NED UNIVERSITY OF

ENGINEERING AND
TECHNOLOGY

COMPLEX ENGINEERING PROBLEM (CEP) #01

(PRODUCTION & MANUFACTURING OF AUTOMOTIVE
SAFETY SEATBELTS)

COURSE: AUTOMOTIVE HEATH, SAFETY AND

ENVIRONMENT

COURSE CODE: AU-433

SUBMISSION DEADLINE : 14TH JANUARY, 2022 (FRIDAY)

SUBMITTED TO: DR. FARAZ AKBAR

GROUP MEMBERS

NAZIM NAVEED (AU-18013)

MUHAMMAD ABDULLAH BIN SALEEM (AU-18015)

SAMEER ARGHAWANI (AU-18006)

ABDUL SAAD KHAN (AU-18017)

 COMPLEX ENGINEERING PROBLEM (CEP) #01

INTRODUCTION

Automotive textiles happen to be the rewarding sector finding extensive use of technical textiles
in the product categories viz. interior trims, safety devices like seat belts and airbags, carpets,
filters, battery separators, hood liners, hoses & belt reinforcement. Textiles, which constitute
approximately 20-25 Kgs in a car, are not only used for enhanced aesthetic of automotive but
also for sensual comfort & safety. Additionally, few textile products found their applications as
design solutions to engineering problems in the form of composites, tire reinforcement, sound
insulation & vibration control. Apart from woven & knitted constructions, Nonwovens also find
applications in transport textiles due to certain advantages served by them.

ORIGIN AND BRIEF HISTORY OF SEATBELTS

Fact Check: The seat belt is one of our best protections in a car crash. In fact, according to the
Center’s for Disease Control and Prevention, “seat belt use is the most effective way to save
lives and reduce injuries in crashes as more than half (range from 53% – 59%) of teens and
aged 13 – 44 years who died in crashes in 2014 were unrestrained at the time of the crash.”
In short, seat belts save lives, but how did then end up in our cars in the first place?
The seat belt was invented by George Cayley, an English engineer in the late 1800’s who created
these belts to help keep pilots inside their gliders. However, the first patented seat belt was
created by American Edward J. Claghorn on February 10, 1885 in order to keep tourists safe in
taxis in New York City. Over time, the seat belt slowly starting showing up in manufacture cars
to help passengers and drivers stay put inside their car seats. There was less concern for overall
driving safety.
Though invented in the late 1800’s, it wasn’t until the mid-1930’s when several U.S. physicians
began testing lap belts and immediately saw their impact and began urging manufacturers to
provide seat belts in all cars. In 1954, Sports Car Club of America required competing drivers
to wear lap belts during competitions and in the following year, the Society of Automotive
Engineers (SAE) appointed a Motor Vehicle Seat Belt Committee. Race car drivers were the first
to really wear seat belts to help protect them against serious internal injuries.
The real breakthrough with modern seat belts came in 1958 when Swedish engineer Nils Bohlin
invented the three-point seatbelt. Up until this point, seat belts in cars were two-point lap belts,
which strapped across the body, with the buckle placed over the abdomen. Volvo hired Bohlin
in 1958 and he designed the seat belts we know today through a three-point seat belt that better
protects the driver and passenger in an accident. The three-point design was created to help
secure both the upper and lower body. Better yet, this seat belt design was simple and effective,
leading other car manufacturers to borrow the design. When Bohlin passed away in 2002, Volvo
had estimated that the seat belt had saved more than one million lives in the four decades since
it was introduced.

