2007 BMW 3-series

Safety 

Safety engineering and features: improving on a star performer

The previous 3 Series’ safety performance has long been recognized by authoritative, independent observers:

•  After conducting its own offset crash test of a 3 Series Sedan for the March 11, ’99 issue, Germany’s auto motor und sport magazine concluded, “Occupant protection by the new 3 Series is already at such a high level that only marginal improvements can be imagined.”
•  And in the U.S., the Insurance Institute for Highway Safety, after conducting its own crash test of the 3 Series Sedan, concluded simply, “A Best Pick.”

In developing the all-new vehicle structure, BMW’s safety engineers set out not just to match, but to improve on, the predecessors‘ excellent safety performance. Integrated into this overall goal were specific targets, including –

•  Achieving 5 stars in the Euro-NCAP (New Car Assessment Program) offset frontal crash test
•  Meeting the new U.S. FMVSS (Federal Motor Vehicle Safety Standard) 301, which specifies a brutal 50-mph rear-end offset crash. The impact is taken by 70% of the test vehicle’s width; not only must stringent injury criteria be met, but the fuel system must remain free of leaks.
•  Meeting the new IIHS (Insurance Institute for Highway Safety) “SUV side-impact” test, in which an impact from a tall vehicle at 50 km/h (31.1 mph) is simulated.

Various engineering approaches toward the new 3’s even higher-performing structure included:

•  Use of new high-strength steels in the large-section structural elements.
•  Targeted application of further new types of steel, including multi-phase types, at various points to promote effective energy management.
•   Developing and improving energy paths by which the immense forces of frontal crash impacts are led through the structure and dissipated. Here, the engineers concentrated on optimizing the interaction between front-end deformation and the ability of the passenger space to remain intact. For severe frontal collisions – especially offset, when one side of the vehicle takes the brunt – they found ways to transfer the forces into the other side, so that the more heavily impacted side doesn’t have to absorb all the forces. The resulting extremely high energy-absorption capability is the basis for keeping the passenger space intact – and for optimum calibration of passive-safety systems such as safety belts and airbags.

•  In side impacts as well, the structure is similarly designed to transfer impact energy to the side away from the impact. Here the IIHS’s “SUV test” raised the bar for occupant safety in severe side collisions. Elements that manage this massive impact energy include the –
•  floor structure
•  doors, which retain BMW’s effective interlocking door anchoring system
•  reinforced B-pillars
•  dash structure, which functions as much more than just a carrier for instruments, climate control, etc.
•  roof framing.

•  In rear-end impacts, the deformable area consists of –
•  two longitudinal structural members
•  the trunk floor and lid (Sedans) or tailgate (Sports Wagons)
•   trunk or cargo-area side walls, as integral elements of the overall body-side structures
•  various additional reinforcements.

Here, the engineers worked to ensure that even in the radically severe offset rear-end crash specified by FMVSS 301, the passenger space would remain intact, the doors could be opened and the fuel system would still be sealed.

The structure is virtually fully galvanized, enhancing corrosion resistance and thus helping preserve its strength and energy management over the years.

Front-to-rear Head Protection System. Now all BMW Sedans and Sports Wagons have this feature. Compared to the 5 and 7 Series’ inflatable-tubular/sail system, the
3 Series‘ curtain-type system takes up less space in the headliner – an advantage for the compact 3 Series. Like the tubular system, BMW’s curtain-type HPS can remain inflated for several seconds after initial deployment, an important function in case of rollover.

Automatic safety-belt tensioners and force limiters front and rear. Long standard on BMW front safety belts, these features now enhance the outboard rear belts’ effectiveness as well.

New occupant-detection sensor. BMW has long employed a sophisticated electronic control strategy for managing the deployment of airbags and safety-belt tensioners. This approach now becomes even more precise, thanks to a new sensing mat in the front passenger seat. Called OC3, the mat is more highly sophisticated than its predecessor; it measures the weight and analyzes the pressure distribution of the occupant in order to distinguish between an adult and an infant in a child safety seat.

New features for protecting the driver’s feet and knees. Two measures reduce the likelihood of injuries to the driver’s feet and legs:

•  The footrest is designed to crush under the force of the driver’s left foot, so that the full impact force is not transmitted to his or her foot and leg.
•  Brake and clutch pedals move forward under impact force, also reducing force transfer to the driver’s feet and legs if they are on the pedals.

Performance with a conscience

BMW strives to produce its motor vehicles and other products with the utmost attention to environmental compatibility and protection. Integrated into the design and development of BMW automobiles are such criteria as resource efficiency and emission control in production; environmentally responsible selection of materials; recyclability during production and within the vehicle; elimination of CFCs and hazardous materials in production; and continuing research into environmentally friendly automotive power sources.

 Tangible results of these efforts include the recycling of bumper cladding into other vehicle components; water-based paint color coats and powder clear coats; near-future availability of hydrogen-powered models; and various design and engineering elements that help make BMWs easier to dismantle at the end of their service life.

Driving and chassis

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