Predicting the performance of cost-effective rollover protective structure designs

Agricultural tractor overturns kill more than 100 workers each year in the United States. Rollover protective structures (ROPS) can prevent most of these deaths but can be expensive in retrofit applications. Cost-effective ROPS (CROPS) have been designed and built at the National Institute for Occupational Safety and Health but performance must be evaluated. This study: (1) evaluated CROPS performance, (2) developed a simulation model for probabilistic CROPS evaluation, and (3) evaluated exemplar prototype CROPS performance via simulation of testing requirements. The CROPS prototype evaluated in this study was a Ford-3000 CROPS prototype design. Simulations based on ROPS performance standard SAE J2194 (Society of Automotive Engineers) identified scenarios where the Ford-3000 CROPS might fail. No failure scenarios were identified during simulation of ROPS performance testing to Occupational Safety and Health Administration (OSHA) test procedures and performance requirements. Despite passing experimental SAE J2194 testing, computer simulations found scenarios where the Ford-3000 CROPS prototype design might fail. Re-design of the Ford-3000 concept is necessary before field implementation.

► Tractor overturns kill more than 100 people in the United States each year.
► Rollover protective structures (ROPS) can prevent tractor overturn fatalities.
► Cost-effective ROPS (CROPS) have been developed to lower ROPS cost.
► Simulation methods can estimate CROPS performance for many test scenarios.
► Two standard ROPS test methods may yield different pass/fail results.