APPENDIX E
PART 572, SUBPART R (12-MONTH-OLD) DUMMY PERFORMANCE CALIBRATION TEST
PROCEDURE
E-i
APPENDIX E
PART 572, SUBPART R DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE
TABLE OF CONTENTS
1.
PAGE
PURPOSE AND APPLICATION ............................................................................................... E-1
2.
GENERAL REQUIREMENTS ................................................................................................... E-1
3.
SECURITY
4.
GOOD HOUSEKEEPING ......................................................................................................... E-2
5.
TEST SCHEDULING AND MONITORING................................................................................ E-2
6.
TEST DATA DISPOSITION ...................................................................................................... E-2
7.
GOVERNMENT FURNISHED PROPERTY (GFP) ................................................................... E-2
8.
CALIBRATION AND TEST INSTRUMENTATION .................................................................... E-5
9.
PHOTOGRAPHY ...................................................................................................................... E-6
10.
DEFINITIONS ........................................................................................................................... E-6
11.
PRETEST REQUIREMENTS.................................................................................................... E-6
11.1
11.2
11.3
11.4
........................................................................................................................... E-1
TRANSDUCER REQUIREMENTS.................................................................... E-6
OTHER TRANSDUCER CONDITIONS............................................................. E-7
THORAX IMPACTOR PROBE .......................................................................... E-8
GENERAL TEST CONDITIONS...................................................................... E-11
12.
CALIBRATION TEST EXECUTION ........................................................................................ E-11
13.
POST TEST REQUIREMENTS .............................................................................................. E-11
14.
REPORTS
......................................................................................................................... E-11
14.1
14.2
APPARENT TEST FAILURE ........................................................................... E-11
FINAL PERFORMANCE CALIBRATION REPORTS ...................................... E-12
15.
DATA SHEETS ....................................................................................................................... E-14
E1
DUMMY DAMAGE CHECKLIST ..................................................................... E-14
E2
EXTERNAL MEASUREMENTS ...................................................................... E-16
E3
FRONTAL HEAD DROP TEST ....................................................................... E-21
E4
REAR HEAD DROP TEST .............................................................................. E-24
E5
NECK FLEXION TEST .................................................................................... E-27
E6
NECK EXTENSION TEST............................................................................... E-29
E7
THORAX IMPACT TEST ................................................................................. E-34
E8
INSTRUMENTATION CALIBRATION INFORMATION ................................... E-37
E-ii
FIGURES
1E
2E
3E
4E
5E
6E
7E
8E
9E
10E
PAGE
DUMMY HANGER PLATE ......................................................................................................... E3
DUMMY HANGER ..................................................................................................................... E4
SIGN CONVENTION ................................................................................................................ E-9
EXTERNAL DIMENSIONS ..................................................................................................... E-20
FRONTAL HEAD DROP TEST SET-UP SPECIFICATIONS.................................................. E-23
REAR HEAD DROP TEST SET-UP SPECIFICATIONS......................................................... E-26
NECK PENDULUM SPECIFICATIONS .................................................................................. E-31
NECK FLEXION TEST SETUP SPECIFICATIONS................................................................ E-32
NECK EXTENSION TEST SETUP SPECIFICATIONS .......................................................... E-33
THORAX IMPACT TEST SETUP SPECIFICATIONS............................................................. E-36
TABLES
1E
SIGN CONVENTION FOR HYBRID III TRANSDUCER OUTPUTS ....................................... E-10
E-iii
1.
PURPOSE AND APPLICATION
The purpose of this laboratory procedure is to provide dummy users (independent
testing laboratories under contract with the Office of Vehicle Safety Compliance) with
standard test procedures for performing receiving-inspection and performance
calibration tests on the Part 572, Subpart R dummy so that repetitive and correlative test
results can be obtained. The following tests have been developed to establish a uniform
calibration procedure for all users as the means of verifying the performance of the
dummy.
A.
EXTERNAL DIMENSIONS (PADI)
B.
HEAD DROP TEST (572.152)
C.
NECK FLEXION TEST (572.153(b)(1))
D.
NECK EXTENSION TEST 572.153(b)(2)
E.
THORAX IMPACT TEST ((572.154)
National Highway Traffic Safety Administration (NHTSA) contract laboratories
performing FMVSS 213 testing for the Office of Vehicle Safety Compliance (OVSC) must
use this laboratory procedure for the calibration of Part 572, Subpart R dummies.
2.
GENERAL REQUIREMENTS
The Code of Federal Regulations (49CFR), Parts 571 and 572, was amended to adopt
the Hybrid III, CRABI 12-Month-Old Dummy as the means of determining a Child
Restraint System’s (CRS’s) conformance to the performance requirements of FMVSS
213. Each Part 572, Subpart R dummy used in a compliance test must meet the
specifications and performance criteria of Part 572 before and after each CRS test in
order to be an acceptable compliance test tool.
The Part 572, Subpart R Hybrid III, CRABI 12-Month-Old Dummy consists of
components and assemblies specified in the drawing and specifications package which
is available from Reprographics Technologies, 9000 Virginia Manor, Beltsville, MD
20705, telephone - (301) 419-5070.
3.
SECURITY
All NHTSA Part 572, Subpart R test dummies delivered to the contract laboratory
as Government Furnished Property (GFP) will be stored in a safe and secure
area such as the dummy calibration laboratory. The contractor is financially
responsible for any acts of theft and/or vandalism that occur during the storage of
GFP. Any security problems shall be reported by telephone to the Industrial
Property Manager (IPM), Office of Contracts and Procurement, within two
working days after the incident. A letter containing specific details of the security
problem will be sent to the IPM (with copy to the COTR) within 48 hours.
E-1
The contractor is responsible for maintaining the NHTSA test dummies in good
working order, and shall protect and segregate the data that evolves from
conducting Part 572, Subpart R dummy calibration tests before and after each
CRS test.
No Information concerning the Part 572, Subpart R dummy calibration data shall
be released to anyone except the COTR, unless specifically authorized by the
COTR or the COTR's Branch or Division Chief.
NOTE: No Individuals, other than contractor personnel directly involved in the
dummy calibration test program, shall be allowed to witness dummy calibration
tests unless specifically authorized by the COTR.