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Once the idea of safety benefits of seat belts caught on in the U.S. public, sales of seat belts
skyrocketed. Auto companies offered seat belts as optional equipment and were even sold at
local gas stations.
Since 1966, American vehicles are required to have seat belts in their cars. As such, by 1975,
most first-world countries had a seat belt requirement in their cars. Once they became more
common in cars, laws soon followed afterwards. By 1970, the world’s first seat belt law was
created in Victoria, Australia, which required passengers to wear their seat belts at all times. In
the U.S., seat belt laws came around the time of the creation of The National Traffic and Motor
Vehicle Safety Act of 1966.
Though they were required by law to be in cars, wearing seat belt laws were a different story.
The National Ad Council ran countless ads for 25 plus years encouraging drivers to “Buckle
Up.” States slowly starting implementing laws and by 1995, every state except New Hampshire
had “Click it or ticket” laws. Currently, all states have a seat belt enforcing law.
So, what’s next for the seat belt? Ford demonstrated its inflatable safety belt in 2001 where a
shoulder belt containing an airbag would instantaneously inflate when a car is in a collision.
Other car manufacturers are looking to make the seat belt more comfortable and convenient for
drivers. From the crisscross experimental safety belts to seat belts that are tailored to our
individual bodies, there are many experimental seat belt types in the pipeline that could affect
the way we drive.

ENGINEERING PRINCIPLE OF A SEATBELT

The seat belt is an energy-absorbing device that is designed to keep the load imposed on a
victim's body during a crash down to survivable limits. Fundamentally, it is designed to deliver
non-recoverable extension to reduce the deceleration forces, which the body encounters in a
crash. Basically, it is designed to offer non recoverable extension to decrease the deceleration
forces that the body comes across in a crash. Non recoverable extension is significant to prevent
the occupants from being restrained into their seats and sustaining whiplash injuries right away
after a collision. An efficient seat belt will only permit its wearer to move forward a maximum
of about 30 cm to avoid contact with any fixed parts of the car. Seat belt was invented
concurrently in United States and Sweden. Earlier seat belts were fixed and adjusted manually
by the wearer.

Figure 1. Forces in Car Crashes

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SCIENTIFIC APPROACHES TOWARDS SEAT BELT

It’s a simple Newton’s first law of motion and law of energy conservation. According to
Newton’s first law of motion an object at rest tends to stay at rest and an object in motion tends
to stay in motion with the same speed and in the same direction unless acted upon by an
unbalanced force. Thus, driver continues in motion, sliding forward along the seat. A driver in
motion tends to stay in motion with the same speed and in the same direction, unless acted upon
by the unbalanced force of a seat belt. Seat belts are used to provide safety for passengers whose
motion is governed by Newton's laws (Figure 1). The seat belt provides the unbalanced force,
which brings driver from a state of motion to a state of rest.
Assume, car speed is 13.41 m/s, driver’s weight is 50 kg, then what will be the impact force
acting on the car driver?
If driver is wearing a non-stretchable seat belt, stopping distance is 0.304 mt.
Impact force on driver = [0.5x 50x (13.41)2] / 0.304 = 14788.5 N = 1.5 tons
Deceleration of driver = 14788.5/50 = 295.77 m/s2
If driver is without seat belt, suppose stopping distance is 0.0608 mt.
Impact force on driver = [0.5x 50x (13.41)2] / 0.0608 = 73942.5 N = 7.5 tons
Deceleration of driver = 73942.5/50 =1478.8 m/s2; now if driver is wearing stretchable seat
belt, stopping distance is 0.456 mt
Force on driver = [0.5x 50x (13.41)2] /0.456 = 9467.65 N = 0.96 ton and deceleration of driver
= 9467.65/50 = 189.353 m/s2
A moderate amount of stretch in a seatbelt harness can extend the stopping distance and reduce
the average impact force on the driver compared to a non-stretching harness. If the belt stretched
0.125 mt. it would reduce the deceleration to 189.353 m/s2 and the average impact force to 0.96
ton compared to 295.77 m/s2 and 1.5 tons for a non-stretching seat belt. Either a stretching or
non-stretching seat belt reduces the impact force compared to no seat belt.

