TP-201-02
March 3, 1989
U.S. DEPARTMENT OF TRANSPORTATION
NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION
LABORATORY TEST PROCEDURE
FOR
FMVSS 201
Occupant Protection in Interior Impact
SAFETY ASSURANCE
Office of Vehicle Safety Compliance
Room 6115, NSA-30
400 Seventh Street, SW
Washington, DC 20590
OVSC LABORATORY TEST PROCEDURE NO. 201
TABLE OF CONTENTS
PAGE
1.
PURPOSE AND APPLICATION.............................................................................
1
2.
GENERAL REQUIREMENTS.................................................................................
2
3.
SECURITY .............................................................................................................
3
4.
GOOD HOUSEKEEPING .......................................................................................
3
5.
TEST SCHEDULING AND MONITORING .............................................................
3
6.
TEST DATA DISPOSITION....................................................................................
4
7.
GOVERNMENT FURNISHED PROPERTY (GFP).................................................
4
8.
CALIBRATION OF TEST INSTRUMENTATION ....................................................
5
9.
PHOTOGRAPHIC DOCUMENTATION..................................................................
6
10.
DEFINITIONS.........................................................................................................
7
11.
PRETEST REQUIREMENTS .................................................................................
10
12.
COMPLIANCE TEST EXECUTION........................................................................
11
13.
POST TEST REQUIREMENTS..............................................................................
27
14.
REPORTS ..............................................................................................................
28
14.1
MONTHLY STATUS REPORTS.................................................................
28
14.2
APPARENT NONCOMPLIANCE................................................................
28
14.3
FINAL TEST REPORTS .............................................................................
28
14.3.1 COPIES .........................................................................................
28
14.3.2 REQUIREMENTS..........................................................................
29
14.3.3 FIRST THREE PAGES OF FINAL REPORT.................................
29
14.3.4 TABLE OF CONTENTS ................................................................
35
15.
DATA SHEETS.......................................................................................................
36
16.
FORMS ..................................................................................................................
44
2
APPENDIX A
FMVSS 201 ............................................................................
47
APPENDIX B
SAE J921 ...............................................................................
51
APPENDIX C
SAE J839 ...............................................................................
67
APPENDIX D
SAE J984 ...............................................................................
76
APPENDIX E
SAE J211 ...............................................................................
80
1
1.
PURPOSE AND APPLICATION
The Office of Vehicle Safety Compliance (OVSC) provides contracted
laboratories with Laboratory Test Procedures (TPs) which serve as guidelines for
obtaining compliance test data. The data are used to determine if a specific
vehicle meets the minimum performance requirements of the subject Federal
Motor Vehicle Safety Standard (FMVSS). The purpose of the OVSC Laboratory
Test Procedures is to present a uniform testing and data recording format, and
provide suggestions for the use of specific equipment and procedures. Any
contractor interpreting any part of an OVSC Laboratory Test Procedure to be in
conflict with a Federal Motor Vehicle Safety Standard or observing any
deficiencies in a Laboratory Test Procedure is required to advise the Contracting
Officer's Technical Representative (COTR) and resolve the discrepancy prior to
the start of compliance testing.
Contractors are required to submit a detailed test procedure to the COTR before
initiating the compliance test program. The procedure must include a step-by-step
description of the methodology to be used.
The OVSC Laboratory Test Procedures are not intended to limit or restrain a contractor
from developing or utilizing any testing techniques or equipment which will assist in
procuring the required compliance test data.
NOTE: The OVSC Laboratory Test Procedures, prepared for use by independent
laboratories under contract to conduct compliance tests for the OVSC, are not intended
to limit the requirements of the applicable FMVSS(s). In some cases, the OVSC
Laboratory Test Procedures do not include all of the various FMVSS minimum
performance requirements. Sometimes, recognizing applicable test tolerances, the Test
Procedures specify test conditions which are less severe than the minimum
requirements of the standards themselves. Therefore, compliance of a vehicle or item
of motor vehicle equipment is not necessarily guaranteed if the manufacturer limits
certification tests to those described in the OVSC Laboratory Test Procedures.
2
2.
GENERAL REQUIREMENTS
Within the provisions of the National Traffic and Motor Vehicle Safety Act of 1966 and
the Highway Safety Act of 1966, the Department of Transportation is charged with the
responsibility of setting Motor Vehicle Safety Standards and ensuring that they are met.
