Tesla Model S Earns Highest NHTSA Score Ever Recorded

[Intrepidation]

Tesla has been on a roll as of late, and now it can add some more good news to its rather large list of positive press: the Model S earned the highest crash test scores in NHTSA's history. While NHTSA's highest public rating is five stars, the Vehicle Safety Number it gives to manufacturers can go higher, and Tesla says the Model S scored a 5.4.

Part of the success lies in the fact that the Model S has no engine up front, allowing more room for the energy absorbing structure. The battery pack, which is nestled in the floor and creates a low center of gravity, lead to NHTSA being unable to roll over the car "via the normal methods, and special means were needed to induce the car to roll."

In the side pole intrusion test, the Model S left almost 9-times "driver residual space" post-impact than the five-star rated Volvo S60, thanks to nested aluminum intrusions along its flanks.

However, that is not the end of the story, because not only did it score 5 star ratings across all categories, its roof structure proved to be so strong that it actually broke the testing machine after it passed the 4G mark, while the Model S's roof remained undamaged.

Full press release below:

Tesla Model S Achieves Best Safety Rating of Any Car Ever Tested
Sets New NHTSA Vehicle Safety Score Record

Monday, August 19, 2013, Palo Alto, CA - Independent testing by the National Highway Traffic Safety Administration (NHTSA) has awarded the Tesla Model S a 5-star safety rating, not just overall, but in every subcategory without exception. Approximately one percent of all cars tested by the federal government achieve 5 stars across the board. NHTSA does not publish a star rating above 5, however safety levels better than 5 stars are captured in the overall Vehicle Safety Score (VSS) provided to manufacturers, where the Model S achieved a new combined record of 5.4 stars.

Of all vehicles tested, including every major make and model approved for sale in the United States, the Model S set a new record for the lowest likelihood of injury to occupants. While the Model S is a sedan, it also exceeded the safety score of all SUVs and minivans. This score takes into account the probability of injury from front, side, rear and rollover accidents.

The Model S has the advantage in the front of not having a large gasoline engine block, thus creating a much longer crumple zone to absorb a high speed impact. This is fundamentally a force over distance problem – the longer the crumple zone, the more time there is to slow down occupants at g loads that do not cause injuries. Just like jumping into a pool of water from a tall height, it is better to have the pool be deep and not contain rocks. The Model S motor is only about a foot in diameter and is mounted close to the rear axle, and the front section that would normally contain a gasoline engine is used for a second trunk.

For the side pole intrusion test, considered one of the most difficult to pass, the Model S was the only car in the "good" category among the other top one percent of vehicles tested. Compared to the Volvo S60, which is also 5-star rated in all categories, the Model S preserved 63.5 percent of driver residual space vs. 7.8 percent for the Volvo. Tesla achieved this outcome by nesting multiple deep aluminum extrusions in the side rail of the car that absorb the impact energy (a similar approach was used by the Apollo Lunar Lander) and transfer load to the rest of the vehicle. This causes the pole to be either sheared off or to stop the car before the pole hits an occupant.

The rear crash testing was particularly important, given the optional third row children's seat. For this, Tesla factory installs a double bumper if the third row seat is ordered. This was needed in order to protect against a highway speed impact in the rear with no permanently disabling injury to the third row occupants. The third row is already the safest location in the car for frontal or side injuries.

The Model S was also substantially better in rollover risk, with the other top vehicles being approximately 50 percent worse. During testing at an independent facility, the Model S refused to turn over via the normal methods and special means were needed to induce the car to roll. The reason for such a good outcome is that the battery pack is mounted below the floor pan, providing a very low center of gravity, which simultaneously ensures exceptional handling and safety.

Of note, during validation of Model S roof crush protection at an independent commercial facility, the testing machine failed at just above 4 g's. While the exact number is uncertain due to Model S breaking the testing machine, what this means is that at least four additional fully loaded Model S vehicles could be placed on top of an owner's car without the roof caving in. This is achieved primarily through a center (B) pillar reinforcement attached via aerospace grade bolts.

The above results do not tell the full story. It is possible to game the regulatory testing score to some degree by strengthening a car at the exact locations used by the regulatory testing machines. After verifying through internal testing that the Model S would achieve a NHTSA 5-star rating, Tesla then analyzed the Model S to determine the weakest points in the car and retested at those locations until the car achieved 5 stars no matter how the test equipment was configured.

The Model S lithium-ion battery did not catch fire at any time before, during or after the NHTSA testing. It is worth mentioning that no production Tesla lithium-ion battery has ever caught fire in the Model S or Roadster, despite several high speed impacts. While this is statistically unlikely to remain the case long term, Tesla is unaware of any Model S or Roadster occupant fatalities in any car ever.

The graphic below shows the statistical Relative Risk Score (RSS) of Model S compared with all other vehicles tested against the exceptionally difficult NHTSA 2011 standards. In 2011, the standards were revised upward to make it more difficult to achieve a high safety rating.