Figure 2. Safety and significance of the seatbelt

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RAW MATERIAL AND MANUFACTURING METHOD

CONSTRUCTIONAL DETAILS
Raw material used for seat belt webbings are Nylon, PET and its derivatives like HTPY. Nylon was
utilized in some early seat belts, but due to of its higher UV degradation resistance; polyester is now
widely used worldwide and also polyester scores over nylon because of lower extensibility and higher
stiffness. Seat belt structures can be single layer or double layer and manufactured on needle looms with
plain weave, twill weave, satin weave. Normally 2/2-twill structure is used. The needle loom used
presently is shuttle less and capable of delivering over 1000 picks per minute.
A typical seat belt is made of 320 ends of 1,100 dtex (deci-tex) (Grams per 10,000 metres of yarn)
polyester each. Most weft yarns made from polyester are 550dtex. Commonly used seat belt webbing is
a narrow fabric measuring 46mm wide. Commercial needle looms can accommodate six weaving stations
simultaneously side by side. In case of nylon seat belts, the warp yarns are 180 dtex and the weft is either
470 or 940 dtex. Normally, 1000-1500 denier used for main warp yarns, 250-500 denier used for selvedge
yarns and same denier or slightly higher denier as selvedge yarns used for weft. Typically, 320 ends of
1100 dtex or 260 ends of 1670 dtex yarn. This structure permits highest yarn packing within a given area
for highest strength and sometimes-coarser yarns are used for good abrasion resistance.

MAJOR MACHINERIES REQUIRED FOR SEAT BELT MANUFACTURING

Major Machineries Required for the Manufacture of Seat Belt Webbings are High speed automatic
needle looms, Warp yarn tension control device, Tape collection machine Cone Creel of 600 ends,
Continuous Dying machine Steam Boiler, Compressor

MANUFACTURING METHOD OF SEAT BELTS USED IN AUTOMOBILE CAR

In the needle loom, the weft is inserted from one side of the warp sheet and here a selvedge is formed.
The other side of webbing is held by an auxiliary needle, which manipulates a binder and a lock thread.
Once these are combined with the weft yarn, a run-proof selvedge is created. Special care is taken when
constructing the selvedge to ensure it is abrasion resistant. It is equally important to ensure that the
selvedge is soft and comfortable to wear. In a loom, needle used to move monofilament and multifilament
weft yarn across width of the web in single shed. A high tension applied to monofilament compared to
multifilament yarn so that it doesn’t protrude beyond selvedge. For selvedge single ply warp yarn is used
with reverse twill weave that gives close packing and soft, round edge selvedge. Monofilament weft yarns
are rigid yarn that provides good stiffness across web and high resiliency. Monofilament weft yarns are
under high tension which controls webbing softness and round shape together with catch cord yarns and
finer warp yarns in selvedge than body of the webbing. Low longitudinal stiffness and thinner web gives
good winding performance with use of smooth monofilament weft yarns.

SEATBELT WEBBING
Webbing is the part of the seat belt in contact with the passenger that receives and softens the shock of
an impact. Nylon is among the strongest synthetic fibers, it doesn’t rot as quickly, it doesn’t stretch as
much, and woven nylon it is smooth and comfortable to the touch, as it does not leave rough ends of fibers
embedded in the weave. So, the seat belt webbing material made of polyester and woven from about 300
warp strands and one weft strand. The width of the webbing is about 48mm and has a tensile strength
sufficient to support approximately three metric tons. Seat belt material properties are the same as
polyester, now let us see the properties of polyester webbing.

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PRODUCTION FLOW OF MANUFACTURING AUTOMOTIVE SEAT

BELTS IN AN INDUSTRY

Cutting Sewing

Quality Control Assembly

Packing Packed Products

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SEAT BELT MATERIAL PROPERTIES

The following are some of the qualities that webbing made of polyester has:
➢ Static load bearing capacity up to 1500 kg
➢ Very high strength tenacity (Up to 10g/den).
➢ Elongation and Extensibility – up to 25-30% at break.
➢ Flexibility for use
➢ Abrasion: excellent resistance to abrasion.
➢ Moisture: has a very low regain of 0.4% making it feel damp very quickly.
➢ Temperature – the melting point is around 260°C and will withstand temperatures above 180°C
for some time. It will lose some strength if kept at high temperature for extended periods.
➢ Polyester is very good in low temperatures increasing in strength and reducing elongation.
➢ Polyester webbing is difficult to ignite and tightly woven structures do not burn quickly.
➢ Polyester has excellent resistance to sunlight (one of the best for outdoor use).
➢ Polyester is resistant to most common chemicals.