4.
GOOD HOUSEKEEPING
Contractors shall maintain the entire dummy calibration laboratory, test fixtures,
and instrumentation in a neat, clean, and painted condition with test instruments
arranged in an orderly manner consistent with good test laboratory housekeeping
practices.
5.
TEST SCHEDULING AND MONITORING
The Part 572, Subpart R dummies are being calibrated as test tools to be used in
determining CRS compliance with the requirements of FMVSS 213. The
schedule for these performance calibration tests must be correlated with that of
the CRS tests. All testing shall be coordinated to allow monitoring by the COTR.
6.
TEST DATA DISPOSITION
The contractor shall make all dummy calibration data available to the COTR for
review and analysis as required. All calibration test data for each particular
Part 572, Subpart R dummy will be sent to the COTR with each test report.
All backup data sheets, strip charts, recordings, plots, technicians notes, etc.
shall be either sent to the COTR or destroyed at the conclusion of each delivery
order, purchase order, etc.
7.
GOVERNMENT FURNISHED PROPERTY (GFP)
Part 572, Subpart R test dummies will be furnished to the contract laboratory by
the OVSC. The dummies shall be stored in a hanging position using the bracket
and positioning shown in Figures 1E and 2E.
E-2
FIGURE 1E
E-3
FIGURE 2E
E-4
These dummies shall be stored in a secured room that is kept between 55ºF and
85ºF. The contractor will check dummy components for damage after each low
risk deployment test and complete a dummy damage checklist that will be
included with the posttest dummy calibration. The COTR will be kept informed of
the dummies condition in order that replacement parts can be provided.
8.
CALIBRATION AND TEST INSTRUMENTATION
Before the contractor initiates the dummy performance calibration test program, a
test instrumentation calibration system must be implemented and maintained in
accordance with established calibration practices. The calibration system shall
be set up and maintained as follows:
A.
Standards for calibrating the measuring and test equipment shall be
stored and used under appropriate environmental conditions to assure
their accuracy and stability.
B.
All measuring instruments and standards shall be calibrated by the
contractor, or a commercial facility, against a higher order standard at
periodic intervals not exceeding 6 months for instruments and 12 months
for calibration standards. Records, showing the calibration traceability to
the National Institute of Standards and Technology (NIST), shall be
maintained for all measuring and test equipment.
C.
All measuring and test equipment and measuring standards shall be
labeled with the following information:
(1)
(2)
Date of next scheduled calibration
(3)
D.
Date of calibration
Name of the technician who calibrated the equipment
The contractor shall provide a written calibration procedure that includes,
as a minimum, the following information for all measurement and test
equipment:
(1)
Type of equipment, manufacturer, model number, etc.
(2)
Measurement range
(3)
Accuracy
(4)
Calibration interval
E-5
(5)
Type of standard used to calibrate the equipment (calibration
traceability of the standard must be evident)
(6)
The actual procedures and forms used to perform calibrations.
E.
The contractor shall keep records of calibrations for all test
instrumentation in a manner that assures the maintenance of established
calibration schedules. All such records shall be readily available for
inspection when requested by the COTR. The calibration system will
need the written acceptance of the COTR before testing begins.
F.
Test equipment shall receive a calibration check immediately prior to and
after each test. This check shall be recorded by the test technician(s) and
submitted with the final report.
9.
RESERVED
10.
DEFINITIONS
PADI: Procedures for Assembly, Disassembly, and Inspection
11.
PRETEST REQUIREMENTS
11.1
TRANSDUCER REQUIREMENTS
The contractor shall provide and install the following instrumentation to the GFP
dummies (excluding the chest deflection transducer).
A.
HEAD – The head accelerometers shall have dimensions, response
characteristics and sensitive mass locations specified in drawing SA572-S4
and be mounted in the head as shown in drawing 921022-000.
(572.155(b))
Three accelerometers shall be mounted in the head cavity to measure
orthogonal accelerations (Ax, Ay, Az) at the center of gravity (CG) of the
head assembly.
B.
NECK – The neck force-moment transducer shall have the dimensions,
response characteristics, and sensitive axis locations specified in drawing
SA572-S23 and shall be mounted as shown in drawing 921022-000.
(572.155(c))
C.
CHEST – The chest accelerometers shall have the dimensions, response
characteristics, and sensitive mass locations specified in drawing
E-6
SA572-S4 and be mounted in the torso assembly in traxial configuration at
the T4 location as shown drawing 921022-000. The chest accelerometers
are not required for dummy calibration testing but are required for FMVSS
213 CRS testing. (572.155(e))
D.
11.2
TEST FIXTURE – The neck pendulum, and thorax accelerometers shall
have the dimensions and characteristics of drawing SA572-S4.
OTHER TRANSDUCER CONDITIONS
A.
TRANSDUCER MOUNTS – The mountings for sensing devices shall have
no resonance frequency less than 3 times the frequency range of the
applicable channel class. (572.155(k))
B.
TRANSDUCER SIGN CONVENTION - The sign convention for outputs of
transducers mounted within the dummy that measure head and chest
accelerations, chest deflection and neck loads are located in Figure 3E
and Table 1E. For other transducers see SAE J1733DEC94. (572.155(j))
C.
TRANSDUCER OUTPUTS and FILTERING- The outputs of acceleration
and force-sensing devices installed in the dummy and in the test
apparatus specified by this part are recorded with individual data
channels. Each data channel will be comprised of a sensor, signal
conditioner, data acquisition device, and all interconnecting cables, and
must conform to the requirements of SAE Recommended Practice J211/1
MAR95, "Instrumentation for Impact Test," with channel classes as
follows: (572.155(i))
(1) Head acceleration
(2) Neck force
(3) Neck moment
(4) Neck pendulum acceleration
(5) Neck rotation transducers
(6) Thorax spine acceleration
(7) Thorax pendulum
acceleration
Class 1000
Class 1000
Class 600
Class 180
Class 60
Class 180
Class 180
(572.155(i)(1))
(572.155(i)(2)(i))
(572.155(i)(2)(ii))
(572.155(i)(2)(iii))
(572.155(i)(2)(iv))
(572.155(i)(3)(i))
(572.155(i)(3)(i))
All filter classes should be of the "phaseless" type to be compatible with
the "time" dependent test parameters.