Within the charter, the Department of Transportation has specified various minimum
performance requirements for motor vehicles and motor vehicle equipment.
FMVSS 201 sets forth minimum requirements for instrument panels, seat backs,
interior compartment doors, sun visors and armrests. The purpose of this
standard is to afford impact protection for occupants.
FMVSS 201 applies to passenger cars and to multipurpose passenger vehicles,
trucks and buses with a GVWR of 10,000 pounds of less.
IMPACT PROTECTION REQUIREMENTS
Instrument Panel and Seat Backs
A point within the "head impact area" is impacted by a 15 pound, 6.5 inch
diameter head form at a velocity of 15 miles per hour. The deceleration of the
head form shall not exceed 80g continuously for more than 3 milliseconds (ms).
Interior Compartment Doors
The interior compartment doors are subjected to the inertia load requirements of
SAE J839b, Passenger Car Side Door Latch Systems, May 1965, or approved
equivalent.
Sun Visors
Constructed of or covered with energy absorbing material and have no rigid
material edge radius of less than 0.125 inch.
Armrests
The armrest shall meet the requirements under S3.5 of FMVSS 201.
3
3.
SECURITY
The contractor shall provide appropriate security measures to protect the OVSC test
vehicles and Government Furnished Property (GFP) from unauthorized personnel
during the entire compliance testing program. The contractor is financially responsible
for any acts of theft and/or vandalism which occur during the storage of test vehicles
and GFP. Any security problems which arise 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.
The contractor shall protect and segregate the data that evolves from compliance
testing and test dummy calibration (if applicable) before and after each vehicle test. No
information concerning the vehicle safety compliance testing program shall be released
to anyone except the COTR, unless specifically authorized by the COTR or the COTR's
Group Supervisor or Division Chief.
NOTE: NO INDIVIDUALS, OTHER THAN CONTRACTOR PERSONNEL DIRECTLY
INVOLVED IN THE COMPLIANCE TESTING PROGRAM OR OVSC PERSONNEL,
SHALL BE ALLOWED TO WITNESS ANY VEHICLE OR EQUIPMENT ITEM
COMPLIANCE TEST OR TEST DUMMY CALIBRATION UNLESS SPECIFICALLY
AUTHORIZED BY THE COTR.
4.
GOOD HOUSEKEEPING
Contractors shall maintain the entire vehicle compliance testing area, 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 contractor shall submit a vehicle test schedule to the COTR prior to conducting the
first compliance test. Tests shall be completed as required in the contract.
Scheduling of vehicle tests shall be adjusted to permit vehicles to be tested to other
FMVSSs as may be required by the OVSC. All vehicle compliance testing shall be
coordinated with the COTR in order to allow monitoring by the COTR and/or other
OVSC personnel if desired.
6.
TEST DATA DISPOSITION
The contractor shall make all vehicle preliminary compliance test data available to the
COTR immediately. Final test data, including digital printouts and computer generated
plots (if applicable), shall be furnished to the COTR within five working days.
Additionally, the contractor shall analyze the preliminary test results as directed by the
COTR.
4
6.
TEST DATA DISPOSITION....Continued
All backup data sheets, strip charts, recordings, plots, technician's 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)
GFP shall consist of test vehicles.
ACCEPTANCE OF VEHICLE
The Contractor has the responsibility of accepting the test vehicle from either a new car
dealer or a vehicle transporter. In both instances, the contractor acts in the OVSC's
behalf when signing an acceptance of the test vehicle. If the vehicle is delivered by a
dealer, the contractor must check to verify the following:
A.
All options listed on the "window sticker" are present on the test vehicle.
B.
Tires and wheel rims are new and the same as listed.
C.
There are no dents or other interior or exterior flaws.
D.
The vehicle has been properly prepared and is in running condition.
E.
The glove box contains an owner's manual, warranty document, consumer
information, and extra set of keys.
F.
Proper fuel filler cap is supplied on the test vehicle.
If the test vehicle is delivered by a government contracted transporter, the contractor
should check for damage which may have occurred during transit.
A "Vehicle Condition" form will be supplied to the contractor by the COTR when the test
vehicle is transferred from the new car dealer or between test contracts. The upper half
of the form describes the vehicle in detail, and the lower half provides space for a
detailed description of the post test condition. Vehicle Condition forms must be returned
to the COTR with the copies of the Final Test Report or the reports will NOT be
accepted.
NOTIFICATION OF COTR
The COTR must be notified within 24 hours after a vehicle has been delivered.
