Abstract: Design variables have some uncertainties during the design process of occupant restraint system. Conventional optimization design, however, neglects uncertainties, it always leads to optimal object beyond constraints or object function very sensitive to the fluctuation of design variables, thus resulting in design failure. Aiming at a minibus，by means of the occupant injury analysis software, a simulation model of occupant restraint system for frontal impact of the minibus is built and the verification of the model is carried out. Based on the model, through the applications of experimental design, Kriging models and Monte Carlo simulation technique, a 6σ robustness optimization method based on product quality engineering is constructed. The method not only searches the optimum results for the design object, but also improves the reliability of the design parameters and the robustness of objective function. Engineering example indicates this method has stronger engineering practicability in the design of occupant restraint system.

Key words: Frontal impact, Occupant restraint system, Robustness optimization, Vehicle safety