11.3
THORAX IMPACTOR PROBE (572.155(a))
A.
B.
The test probe for thoracic impacts shall be of rigid metallic construction,
concentric about its longitudinal axis.
It shall have a mass of 2.86 ± 0.02 kg (6.3 ± 0.05 lbs). 1/3 of the weight of
the suspension cables and any attachments to the impact probe must be
E-7
C.
D.
E.
F.
G.
included in the calculation of mass, and such components may not exceed
5 percent of the total weight of the test probe.
It shall have a minimum mass moment of inertia of 164 kg-cm2
(0.145 lbs-in-sec2) in yaw and pitch about the center of gravity.
The impacting end of the probe is perpendicular to and concentric with the
longitudinal axis. The face has a diameter of 101.6 ± 0.25 mm (4.00 ±
0.01 in), a maximum edge radius of 7.6 to 12.7 mm (0.3 to 0.5 in) and is
flat, continuous and non-deformable.
A 101-103 mm diameter cylinder surface extends at least 12.5 mm to the
rear of the impact face.
The probe’s end opposite to the impact face must have provisions for
mounting of an accelerometer with its sensitive axis collinear with the
longitudinal axis of the probe.
The impact probe shall have a free air resonant frequency of not less than
1000 Hz measured in line with the longitudinal axis of the impactor.
E-8
SIGN CONVENTIONS FOR
SIGN CONVENTION FOR PART 572 TEST
DUMMIES
PART 572 SUBPART E TEST DUMMIES
POSSIBLE AR
3 UNIAXIAL ACCELEROMETERS
LOCATED AT THE C.G. OF THE
HEAD ASSEMBLY
-AX
+AY
+AX
2
X
2
Y
2
Z
AR = A + A + A
+AY
Gs
C.G.
TARGET
-AZ
3 UNIAXIAL ACCELEROMETERS
LOCATED AT THE C.G. OF THE
CHEST ASSEMBLY
+AZ
-AZ
-AY
-AX
-AY
+AX
+AZ
RIGHT FEMUR
LOAD CELL
(FR )
- FR
- FL (Tension)
+ FR
+ FL (Tension)
LEFT FEMUR
LOAD CELL
(FL )
FIGURE 3E
E-9
TABLE 1E
SIGN CONVENTION FOR HYBRID III TRANSDUCER OUTPUTS
BODY SEGMENT —
MEASURED FORCE
NECK
FX SHEAR
FY SHEAR
FZ AXIAL
MX MOMENT (ROLL)
MY MOMENT (PITCH)
MZ MOMENT (YAW)
LEFT SHOULDER
FX
FZ
RIGHT SHOULDER
FX
FZ
LUMBAR SPINE
FX
FY
FZ
MX MOMENT
MY MOMENT
MZ MOMENT
PUBIC
FX SHEAR
FZ AXIAL
POSITIVE OUTPUT DIRECTION
HEAD REARWARD OR CHEST FORWARD
HEAD LEFTWARD, CHEST RIGHTWARD
HEAD UPWARD, CHEST DOWNWARD
LEFT EAR TOWARD LEFT SHOULDER
CHIN TOWARD STERNUM
CHIN TOWARD LEFT SHOULDER
LEFT ARM/SHOULDER FORWARD, CHEST
REARWARD
LEFT ARM/SHOULDER DOWNWARD, CHEST
UPWARD
RIGHT ARM/SHOULDER FORWARD, CHEST
REARWARD
RIGHT ARM/SHOULDER DOWNWARD, CHEST
UPWARD
CHEST REARWARD, PELVIS FORWARD
CHEST LEFTWARD, PELVIS RIGHTWARD
CHEST UPWARD, PELVIS DOWNWARD
LEFT SHOULDER TOWARD LEFT HIP
STERNUM TOWARD FRONT OF LEGS
RIGHT SHOULDER FORWARD, LEFT SHOULDER
REARWARD
PUBIC REARWARD, CHEST FORWARD
PUBIC UPWARD, CHEST DOWNWARD
NOTE: DIRECTIONS ARE DEFINED IN RELATION TO A SEATED DUMMY
E-10
11.4
GENERAL TEST CONDITIONS
A.
B.
Dummy performance tests of the same component, segment, assembly,
or fully assembled dummy are separated in time by a period of not less
than 30 minutes unless otherwise specified. (572.155(m))
C.
The dummy head performance tests are conducted at any temperature
from 18.9oC (66ºF) to 25.6oC (78ºF) and at any relative humidity from 10%
to 70% after exposure of the dummy to these conditions for a period of not
less than 4 hours. For the neck-headform assembly and thorax assembly,
the temperature range is 20.6oC (69ºF) to 22.2oC (72ºF) and at any
relative humidity from 10% to 70% after exposure of the dummy to these
conditions for a period of not less than 4 hours.
D.
Dummy limb joints are set at 1 G, barely restraining the weight of the limb
when it is extended horizontally. The force required to move a limb
segment does not exceed 2 Gs throughout the range of limb motion.
(572.155(l))
E.
12.
Surfaces of dummy components are not painted unless otherwise
specified. (572.155(n))
Dummies will be clothed for the thorax calibration tests with a form fitting
cotton-polyester-based tight-fitting sweat shirt with long sleeves and ankle
length pants. The total weight of the shirt and pants shall not exceed
0.25 kg (0.55 lb). (572.154(c)(2))
CALIBRATION TEST EXECUTION
Complete the Data Sheets in section 15.
13.
POST TEST REQUIREMENTS
The contractor shall verify all instrumentation and check data sheets and
photographs. Make sure data is recorded in all data blocks on every
performance calibration test data sheet.
14.
REPORTS
14.1
APPARENT NONCONFORMANCE
During the posttest calibration verification, any indication of apparent
nonconformance to the requirements of Regulation P572 shall be communicated
by telephone to the COTR within 24 hours with written notification mailed within
48 hours (Saturdays and Sundays excluded). Written notification shall be
E-11
submitted with a copy of the particular test data sheet(s) and preliminary data
plot(s).
