Design and Validation of an Active Headrest System with Integrated Sensing in Rear-End Crash Scenarios

Rear-end collisions represent a major concern in automotive safety, particularly due to the risk of whiplash injuries among vehicle occupants. The accurate simulation of occupant kinematics during such impacts is critical for the development of advanced safety systems. This paper presents an enhanced multibody simulation model specifically designed for rear-end crash scenarios, incorporating integrated active headrest mechanisms and sensor-based activation logic. The model combines detailed representations of vehicle structures, suspension systems, restraint systems, and occupant biomechanics, allowing for the precise prediction of crash dynamics and occupant responses. The system was developed using Simscape Multibody, with CAD-derived components interconnected through physical joints and validated using controlled experimental crash tests. Special attention was given to modelling contact forces, suspension behaviour, and actuator response times for the active headrest system. The model achieved a root mean square error (RMSE) of 4.19 m/s² and a mean absolute percentage error (MAPE) of 0.71% when comparing head acceleration in frontal collision tests, confirming its high accuracy. Validation results demonstrate that the model accurately reproduces occupant kinematics and head acceleration profiles, confirming its reliability and effectiveness as a predictive tool. This research highlights the critical role of integrated sensor-actuator systems in improving occupant safety and provides a flexible platform for future studies on intelligent vehicle safety technologies.