Saving Lives: 50 years of Seat Belts in all Opel Vehicles

• Ahead of the times: In 1973, Opel introduced seat belts as standard across range, three years before they became mandatory
• Start 1968: Opel Kadett, Admiral and Diplomat already available with front seat belts
• Comfortable: Opel Omega 1986 - first car with height-adjustable belts as standard
• Fine-tuned: New Opel Astra Electric with further developed “belt anti-lock braking system”

Newly developed electric motor, class-leading IntelliLux LED Pixel Light with a total of 168 LED elements, head-up display or natural voice recognition "Hey Opel" – first electrified Opel Astra is full of technical highlights. But the engineers have also further developed compact class bestseller in less visible areas. One safety specific feature now makes new Opel Astra Electric even safer: adaptive belt force limiter. It controls the belt force, which acts on the body during an impact, even more precisely in order to reduce injuries as far as possible and at the same time protect the driver as much as possible.

Adaptively controlled restraint system uses sensors to recognize severity of accident and optimally adapts belt force to course of crash. A plus in safety that can make all difference. Despite all airbags and assistance systems: “Seat belt is still the most important lifesaver in the car,” says Peter Schüßler, Manager of Passive Restraint Systems at Opel in Rüsselsheim. And the most important of all safety features is celebrating an even-number anniversary this summer: 50 years ago, in 1973, Opel began to install three-point belt systems with practical one-hand operation as standard in all models – and that three years prior to wearing seat belts became compulsory in Germany. A lot has happened in 50 years: an average of 15 metres of seat belts are installed in every Opel model. In total, after five decades, this results in around 750 million metres of seat belt webbing. This corresponds to 18 circumnavigations of equator.

Safety comes first at Opel: Seat belt as a lifesaver

As early as the 1960s, Opel engineers were testing seat belts as a life-saving restraint system in cars. As early as April 1968, Opel Kadett, Admiral and Diplomat, among others, could be ordered with front seat belts. Classic Opel Manta A coupé followed in October 1970. Opel lifesaver was also available as standard in sporty models – for example in Opel Kadett B Rallye from 1967 and in Opel Commodore A GS a year later.

At same time, Opel actively campaigned for acceptance of seat belts early on and thus assumed a pioneering role. In 1969, Opel engineers demonstrated results of their accident research programme to representatives of media at Dudenhofen Test Centre. 

Most important message: more than half of all accident victims could still be alive if they had worn seat belts. At the beginning of 1972, Opel’s management sent a letter to all employees, asking them to wear their seat belts – and offered all employees discounted belts for retrofitting. Offer proved hugely popular with 12,000 sets being provided within a very short time.

Significance recognised early on

General public were somewhat more reluctant to accept seat belt as an indispensable part of vehicle safety. Millions of people initially refused to “buckle up” when it became compulsory to wear seat belts as of January 1, 1976. At that time, many considered it to be too cumbersome to wear a seat belt. Especially when car was used by different family members and the seat belt had to be adjusted in each case. This problem was soon solved by the automatic seat belt retractor. For a long time, however, there seemed to be no cure for various prejudices such as: Belt curtails personal freedom, and its safety effect is questionable. But the concerns were silenced when the number of road fatalities began to fall.

Simultaneously, the safety specialists were constantly improving the systems. In 1986, Opel Omega was first car in world to offer height-adjustable seat belts at front and rear seats as standard. In 1991, Opel presented belt tensioner in Opel Astra F, followed by full-size airbag and active safety systems such as Anti-lock Braking System (ABS) and Electronic Stability Program (ESP).

Airbags, in particular, further reduce risk of injury significantly – assuming that driver and passengers are actually buckled up. One system restrains body in event of a collision, other cushions impact. Seat belt absorbs around two-thirds of energy of an impact. First belt force limiters were used from 2000s to avoid peak loads. Other improvements increase comfort, such as electric seat belt feeder in convertibles.

Crucial millimetres: Collapsible steering column

Opel engineers identified another key factor for more safety back in 1960s: safety steering column. Preventing steering wheel and column from penetrating passenger compartment is still one of starting points of safety strategy. In event of an impact, steering column collapses slightly. In this way, system, in combination with seat belt and airbag, enables a dynamic crushable distance of up to 100 millimetres – crucial millimetres that minimise the risk of injury.

Adaptive belt force limiter now installed in Opel Astra Electric has an even more refined “anti-lock braking system” for belt. “Belt force is electronically controlled during the course of the impact,” the specialists explain. “In order to measure biomechanical load acting on the chest, four sensors are installed in THOR crash test dummy.” In earlier versions, only single measurements were possible. This increase in sensitivity was made possible by the latest generation of crash test dummies, which have been in use since 2020.

Sensors galore: New dummies provide crucial insights

Development of the safety belt is inextricably linked to the further development of the intelligent high-tech dummies that are used in tests to simulate the effects of an impact on the human body before a safety system is approved for series production. Youngest generation is known as THOR.  Abbreviation stands for “Test device for Human Occupant Restraint”. Equipped with over 120 sensors, THOR electronically senses and communicates what happens to it in event of an impact. With this dummy’s help, adaptive belt force limiter was developed, which was first used in Opel Mokka and now in Opel  Astra. It is another milestone in decades-long development of passive safety features. And possibilities are far from exhausted.

New challenges posed by automated driving

From 2026, for example, consumer protection tests are to evaluate injury values that consider the more fragile bone structure of senior citizens. Team in Rüsselsheim also has its sights firmly set on more distant future: Automated driving will alter a lot completely. Above all, because vehicle occupants will no longer necessarily sit facing forwards, but may face each other. And some could even be lying down. Seat belts could be fully integrated into seats. “We are already working intensively on what this means in detail for the restraint systems,” explains Peter Schüßler. With automated driving, the success story of seat belts, which has lasted for five decades, will then enter a new era of saving lives.