5
8.
CALIBRATION OF TEST INSTRUMENTS
Before the contractor initiates the safety compliance test program, a test instrumentation
calibration system will 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 will 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
TO EXCEED TWELVE (12) MONTHS! 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 will be labeled with
the following information:
(1)
(2)
(3)
D.
A written calibration procedure shall be provided by the contractor which includes
as a minimum the following information for all measurement and test equipment:
(1)
(2)
(3)
(4)
(5)
E.
Date of calibration
Date of next scheduled calibration
Name of the technician who calibrated the equipment
Type of equipment, manufacturer, model number, etc.
Measurement range
Accuracy
Calibration interval
Type of standard used to calibrate the equipment (calibration traceability
of the standard must be evident)
Records of calibration for all test instrumentation shall be kept by the contractor
in a manner which assures the maintenance of established calibration schedules.
All such records shall be readily available for inspection when requested by the
COTR. The calibration procedure must be approved by the COTR before the
test program commences.
6
9.
PHOTOGRAPHIC DOCUMENTATION
Photographs, if required, shall be glossy black and white, 8½ x 11 inches, and properly
focused for clear images. A tag, label or placard identifying the test vehicle model,
NHTSA number and date shall appear in each photograph and must be legible. Each
photograph shall be labeled as to the subject matter. As a minimum the following
photographs shall be included in each final test report:
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
P.
Q.
R.
S.
Left side view of vehicle
Right side view of vehicle
3/4 frontal view from left side of vehicle
3/4 rear view from right side of vehicle
Vehicle's certification label
Vehicle's tire information label
Head impact location fixture
Instrument panel and seat backs marked to indicate areas to be
investigated
Instrument panel, seat backs and sun visors marked to show areas of possible
head impact
Instrument panel and seat backs with impact locations marked and identified
Areas on the instrument panel creating local stiffness.
Impactor fixture
Instrument panel and seat backs before and after impact
Sun visor marked to indicate which edges could suffer head impact
Interior compartment doors that will have their latch analyzed
Armrests marked to indicate areas of possible pelvic impact
Armrests before and after evaluation
Instrumentation setup
Any areas of potential failure or hazard not clearly evident in the above list of
photographs
7
10.
DEFINITIONS
INSTRUMENT PANEL AREA TO BE INVESTIGATED
Area of the instrument panel NOT excluded by the following (see Figure 1):
Console assemblies
Areas less than 5 inches inboard from the juncture of the instrument panel
attachment to the body side inner structure
Areas closer to the windshield juncture than those statically contactable by the
head form with the windshield in place
Areas outboard of any point of tangency on the instrument panel of a 6.5 inch
diameter head form tangent to and inboard of a vertical longitudinal plane
tangent to the inboard edge of the steering wheel
Areas below any point at which a vertical line is tangent to the rearmost surface
of the panel
EXCLUDED AREA
INSTRUMENT PANEL
5"
HEADFORM
VERTICAL PLANE
STEERING WHEEL
TOP VIEW
WINDSHIELD
HEADFORM
VERTICAL PLANE
EXCLUDED AREA
INSTRUMENT PANEL
FIGURE 1
LEFT SIDE VIEW
8
10.
DEFINITIONS....Continued
HEAD IMPACT LOCATION FIXTURE
Fixture that is placed in each Designated Seating Position (DSP) to determine areas of
possible head impact for each position. Fixture has a pivoted arm with a head form
attached to determine points of contact as the arm is swung forward.
HEAD IMPACT AREA
All nonglazed surfaces of the interior of a vehicle that are statically contactable by 6.5
inch diameter head form of a measuring device having a pivot point to "top-of-head"
dimension infinitely adjustable from 29 to 33 inches in accordance with the following
procedure, or its graphic equivalent:
A.
At each Designated Seating Position (DSP), place the pivot point of the
measuring device —(1)
For seats that are adjustable fore and aft, at —(A)
(B)
(2)
the Seating Reference Point (SRP).
a point 5 inches horizontally forward of the Seating Reference Point
(SRP) and vertically above the SRP an amount equal to the rise
which results from a 5 inch forward adjustment of the seat or 0.75
inch.
For seats that are not adjustable fore and aft, at the SRP.
B.
With the pivot point to "top-of-head" dimension at each value allowed by the
device and the interior dimensions of the vehicle, determine all contact points
above the lower windshield glass line and forward of the SRP.
C.