[FAPTurbo]

But the Cheers & Gears told me electric cars are face-melting death traps and are as safe as golf carts.

[David]

YAWN! Like the average person could afford this limited range car.

Only positive I see is that this will make auto companies rethink how they build their cars.

[SAmadei]

I'm impressed, considering this is Tesla's first body they've designed. They must've gotten some top engineers and they worked well together.

[FAPTurbo]

YAWN! Like the average person could afford this limited range car.

Using this criterion, the Cadillac El-whateversomethingstupidname is not worth caring about either.

[David]

YAWN! Like the average person could afford this limited range car.

Using this criterion, the Cadillac El-whateversomethingstupidname is not worth caring about either.

More will probably buy and afford The El Miraj than a Tesla.

[Drew Dowdell]

YAWN! Like the average person could afford this limited range car.

Only positive I see is that this will make auto companies rethink how they build their cars.

The Tesla Model S has a longer range than our 2004 CR-V

[David]

YAWN! Like the average person could afford this limited range car.

Only positive I see is that this will make auto companies rethink how they build their cars.

The Tesla Model S has a longer range than our 2004 CR-V

That might be true, but then you can stop and quickly fill up with gas and keep going compared to trying to find a level 3 fast charger or have to do the slow boat 110 charge.

[Drew Dowdell]

In 12 months or less, there will be a sufficient number of Tesla SuperCharger stations that offer 30 minute recharges such that you will be able to travel coast to coast for FREE.

[David]

In 12 months or less, there will be a sufficient number of Tesla SuperCharger stations that offer 30 minute recharges such that you will be able to travel coast to coast for FREE.

So Tesla expects to make enough money on selling cars so that they can offer these super charging stations for free. I know there was the story about these stations. Has it been updated that Tesla is now going to actually do this? I do not see how this will work if it is a free service.

[Drew Dowdell]

The supercharger stations are solar powered and feed electricity back into the grid when they have extra or feed from the grid when there isn't enough sun to charge the car. The cost of the power to Tesla will be net 0 or even negative. The only real cost to Tesla is building/maintaining the stations which then becomes a gateway to selling more cars.

It's a play on the cellular network business model. Build the best network of cell towers and you'll get the most customers buying your service, but in Tesla's case it is SuperCharger locations and selling cars.

They plan to have 98% of the US & Canadian population covered by the end of 2015.

But in the end, Elon Musk is a multi-billionaire... Tesla only has to break even for the next few years.

[Drew Dowdell]

Also... building great cars doesn't hurt either. The CR report about being the best car ever tested plus this crash test report will do wonders for them.

[balthazar]

Tesla seems to be firming up their image nicely so far. Right now tho, the station count is nearly non-existant (30). I've seen Teslas in my area but the nearest SC station is 95 miles from here. We'll see how quickly they get their network up vs. their projections. If it's like most other projects, they will not hit that time table.

[Drew Dowdell]

Well.. they've promised coast to coast travel which means a station every 200 miles across the country. I'm sure there is an asterisk in there somewhere, but I don't think that should be too too hard to pull off with the asterisk, in the next year.

[balthazar]

If you look @ their site, they show a singular route across the county by then, but what if that's not your desired route?
But corporate promises are only 2 clicks better than political ones- only time will tell.

[balthazar]

Uh-oh :

>>"Always able to find itself at the center of controversy, Tesla’s latest PR stunt has earned it a slap on the wrist by a Federal safety agency.

The National Highway Traffic Safety Administration (NHTSA) has released a statement in rebuttal to Tesla‘s claim that the Model S is the safest car ever and that it earned a, “new combined record of 5.4 stars” according to a Tesla release.

“The agency’s 5-Star Safety Ratings program is designed to provide consumers with information about the crash protection and rollover safety of new vehicles beyond what is required by Federal standards,” says the NHTSA release. “One star is the lowest rating; five stars is the highest. More stars equal safer cars.” The statement goes on to comment that the agency, “does not rate vehicles beyond 5 stars and does not rank or order vehicles within the star rating categories.”
That said, a 5-star rating for the Tesla Model S is equal to any other car with a rating of 5-stars, with another example being the Volvo S60.

In addition, the agency chides Tesla’s overzealous claims, commenting that it, “has guidelines in place for automakers and advertising agencies to follow, helping ensure that accurate information is portrayed to the public.”
Did Tesla follow those guidelines? It’s likely the electric automaker, its eccentric CEO, Elon Musk, and its clever PR department will find a way to chime-in."<<

Crap like this is a black eye to credibility. Let's hope it doesn't happen again.

[Drew Dowdell]

Eh, the NHTSA is just pissed the Model S broke their equipment.

[ocnblu]

I love it! He got his arrogant ass smacked down a couple of pegs!

[David]

Interesting, time to pull up a chair to see his response to the Gov Goons.

[riviera74]

That is great that Tesla really made a VERY safe car. Now if only GM and Ford can be just as good. . . . .