In the event of an apparent nonconformance, a posttest calibration check of
some critically sensitive test equipment and instrumentation may be required for
verification of accuracy. The necessity for the calibration shall be at the COTR's
discretion and shall be performed without additional costs to the OVSC.
14.2
FINAL PERFORMANCE CALIBRATION REPORTS
14.2.1 COPIES
A report containing the pre-test calibration and post test calibration verification
data for each Part 572, Subpart R dummy used in the CRS testing shall be
submitted with FMVSS 213 final test reports.
Contractors are required to PROOF READ all Final Test Reports before submittal
to the COTR. The OVSC will not act as a report quality control office for
contractors. Reports containing a significant number of errors will be returned to
the contractor for correction, and a "hold" will be placed on invoice payment for
the particular test.
14.2.2 REQUIREMENTS
Performance calibration report Table of Contents shall include the following:
A.
Section 1 — Purpose of Calibration Test
B.
Section 2 — Calibration Data Summary
C.
Section 3 — Test Data
D.
Section 4 — Test Equipment List and Calibration Information
E.
Section 5 — Photographs (if applicable)
The test data for each dummy will be presented in separate sections. Each
section shall contain a title page, test results summary and the test data. The
title page shall include the dummy's serial number and the manufacturer's name.
It will also indicate whether the calibration data is pre or posttest. The test results
sheets will provide a summary of each test and describe any damage, failures
and/or corrective action taken. The test data shall include the pass/fail data
sheets, the time histories for each data channel used to determine the pass or
fail status, and instrumentation calibration data sheets.
E-12
14.2.3 FIRST PAGE
FRONT COVER
A heavy paperback cover (or transparency) shall be provided for the protection of
the final report. The information required on the cover is as follows:
A.
Final Report Title And Subtitle such as
DUMMY PERFORMANCE CALIBRATION
IN SUPPORT OF
CHILD RESTRAINT SYSTEM
DYNAMIC TESTS
FMVSS No. 213
B.
Contractor's Name and Address such as
ABC TESTING LABORATORIES, INC.
405 Main Street
Detroit, Michigan 48070
NOTE: DOT SYMBOL WILL BE PLACED BETWEEN ITEMS B AND C
C.
Date of Final Performance Calibration Report completion
D.
The sponsoring agency's name and address as follows
U. S. DEPARTMENT OF TRANSPORTATION
National Highway Traffic Safety Administration
Enforcement
Office of Vehicle Safety Compliance
400 Seventh Street, SW
Room 6115 (NVS-222)
Washington, DC 20590
E-13
15.
Data Sheets
DATA SHEET E1
DUMMY DAMAGE CHECKLIST
Dummy Serial Number _____________
Test Date _____________
Technician ___________________________
This check sheet is completed as part of the posttest calibration verification.
Indicate NA in the OK column for any components not applicable to this size dummy.
__Perform general cleaning.
Dummy Item
Outer skin
Head
Neck
Spine
Ribs
Chest
Displacement
Assembly
Transducer
leads
Inspect for
Gashes, rips, cracks
Ballast secure
General appearance
Broken or cracked
rubber
Upper neck bracket
firmly attached to
the lower neck
bracket
Looseness at the
condyle joint
Nodding blocks
cracked or out of
position
Broken or cracks in
rubber.
Broken or bent ribs
Broken or bent rib
supports
Damping material
separated or
cracked
Rubber bumpers in
place
Bent shaft
Comments
Damaged OK
Slider arm riding in
track
Torn cables
E-14
Dummy Item
Inspect for
Accelerometer Head mounting
Mountings
secure
Chest mounting
secure
Knees
Skin condition
Insert (do not
remove)
Casting
Limbs
Normal movement
and adjustment
Knee Sliders
Wires intact
Rubber returned to
“at rest” position
Pelvis
Broken
Other
Comments
Damaged OK
If upon visual examination, damage is apparent in any of these areas, the appropriate
engineer or engineering technician is to be consulted for a decision on repair or
replacement of parts.
Repair or Replacement approved by:
_____________________________
Signature
______________
Date
Describe the repair or replacement of parts:
Checked by
__________________________________
Signature
_______________
Date
E-15
DATA SHEET E2
EXTERNAL MEASUREMENTS
Dummy Serial Number _____________
Test Date _____________
Technician ___________________________
__Pretest calibration
__Post test calibration verification
__1.
__2.
__3.
__4.
__5.
__6.
__7.
__8.
__9.
Seat the dummy on a flat, rigid, smooth, clean, dry, horizontal surface. The
seating surface is at least 406 mm (16 in) wide and 221 mm (8 11/16 in) in depth
with a vertical section at least 406 mm (16 in) wide and 610 mm (24 in) high
attached to the rear of the seating fixture. The dummy's midsagittal plane is
vertical and centered on the test surface.
Secure the dummy to the test fixture so that the upper torso and buttocks are
tangent to the rear vertical surface of the fixture (as tangent as possible).
Push the dummy’s forehead rearward and secure the head (at the forehead)
against the seat back surface.
Place the centerlines of the upper arms vertical.
Place the centerlines of the lower arms horizontal.
Position the upper legs so that they are parallel to one another.
Position the lower legs so that they are perpendicular to the upper legs and the
bottom of the foot is horizontal.
Record the dimensions listed in following table, except for dimension Q
(reference figure 4E).
Place the dummy in supine position on the measurement surface. Place a block
that is perpendicular to the table at both the head and feet of the dummy.
Position the blocks perpendicular to the midsaggital plane of the dummy.
Position the blocks so they are in contact with the head and the heels of the
dummy. Measure the distance between the blocks for Q.
_____________________________
Signature
______________
Date
E-16
EXTERNAL DIMENSIONS
HYBRID III, PART 572, SUBPART O EXTERNAL DIMENSIONS
DIMENSION
DESCRIPTION
DETAILS
ASSEMBLY
DIMENSION
(mm)
A
TOTAL SITTING HEIGHT
Seat surface to highest point on top of the head with head
pulled back to touch vertical surface of fixture.
456-471.2
B
SHOULDER PIVOT HEIGHT
Centerline of shoulder pivot bolt to the seat surface.