PERFORMANCE TESTS AND STANDARD FOR SEAT BELT

Tests are carried out for ascertaining the mechanical performance of the webbing as per BSI and the
SAE on some aspects like; width, thickness, breaking strength and elongation for dry and wet webbing,
abrasion resistance at various environmental conditions and in contact with buckles and fittings,
influence of extreme environmental conditions and temperatures, rubbing fastness, microbial resistance.

TYPES OF SEATBELTS
➢ Lap Belt: This type of seatbelt is commonly seen in airplanes and in older vehicles. The
belt attached at two-end points over a person’s lap.
➢ Sash/Shoulder Belt: Shoulder belts lay diagonally across a person’s older similar to a
sash. Typically, these types of seatbelts will buckle toward the center of the vehicle. These
belts were sometimes used in conjunction with a lap belt to create the typical 3-Point
seatbelt used today.
➢ 3-Point/Y-Shaped: First introduced in 1959 the three-point harness is simply the lap and
shoulder belt combined into one. These types of seatbelts help spread out the energy of the
moving body, in the event of a collision, over the chest, pelvis, and shoulders. These types
of belts are now standard in most modern-day vehicles.
➢ Belt-in-Seat (BIS): This automatic belt slides in and out of place when a driver enters and
exists the vehicle and was commonly combined with a lap belt.
➢ Five-Point Seatbelt: Not for use in everyday vehicles, five-point belts can often be found in
race cars and child safety seats. These harnesses combine two shoulder belts, a lap belt,
and a belt between the legs all of which connect in one center buckle.

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TECHNICALITIES REGARDING MATERIAL SELECTION &

MANUFACTURING OF SEAT BELT
➢ The yarn for a seatbelt should, of course, maintain high strength
➢ it should have good sliding efficiency after being manufactured into a seat belt so as to
sharply decrease repeated friction with a sash guide
➢ An emulsion containing lubricant should be provided to aid good sliding.
➢ The polyester fiber for a seat belt may have intrinsic viscosity of 0.8 to 1.5 dl/g, tensile
strength of 8.8 g/d or more, and total fineness of 400 to 1800 denier.
➢ During the preparation process of polyethylene terephthalate various additives may be
added, and in order to secure excel lent mechanical properties upon being manufactured
into a seatbelt
➢ The polyester fiber may include one or more inorganic additives selected from the group
consisting of TiO, SiO, BaSO.
➢ minimizing woven density to secure Superior thickness and thus improve fabric Softness
➢ It is possible for the polyester fiber for manufacturing a seatbelt to be designed to have a low
number of woven yarns of 280 yarns/inch or less by optimizing the total fineness and the like,
and acquire high strength
➢ The polyester fiber may represent dry heat shrink age of 13% or less, preferably 9% to 13%.
The dry heat shrinkage is based on a measured value under the condition of adding a static
load at 150° C. for 30 minutes.
➢ The polyester fiber may have a characteristic of being stretched by elongation of 0.4% or
more at stress of polyester yarn of 1.0 g/d, elongation of 3.5% or more at stress of 4.0 g/d,
and elongation of 6.0% or more at stress of 7.0 g/d, as measured at room temperature.
➢ The polyester fiber may have crystallinity of 40% to 55%, preferably 42% to 50%, more
preferably 44% to 48%. So as to prevent strain during heat treatment such as coating.
➢ Tensile strength of 2870 to 2887 kgf, and thus had excellent properties.
GENERAL SPECIFICATIONS OF SEATBELTS
MATERIAL OF SEAT BELT
High Strength Polyester (Polyethylene Terephthalate) Fiber
3-point belt:
➢ Width (woven) = 1.875 inches
➢ Total length = 60 inches
➢ Belt length = 37 inches
➢ Cable buckle length = 9 inches According to Standards

➢ Webbing buckle length = 8 inches

➢ Metal bracket buckle length = 6 inches
➢ Thickness = 0.8 – 1.6 mm

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DEVELOPMENT OF 3D CAD MODEL OF SEATBELT ON SOLIDWORKS

BASED ON GENERAL SPECIFICATIONS

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Average thickness of seat belts may vary according to the following chart containing various examples:

