOL Corporation All Rights Reserved 37

 Shape Morphing – 3 step process:
1. Morph the inflated bag to roughly desired shape
– Interactive morphing to change size and shape
– JFOLD reports volume, distance to occupant etc.

Target inflated volume: 90 litres 

Copyright © 2018 JSOL Corporation All Rights Reserved 38

 Shape Morphing – 3 step process:
2. Run simulation to change the original shape to the morphed shape
– Low pressure inflation, interacts with parts to reduce wrinkles
– Check volume, distance to occupant, force on occupant etc.
– Morph again if needed
Morphed inflated volume: 91 litres 

Copyright © 2018 JSOL Corporation All Rights Reserved 39

 Shape Morphing – 3 step process:
3. Map fabric elements into the new morphed shape.

Copyright © 2018 JSOL Corporation All Rights Reserved 40

 PAB Design Tool – Shape Morphing

Refold the new geometry using the same steps as before

Copyright © 2018 JSOL Corporation All Rights Reserved 41

 PAB Design Tool – Shape Morphing
Original PAB compared to morphed shape (CPM)

Design improved 

Copyright © 2018 JSOL Corporation All Rights Reserved 42

 Ongoing Airbag Simulation Research at JSOL & Arup
Particle flow control for better gas dynamics
Decomposition control for faster run times

Post-processing for better flow visualisation

Copyright © 2018 JSOL Corporation All Rights Reserved 43

 Summary and Conclusions
• In this study JFOLD and LS-DYNA were used to
demonstrate examples of SAB, CAB, DAB and PAB
folding.
• Various JFOLD tools and techniques were used to quickly
generate the models.
• JFOLD is a proven enabler for fast and realistic
simulation based folding.
• User feedback, requests and continuous research into
quicker and easier folding techniques drives the
development of the software.
• For more details please see Arup.

Copyright © 2018 JSOL Corporation All Rights Reserved 44

 Thank you very much

Shinya Hayashi Richard Taylor

JSOL Corporation Arup

Copyright © 2018 JSOL Corporation All Rights Reserved 45