276.6-291.8
C
HIP PIVOT HEIGHT
Centerline of hip pivot bolt to seat surface
27.9-38.1
Centerline of hip pivot bolt to vertical surface of seat
40.1-50.3
D
E
F
G
I
HIP PIVOT FROM
BACKLINE
SHOULDER PIVOT FROM
BACKLINE
THIGH CLEARANCE
ELBOW PIVOT TO
FINGERTIP
SHOULDER PIVOT TOELBOW PIVOT
Center of the shoulder pivot bolt to the fixture’s rear
vertical surface.
Fixture’s seat surface to highest point on the upper femur
segment
Elbow pivot to the finger tip, in line with the elbow and
wrist centerlines
ACTUAL
MEASUREMENT
50.3-60.5
63.0-73.2
176.6-191.8
Shoulder pivot bolt to elbow pivot bolt
99.1-114.3
150.1-165.3
J
ELBOW REST HEIGHT
Seat surface to bottom of lower arm
K
BUTTOCK TO KNEE
LENGTH
L
POPLITEAL HEIGHT
M
KNEE PIVOT HEIGHT
N
BUTTOCK POPLITEAL
LENGTH
The forward most part of the knee flesh to the fixture’s
rear vertical surface
Seat surface to the horizontal plane of the bottom of the
feet.
Centerline of knee pivot bolt to the horizontal plane of the
bottom of the feet.
The rearmost surface of the lower leg to the same point
on the rear surface of buttocks used for dimension K
202.7-217.9
138.7-153.9
165.1-180.3
144.8-160
E-17
HYBRID III, SUBPART R EXTERNAL DIMENSIONS, continued
DIMENSION
DESCRIPTION
DETAILS
ASSEMBLY
DIMENSION
(mm)
O
CHEST DEPTH WITH
JACKET
Measured 261.6 ± 5.1 mm above seat surface
107.5-122.7
P
FOOT LENGTH
Tip of toe to rear of heal
92.4-102.6
Q
STATURE
Place the dummy in supine position on the measurement
surface. Place a block that is perpendicular to the table at
both the head and feet of the dummy. Position the blocks
perpendicular to the midsaggital plane of the dummy.
Position the blocks so they are in contact with the head
and the heels of the dummy. Measure the distance
between the blocks.
727.7-753.1
R
BUTTOCK TO KNEE PIVOT
LENGTH
Knee pivot bolt to the fixture’s rear vertical surface.
178.5-188.7
S
HEAD BREADTH
Distance across the head at its widest point
124.4-134.6
T
HEAD DEPTH
U
HIP BREADTH
V
SHOULDER BREADTH
W
FOOT BREADTH
Y
CHEST CIRCUMFERENCE
WITH JACKET
Z
WAIST CIRCUMFERENCE
AA
REFERENCE LOCATION
FOR DIMENSION Y & O
Distance from the forward most surface of the head to the
rearmost surface of the head, in line with the midsgittal
plane.
Distance across the width of the hip at the widest point of
the jacket
Distance between the outside edges of the shoulder flesh,
in line with the shoulder pivot bolts
The widest part of the foot
Distance around chest at reference location AA, with
jacket on. Measured 261.6 ± 5.1 mm above the seat
surface.
Distance around waist at reference location BB, with
jacket on. Measured 111.8 ± 5.1 mm above the seat
surface.
Reference: 261.6 ± 5.1 mm above the seat surface
ACTUAL
MEASUREMENT
N/A
149.9-165.1
158.5-173.7
200.7-215.9
39.1-49.3
452.4-477.8
447-472.4
256.5-266.7
E-18
HYBRID III, SUBPART R EXTERNAL DIMENSIONS, continued
DIMENSION
DESCRIPTION
DETAILS
ASSEMBLY
DIMENSION
(mm)
BB
REFERENCE LOCATION
FOR DIMENSION Z
Reference: 111.8 ± 5.1 mm above seat surface
106.7-116.9
CC
SHOULDER HEIGHT
Top of arm to seat surface
299.7-314.9
DD
CHIN HEIGHT
Bottom of chin to seat surface
289.6-304.8
ACTUAL
MEASUREMENT
E-19
EXTERNAL DIMENSIONS
FIGURE 4E
E-20
DATA SHEET E3
FRONTAL HEAD DROP TEST (572.152)
Dummy Serial Number _____________
Test Date _____________
Technician ___________________________
__Pretest calibration
__Post test calibration verification
Test attempt no. ____ (when successive head drops are necessary)
__1.
__2.
__3.
__4.
__5.
__6.
__7.
It has been at least 2 hours since the last frontal head drop and at least 30
minutes since the last rear head drop. (572.152(c)(5))
__ N/A, ONLY one head drop performed
The head assembly consists of the head (921022-001), triaxial accelerometer
mounting block (SA572-S80), and three (3) accelerometers (SA572-S4).
(572.152(a))
Accelerometers and their respective mounts are smooth and clean.
The data acquisition system, including transducers, conforms to the requirements
of SAE Recommended Practice J211/1 MAR95. (572.155(i))
The head assembly soaked at a temperature between 18.9oC (66ºF) and 25.6oC
(78ºF) and at a relative humidity from 10% to 70% for a period of at least four (4)
hours prior to a test. (572.152(c)(1))
Record the maximum temperature
______
Record the minimum temperature
______
Record the maximum humidity
______
Record the minimum humidity
______
Visually inspect the head skin for cracks, cuts, abrasions, etc. Repair or replace
the head if the damaged area is more than superficial. Note: If the damage
resulted from the CRS test in which the dummy was an occupant, the damaged
area is to be documented with photography and the post test calibration
verification testing completed before any replacement or repairs are made.
Record findings and actions: _________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
Clean the impact surface of the skin and the impact surface of the fixture with
isopropyl alcohol, trichloroethane or equivalent prior to the test. (572.152(c)(2))
E-21
__8.
Suspend and orient the head assembly as shown in Figure 5E. The lowest point
on the forehead is 376.0 ± 1.0 mm (14.8±0.04 inch) from the impact surface.
(572.152(c)(3)(i))
Record the actual distance
______
NOTE: The masses of the suspension device and the accelerometer
cables are to be kept as lightweight as possible to minimize their effect on
the test results.