RECENT DEVELOPMENTS IN SEAT BELT: SMART BELT

Autoliv's Smart Belt System uses a switch mechanism to adapt its restraining force – and hence the load
on the occupant – to the severity of the crash. In a crash, the Smart Belt System starts – as in most modern
seatbelt systems – by tightening the belt, using a pyrotechnic pretensioner. This eliminates slack and
makes it possible to release some webbing at a later stage, if the load on the occupant becomes too high.
On the Smart Belt System, the Smart Belt can adapt its restraining force – and hence the load on the
occupant – to the crash severity. If the vehicle is equipped with an occupant weight sensing system, it is
also possible to adjust the seatbelt load individually to each occupant. This is an important advantage
since smaller, lighter weight occupants, such as many women, are more susceptible to high belt loads
than the average person, and these individuals do not need the same restraining force as a larger
occupant.
➢ TRUNK BELT: Safety belts which protect fragile goods and prevent luggage from penetrating into
the passenger compartment in, for instance, cars with folding rear seats
➢ INFLATABLE BELTS: The inflatable seat belt is an amalgamation of the air bag and the seat
belt. This belt is held by weak stitches that burst open when the belt is inflated. Under impact the belt
gives 450% more surface area than the normal flat belt. These belts could be fitted in the rear seats
of the automobile to replace use of air bags in that compartment. A folded envelop of 3” is covered
by 2” face fabric, which is stitched. A folded envelop is rubber coated. Today’s envelopes are made
from urethane or silicon to make thin, gas leakage proof, high strength, heat resistance and when
crash occurs a gas fill and inflates the envelope. The face fabric (web) is made of a resin such as
PET. Today’s cover fabric uses warp knitted structure. As warp knitted fabric has good strength,
good stretching characteristics, comfortable. Warp knit uses yarn of 3000 denier or below. By using
such belts kinetic energy of passenger is distributed over a larger area, therefore load experienced
by a passenger is small and passenger protected very effectively.

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COST BENEFIT ANALYSIS ON SEAT BELTS (ENFORCED IN SOUTH

AFRICA)
INCREASING SEAT BELT USAGE: An increase in the wearing of seat belts will reduce these
costs because some fatalities will be ‘‘converted’’ into serious injuries, slight injuries, or to no
injuries; some serious injuries will become slight injuries or no injuries; and some slight injuries
will become no injuries. It is also possible that the wearing of seat belts could increase the
severity of injury.

Cost benefit analysis has shown that an investment of R2 million in an enhanced seat belt
enforcement program can be reasonably expected to yield a net present value to society in that
year of R11.6 million. In addition to these positive net benefits to society, municipal finances will
be favorably affected. A limitation of the analysis is its use of US data on seat belt effectiveness
and the effect of enforcement program, given the lack of evidence from South Africa or other
developing countries. To judge the potential seriousness of this, we carried out a breakeven
analysis to show how much seat belt usage would have to increase in order to yield social
benefits equal to the costs of the enforcement program.

CONCLUSION
In today’s agile world, many service providers are marketing their products under slogans likes
instant connectivity, quick service. Everyone wants quicker services, faster car. As per world
health organization, Road accidents are a worldwide problem and now result in over, 1.2 million
people die every year from road crashes all around the globe. Occupant restraint, is the best
solution such as seat belts, are highly effective in preventing death and injury from traffic
collisions. Seat belts are easy to use, effective and inexpensive means of protection in an
accident. Seatbelts alone (if worn) would reduce motor crash fatalities by 40 per cent injury.
Autoliv estimated, seatbelts are expected to reduce the overall risk for serious injuries in crashes
by 60-70% and the risk for fatalities by about 45 percent.

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REFERENCES
➢ https://patentimages.storage.googleapis.com/72/af/75/8950f8fc02ca98/US20150145314A1.pdf
➢ https://louisagreen.com/automotive-seatbelt-surplus/
➢ https://oemseatbelts.com/pages/measure-seat-belts
➢ http://article.sapub.org/10.5923.j.safety.20120101.02.html
➢ https://china-webbing.com/seat-belt-material-properties.html
➢ https://gwrco.com/seatbelts/seat-belts/

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