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Automotive Injury Limit Evaluation and Excel Pass Fail Automation

30 Chapters
View Course Samples Online
01
Course overview
injury limit evaluation in automotive safety, regulatory and consumer-test contexts, and the role of Excel-based pass/fail automation.
evaluationautomotive
02
Injury criteria fundamentals
HIC, HIC15, HIC36, a3ms, chest deflection, chest acceleration, neck injury criteria (Nij, Nkm), femur force, and tibia index, with units and typical limit values.
criteriaHIC
03
Regulatory and rating frameworks
FMVSS 208, FMVSS 214, ECE R94/R95, Euro NCAP, and C-NCAP injury limits, including differences in criteria definitions and pass/fail thresholds.
Regulatoryframeworks
04
Test data sources and formats
dummy channel data from crash tests, ISO-MME/DIAdem files, sampling rates, filtering per SAE J211, and channel naming conventions.
ISO-MME/DIAdemsampling
05
Excel data import and preprocessing
importing CSV/text files, parsing headers, handling missing channels, unit conversion, and time alignment across channels.
preprocessingimporting
06
Signal filtering in Excel
implementing SAE J211 CFC filters (CFC 60, CFC 180, CFC 600, CFC 1000) using formulas or VBA, and validating filter output.
filteringimplementing
07
HIC calculation in Excel
computing resultant acceleration, time-window integration for HIC15 and HIC36, identifying the critical window, and comparing against limits.
HICcalculation
08
ms clip and chest acceleration
calculating a3ms from filtered chest acceleration, handling sign conventions, and applying pass/fail thresholds.
accelerationcalculating
09
Chest deflection and compression criteria
processing deflection channels, peak value extraction, and limit evaluation for frontal and side impact.
deflectioncompression
10
Neck injury criteria
computing Nij and Nkm from upper/lower neck forces and moments, handling normalization, and evaluating against limits.
criteriacomputing
11
Femur force and tibia index
extracting peak femur forces, computing tibia index from axial force and bending moment, and applying limits.
extractingcomputing
12
Building a pass/fail evaluation worksheet
structuring input channels, criteria parameters, computed metrics, and pass/fail flags with conditional formatting.
Buildingpass/fail
13
Excel formula design for automation
using INDEX/MATCH, dynamic arrays, LET, LAMBDA, and named ranges to create reusable injury evaluation functions.
automationINDEX/MATCH
14
VBA automation for repetitive evaluations
writing macros to import data, run calculations, and generate pass/fail summaries across multiple tests.
VBAautomation
15
Power Query for data consolidation
merging multiple test files, unpivoting channel data, and refreshing evaluation workbooks automatically.
consolidationmultiple
16
Dashboard and reporting
creating summary tables, charts, and conditional formatting to visualize pass/fail status and margin to limit.
Dashboardreporting
17
Validation and verification
cross-checking Excel results against reference software (e.g., DIAdem, MATLAB), unit tests for formulas, and error handling.
Validationverification
18
Handling multiple test configurations
parameterizing dummy type, impact mode, and limit sets; using lookup tables for criteria thresholds.
Handlingmultiple
19
Batch processing of test data
designing a master workbook to evaluate a folder of test files and output a consolidated pass/fail report.
processingdesigning
20
Case study
frontal impact (FMVSS 208) — full evaluation workflow from raw data to pass/fail summary using Excel automation.
FMVSSevaluation
21
Case study
side impact (FMVSS 214/Euro NCAP) — adapting criteria and limits, handling side-specific channels, and automating evaluation.
FMVSSNCAP
22
Case study
pedestrian protection (Euro NCAP) — evaluating head and leg impactor data with Excel-based pass/fail logic.
pedestrianprotection
23
Automation of limit updates
maintaining a centralized limit table, version control, and dynamically linking criteria thresholds to evaluation sheets.
Automationmaintaining
24
Error-proofing and data integrity
input validation, checksum tests, flagging out-of-range or missing data, and audit trails in Excel.
Error-proofingintegrity
25
Performance optimization
reducing calculation time for large datasets using efficient formulas, limiting volatile functions, and manual calculation modes.
Performanceoptimization
26
User interface design
creating forms and buttons for non-expert users to run evaluations, select test files, and view results.
interfacecreating
27
Integration with other tools
exporting results to CSV/PDF, linking Excel with Python or R for advanced post-processing, and using Excel as a front-end.
Integrationexporting
28
Documentation and maintainability
writing user guides, commenting VBA code, structuring workbooks for handover, and version control practices.
Documentationmaintainability
29
Practical project
end-to-end automation of a set of crash test data — from import to a final pass/fail report with dashboard.
end-to-endautomation
30
Future trends and advanced topics
machine learning for injury prediction, real-time evaluation, cloud-based automation, and regulatory updates.
advancedprediction