__9.
__10.
__11.
__12.
__13.
__14.
The 3.3 mm (0.13 inch) diameter holes located on either side of the dummy's
head are equidistance within 2 mm from the impact surface. (572.152(c)(3)(i))
Record the right side distance
_______
Record the left side distance
_______
The angle between the lower surface plane of the neck transducer mass
simulator (910420-003) and the plane of the impact surface is 45 ± 1 degrees.
(572.152(c)(3)(i))
Record the angle ____________
The impact surface is clean and dry and has a micro finish in the range of
203.2x10-6 mm (8 micro inches) to 2032.0x10-6 mm (80 micro inches) (RMS).
(572.152(c)(4))
Record actual micro finish
_______
The impact surface is a flat horizontal steel plate 50.8 mm (2 inches) thick and
610 mm (24 inches) square. (572.152(c)(4))
Record thickness _______
Record width
_______
Record length
_______
Drop the head assembly from a height of 376.0 ± 1.0 mm (14.8 inches ±
0.04 inches) by a means that ensures a smooth, instant release onto the impact
surface. (572.152(b) & (572.152(c)(4))
Complete the following table. (572.152(b)):
Parameter
Peak resultant acceleration
Resultant versus time history curve
Oscillations after the main pulse
Lateral acceleration
Specification
100 g ≤ x ≤ 120 g
Unimodal
Less than 17% of the peak
resultant acceleration
y-axis acceleration ≤ ±15 g
Result
__15. Plots of the x, y, z, and resultant acceleration data follow this sheet.
_____________________________
Signature
______________
Date
E-22
FIGURE 5E
E-23
DATA SHEET E4
REAR HEAD DROP TEST (572.152)
Dummy Serial Number _____________
Test Date _____________
Technician ___________________________
__Pretest calibration
__Post test calibration verification
Test attempt no. ____ (when successive head drops are necessary)
__1.
__2.
__3.
__4.
__5.
__6.
__7.
It has been at least 2 hours since the last rear head drop and at least 30 minutes
since the last frontal head drop. (572.152(c)(5))
__ N/A, ONLY one head drop performed
The head assembly consists of the head (921022-001), triaxial accelerometer
mounting block (SA572-S80), and three (3) accelerometers (SA572-S4).
(572.152(a))
Accelerometers and their respective mounts are smooth and clean.
The data acquisition system, including transducers, conforms to the requirements
of SAE Recommended Practice J211/1 MAR95. (572.155(i))
The head assembly soaked at a temperature between 18.9oC (66ºF) and 25.6oC
(78ºF) and at a relative humidity from 10% to 70% for a period of at least four (4)
hours prior to a test. (572.152(c)(1))
Record the maximum temperature
______
Record the minimum temperature
______
Record the maximum humidity
______
Record the minimum humidity
______
Visually inspect the head skin for cracks, cuts, abrasions, etc. Repair or replace
the head if the damaged area is more than superficial. Note: If the damage
resulted from the CRS test in which the dummy was an occupant, the damaged
area is to be documented with photography and the post test calibration
verification testing completed before any replacement or repairs are made.
Record findings and actions: _________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
Clean the impact surface of the skin and the impact surface of the fixture with
isopropyl alcohol, trichloroethane or equivalent prior to the test. (572.152(c)(2))
E-24
__8.
Suspend and orient the head assembly as shown in Figure 6E. The lowest point
on the back of the head is 376.0 ± 1.0 mm (14.8±0.04 inch) from the impact
surface. (572.152(c)(3)(ii))
Record the actual distance
______
NOTE: The masses of the suspension device and the accelerometer
cables are to be kept as lightweight as possible to minimize their effect on
the test results.
__9.
__10.
__11.
__12.
__13.
__14.
The 3.3 mm (0.13 inch) diameter holes located on either side of the dummy's
head are equidistance within 2 mm from the impact surface. (572.152(c)(3)(ii))
Record the right side distance
_______
Record the left side distance
_______
The angle between the lower surface plane of the neck transducer mass
simulator (910420-003) and the plane of the impact surface is 90 ± 1 degrees.
(572.152(c)(3)(ii))
Record the angle ____________
The impact surface is clean and dry and has a micro finish in the range of
203.2x10-6 mm (8 micro inches) to 2032.0x10-6 mm (80 micro inches) (RMS).
(572.152(c)(4))
Record actual micro finish
_______
The impact surface is a flat horizontal steel plate 50.8 mm (2 inches) thick and
610 mm (24 inches) square. (572.152(c)(4))
Record thickness _______
Record width
_______
Record length
_______
Drop the head assembly from a height of 376.0 ± 1.0 mm (14.8 inches ±
0.04 inches) by a means that ensures a smooth, instant release onto the impact
surface. (572.152(b) & (572.152(c)(4))
Complete the following table. (572.152(b)):
Parameter
Peak resultant acceleration
Resultant versus time history curve
Oscillations after the main pulse
Lateral acceleration
Specification
55 g ≤ x ≤ 71 g
Unimodal
Less than 17% of the peak
resultant acceleration
y-axis acceleration ≤ ±15 g
Result
__15. Plots of the x, y, z, and resultant acceleration data follow this sheet.
_____________________________
Signature
______________
Date
E-25
FIGURE 6E
E-26
DATA SHEET E5
NECK FLEXION TEST (572.153)
Dummy Serial Number _____________
Test Date _____________
Technician ___________________________
__Pretest calibration
__Post test calibration verification
Test attempt no. ____ (when successive flexion tests are necessary)
__1.
It has been at least 30 minutes since the last neck test. (572.155(m))
__ N/A, this is the first neck test performed
__2. The components required for the neck tests include the neck assembly
(921022-041), and headform (TE-3200-160). (572.153(a))
__3. The assembly soaked at a temperature between 20.6oC (69ºF) and 22.2oC
(72ºF) and at a relative humidity from 10% to 70% for a period of at least four (4)
hours prior to a test. (572.153(c)(1))
Record the maximum temperature
______
Record the minimum temperature
______
Record the maximum humidity
______
Record the minimum humidity
______
__4. Visually inspect neck assembly for cracks, cuts and separation of the rubber from
the metal segments. Note: If the damage resulted from the CRS test, the
damaged area is to be documented with photography and the post test
calibration verification testing completed before any replacement or repairs are
made.
