This study investigated the feasibility of reducing the crumple zone in the Aachener Rail Shuttle (ARS) by optimizing the energy absorber and obstacle deflector while ensuring compliance with the European crashworthiness standard, EN 15227. The research began by analyzing the current 600 mm deformation length energy absorber and explored the possibility of replacing it with a 550 mm model through finite element analysis (FEA). The results confirmed that the shortened energy absorber maintained sufficient energy dissipation capacity, reduced deformation length while maintaining structural integrity, and led to a more compact crashworthiness design.
Furthermore, the study evaluated the fastening system and structural performance of the obstacle deflector, ensuring it remains securely attached under impact conditions. The simulation results indicated that the obstacle deflector successfully meets the EN 15227 standard under both center load and side load conditions, with no significant permanent deformation occurring. Under overload conditions, the obstacle deflector absorbed approximately 15.2 kJ, exceeding the minimum requirement of 14.4 kJ specified in EN 15227 for Category C-III vehicles operating at 100 km/h. Additionally, in the case of static overload, while some fasteners experienced stress exceeding the yield strength, the stress level remained below the ultimate tensile strength. The redesigned obstacle deflector was successfully relocated beneath the chassis, preventing interference with buffer operations while maintaining compliance with the EN 15227 static load requirements.
However, further research is required to incorporate more detailed models and explore advanced materials, aiming to improve simulation accuracy and structural performance. Additional evaluations under extended EN 15227 scenarios and other relevant standards are also recommended to ensure a more comprehensive crashworthiness assessment.