Record findings and actions: _________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
__6, Torque the jam nut (9001336) on the neck cable (ATD-6206) between 0.2 Nm
and 0.3 Nm. (572.153(c)(2)
__7. The data acquisition system, including transducers, conforms to the requirements
of SAE Recommended Practice J211/1 MAR95. (572.155(i))
__8. The test fixture pendulum conforms to the specifications in Figure 7E.
__9. The head-neck assembly is mounted on the pendulum so the midsagittal plane of
the headform is vertical and coincides with the plane of motion of the pendulum
as shown in Figure 8E for the flexion test. (572.153(c)(3))
__10. Install the transducers or other devices for measuring the "D" plane rotation with
respect to the pendulum longitudinal centerline. Note: Plane "D" is the top
horizontal surface of the neck load cell. These measurement devices should be
designed to minimize their influence upon the performance of the head-neck
assembly and not induce neck torsion. (572.153(c)(3)(ii))
E-27
__11. Plane D is perpendicular ± 1 degree to the centerline of the pendulum.
__12. Set the instrumentation so that the moment and rotation are defined to be zero
when the longitudinal centerline of the neck and pendulum are parallel.
(572.153(c)(3)(i))
__13. Release the pendulum and allow it to fall freely from a height to achieve an
impact speed of 5.1 m/s to 5.3 m/s as measured at the center of the pendulum
accelerometer at the instant of contact with the honeycomb. (572.153(c)(4))
__14. Complete the following table:
Neck Flexion Test Results (572.153(b)(1) & (572.153(c)(4)(ii)
Parameter
Specification
Result
Pendulum impact speed
5.1 m/s ≤ speed ≤ 5.3 m/s
Pendulum
@ 10ms
1.6 m/s ≤ ∆V ≤ 2.3 m/s
∆V with respect @ 20 ms 3.4 m/s ≤ ∆V ≤ 4.2 m/s
to impact
@25ms
4.3 m/s ≤ ∆V ≤ 5.2 m/s
speed
Plane D Rotation
Peak moment*
____Nm @
___degrees
36 Nm ≤ moment ≤ 45 Nm during the
o
o
following rotation range 75 ≤ angle ≤ 86
Positive Moment Decay**
Time to decay to 5Nm
(Flexion)
60 ms ≤ time ≤ 80ms
*Moment about the occipital condyle = My – (0.005842 m x Fx) (572.153(b)(1)(iii)
My = Moment in Nm measured by the transducer
Fx = Force, in N measured by the transducer
**Time zero is defined as the time of initial contact between the pendulum striker
plate and the honeycomb material. (572.153(c)(4)(i))
__15. Plots of pendulum acceleration, pendulum velocity, neck y-axis moment, and
neck rotation about the y-axis follow this sheet.
_____________________________
Signature
______________
Date
E-28
DATA SHEET E6
NECK EXTENSION TEST (572.153)
Dummy Serial Number _____________
Test Date _____________
Technician ___________________________
__Pretest calibration
__Post test calibration verification
Test attempt no. ____ (when successive flexion tests are necessary)
__1.
It has been at least 30 minutes since the last neck test. (572.155(m))
__ N/A, this is the first neck test performed
__2. The components required for the neck tests include the neck assembly
(921022-041), and headform (TE-3200-160). (572.153(a))
__3. The assembly soaked at a temperature between 20.6oC (69ºF) and 22.2oC
(72ºF) and at a relative humidity from 10% to 70% for a period of at least four (4)
hours prior to a test. (572.153(c)(1))
Record the maximum temperature
______
Record the minimum temperature
______
Record the maximum humidity
______
Record the minimum humidity
______
__4. Visually inspect neck assembly for cracks, cuts and separation of the rubber from
the metal segments. Note: If the damage resulted from the CRS test, the
damaged area is to be documented with photography and the post test
calibration verification testing completed before any replacement or repairs are
made.
Record findings and actions: _________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
__6, Torque the jam nut (9001336) on the neck cable (ATD-6206) between 0.2 Nm
and 0.3 Nm. (572.153(c)(2)
__7. The data acquisition system, including transducers, conforms to the requirements
of SAE Recommended Practice J211/1 MAR95. (572.155(i))
__8. The test fixture pendulum conforms to the specifications in Figure 7E.
__9. The head-neck assembly is mounted on the pendulum so the midsagittal plane of
the headform is vertical and coincides with the plane of motion of the pendulum
as shown in Figure 9E for the flexion test. (572.153(c)(3))
__10. Install the transducers or other devices for measuring the "D" plane rotation with
respect to the pendulum longitudinal centerline. Note: Plane "D" is the top
horizontal surface of the neck load cell. These measurement devices should be
designed to minimize their influence upon the performance of the head-neck
assembly and not induce neck torsion. (572.153(c)(3)(ii))
E-29
__11. Plane D is perpendicular ± 1 degree to the centerline of the pendulum.
__12. Set the instrumentation so that the moment and rotation are defined to be zero
when the longitudinal centerline of the neck and pendulum are parallel.
(572.153(c)(3)(i))
__13. Release the pendulum and allow it to fall freely from a height to achieve an
impact speed of 2.4 m/s to 2.6 m/s as measured at the center of the pendulum
accelerometer at the instant of contact with the honeycomb. (572.153(c)(4))
__14. Complete the following table:
Neck Extension Results (572.153(b)(2) & (572.153(c)(4)(ii)
Parameter
Specification
Result
Pendulum impact speed
2.4 m/s ≤ speed ≤ 2.6 m/s
Pendulum
@ 6 ms
0.8 m/s ≤ ∆V ≤ 1.2 m/s
∆V with respect @ 10 ms 1.5 m/s ≤ ∆V ≤ 2.1 m/s
to impact
@ 14 ms 2.2 m/s ≤ ∆V ≤ 2.9 m/s
speed
Plane D Rotation
Peak moment*
____Nm @
-12 Nm > moment > -23 Nm during the
___degrees
following rotation range 80o ≤ angle ≤ 92o
Negative Moment Decay**
Time to decay to -5Nm
(Extension)
76 ms ≤ time ≤ 90ms
*Moment about the occipital condyle = My – (0.005842 m x Fx) (572.153(b)(2)(iii)
My = Moment in Nm measured by the transducer
Fx = Force, in N measured by the transducer
**Time zero is defined as the time of initial contact between the pendulum striker
plate and the honeycomb material. (572.153(c)(4)(i))
__15. Plots of pendulum acceleration, pendulum velocity, neck y-axis moment, and
neck rotation about the y-axis follow this sheet.
_____________________________
Signature
______________
Date
E-30
FIGURE 7E
E-31
FIGURE 8E
E-32
FIGURE 9E
E-33
DATA SHEET E7
THORAX IMPACT TEST (572.154)
Dummy Serial Number _____________
Test Date _____________
Technician ___________________________
__Pretest calibration
__Post test calibration verification
Test attempt no. ____ (when successive thorax impact tests are necessary)
__1.
It has been at least 30 minutes since the last thorax impact test. (572.155(m))
__ N/A, ONLY one thorax impact test performed
__2. The test fixture conforms to the specifications in Figure 10E.
__3. The complete assembled dummy (921022-000) is used (572.154(b)) and is
dressed in cotton-polyester-based tight-fitting long-sleeved sweat shirt and ankle
length pants. The weight of the shirt and pants shall not exceed 0.25 kg.
(572.154(c)(2))
__4. The dummy assembly soaked at a temperature between 20.6oC (69ºF) and
22.2oC (72ºF) and at a relative humidity from 10% to 70% for a period of at least
four (4) hours prior to this test. (572.154(c)(1))
Record the maximum temperature
______
Record the minimum temperature
______
Record the maximum humidity
______
Record the minimum humidity
______
__5. Seat the dummy, without back support on the test fixture surface as shown in
Figure 10E. The legs are extended forward, parallel to the midsagittal plane.
The surface must be long enough to support the pelvis and outstretched legs.
(572.154(c)(3))
__6. The midsagittal plane of the dummy is vertical within ± 1º. (572.154(c)(3))
__7. The posterior surface of the upper spine box is 90o ± 1o from the horizontal.
Shim material may be used under the upper legs to maintain the dummy’s
specified spine box surface alignment. (572.154(c)(3))
__8. Place the upper arms parallel to the torso. Place the lower arms 0º to 5º forward
of vertical. (572.154(c)(3))
__9. The longitudinal centerline of the test probe is centered within ±2.5 mm of the
midsagittal plane, 196 ± 2.5 mm vertically from the plane of the seating surface
and is within ±0.5º of a horizontal line in the dummy's midsagittal plane.
(572.154(c)(4))
__10. The data acquisition system, including transducers, must conform to the
requirements of SAE Recommended Practice J211/1 MAR95 (572.155(i)).
__11. Impact the anterior surface of the thorax with the test probe so the longitudinal
centerline of the probe is within 2º of a horizontal line in the dummy's midsagittal
plane at the moment of impact. (572.154(c)(5)) The velocity of the test probe at
the time of impact is between 4.9 m/s and 5.1 m/s. (572.154(b)) The probe is
E-34
guided so there is no significant lateral, vertical or rotational movement during the
impact. (572.154(c)(6) Neither the suspension hardware, suspension cables, nor
other attachments to the probe, including the velocity vane, shall make contact
with the dummy during the test. (572.154(c)(7)
__12. Complete the following table:
Thorax Impact Results (572.154(b))
Parameter*
Specification
Result
Test Probe Speed
4.9 m/s ≤ speed ≤ 5.1 m/s
Peak force**
1514 N ≤ peak force ≤ 1796 N
*Time zero is defined as the time of initial contact between the test probe and the
chest skin.
**Force = impactor mass x acceleration
__13. Plots of pendulum acceleration, and pendulum force, follow this sheet.
_____________________________
Signature
______________
Date
E-35
Probe specifications:
1.
Rigid metallic construction and concentric about its longitudinal axis.
2.
A mass of 2.86 ± 0.02 kg (6.3 ± 0.05 lbs). 1/3 of the weight of the suspension cables and
their attachments to the impact probe are included in the calculation of mass, and such
components may not exceed 5 percent of the total weight of the test probe.
3.
Minimum mass moment of inertia of 164 kg-cm2 (0.145 lbs-in-sec2) in yaw and pitch
about the center of gravity.
4.
The impacting end of the probe is perpendicular to and concentric with the longitudinal
axis. It has a flat, continuous, and non-deformable face with diameter of
101.6 ± 0.25 mm (4.00 ± 0.01 in) and a edge radius of 7.6 to 12.7 mm (0.3 to 0.5 in.).
5.
A 101-103 mm (4.0-4.1 in) diameter cylinder surface extends at least 12.5 mm to the rear
of the impact face.
6.
The probe’s end opposite to the impact face must have provisions for mounting of an
accelerometer with its sensitive axis collinear with the longitudinal axis of the probe.
7.
The impact probe shall have a free air resonant frequency of not less than 1000 Hz in line
with the longitudinal axis of the impactor.
FIGURE 10E
E-36
DATA SHEET E8
PART 572 INSTRUMENTATION CALIBRATION INFORMATION
I.D. NO.
MANUFACTURER
MODEL NO.
SERIAL NO.
DATE OF LAST
CALIBRATION
DATE OF NEXT
CALIBRATION
DUMMY INSTRUMENTATION
HEAD ACCELEROMETERS
(1) LONGITUDINAL
(2) LATERAL
(3) VERTICAL
NECK TRANSDUCER
CHEST ACCELEROMETERS
(1) LONGITUDINAL
(2) LATERAL
(3) VERTICAL
CHEST
POTENTIOMETER
FEMUR LOAD CELLS
(1) RIGHT FEMUR
(2) LEFT FEMUR
LABORATORY INSTRUMENTATION
NECK PENDULUM
ACCELEROMETER
THORAX PENDULUM
ACCELEROMETER
KNEE PENDULUM
ACCELEROMETER
NECK ROTATION
TRANSDUCER 1
(OPTIONAL)
NECK ROTATION
TRANSDUCER 2
(OPTIONAL)
LABORATORY TECHNICIAN: ____________________________________________
E-37