With the head form at each contact point, and with the device in a vertical
position if no contact points exists for a particular adjusted length, pivot the
measuring device forward and downward through all arcs in vertical planes to 90
degrees each side of the vertical longitudinal plane through the SRP, until the
head form contacts an interior surface or until it is tangent to a horizontal plane 1
inch above the SRP, whichever occurs first.
INTERIOR COMPARTMENT DOOR
Any door in the interior of the vehicle installed by the manufacturer as a cover for
storage space normally used for personal effects.
9
10.
DEFINITIONS....Continued
PELVIC IMPACT AREA
Any area of the door or body side panel adjacent to any outboard Designated Seating
Position (DSP) which is bounded by horizontal planes 7 inches above and 4 inches
below the SRP and vertical transverse planes 8 inches forward and 2 inches rearward
of the SRP.
SEATING REFERENCE POINT (SRP)
Manufacturer's Design Reference Point which does the following:
A.
Establishes the rearmost normal design driving or riding position of each DSP in
a vehicle
B.
Has coordinates established relative to the designed vehicle structure
C.
Simulates the position of the pivot center of the human torso and thigh
D.
Is the reference point employed to position the two dimensional templates
described in SAE J826, Manikins for Use in Defining Vehicle Seating
Accommodations, Nov62
10
11.
PRETEST REQUIREMENTS
Prior to conducting any compliance tests, contractors are required to submit a detailed
in-house compliance test procedure to the COTR which includes a step-by-step
description of the methodology to be used. Written approval must be obtained from the
COTR before initiating the compliance test program so that all parties are in agreement.
The contractor's test procedure shall contain a complete listing of test equipment and a
detailed check-off list. There shall be no contradiction between the OVSC Laboratory
Test Procedure and the contractor's in-house test procedure. The list of test equipment
shall include instrument accuracy and calibration dates.
TEST DATA LOSS
A compliance test is not to be conducted unless all of the various test conditions
specified in the applicable OVSC Laboratory Test Procedure have been met. Failure of
a contractor to obtain the required test data and to maintain acceptable limits on test
parameters (such as impact velocity) in the manner outlined in the applicable OVSC
Laboratory Test Procedure may require a retest at the expense of the contractor. The
retest costs will include the cost of the replacement vehicle (with the same equipment
as the original vehicle) or item of motor vehicle equipment and all costs associated with
conducting the retest. The original test specimen (vehicle or equipment item) used for
the invalid test shall remain the property of OVSC, and the retest specimen shall remain
the property of the contractor. If there is a test failure, the contractor shall retain the
retest specimen for a period not exceeding 180 days. If there is no test failure, the
Contractor may dispose of the test specimen upon notification from the COTR that the
final test report has been accepted.
The Contracting Officer of NHTSA is the only NHTSA official authorized to notify the
contractor that a retest is required. The retest shall be completed within two (2) weeks
after receipt of notification by the Contracting Officer that a retest is required. If a retest
is conducted, no test report is required for the original test.
11
12.
COMPLIANCE TEST EXECUTION
12.1
PREPARATION OF VEHICLE
A.
Place vehicle on rigid supports such that side sills are parallel to the ground. Set
parking brake and provide ground supports so that vehicle will not move.
B.
Place front seats in rearmost position.
C.
Place adjustable seat backs in their Nominal Design Driving Position, as
furnished by the manufacturer, through the COTR.
D.
Close and latch all interior compartment doors. If any doors have locking
devices, set locks to the unlocked position.
NOTE: In an instance where the desired direction of impact is not possible to attain
because of space constraints or otherwise, the COTR shall be notified. A decision can
be made in using a suitable laboratory fixture or the COTR may authorize cutting up of
the intruding vehicle parts to permit the impact test sequence.
12.2
PREPARATION OF THE AREAS TO BE INVESTIGATED
INSTRUMENT PANEL
As shown in Figure 1, outline the area on the instrument panel that is to be investigated
with a marker or tape. The instrument panel area to be evaluated for head impact is
specified in S201 S3.1.1.
Photograph the panel with the outlined area.
SEAT BACKS
As shown on Figures 2 and 2A, outline the area on the seat backs that are to be
investigated. The seat back area to be evaluated for head impact is specified in S201
S3.2.2
Photograph the seat backs with the outlined areas.
12
12.
COMPLIANCE TEST EXECUTION....Continued
INSTRUMENT PANEL
EXCLUDED AREA
5"
HEADFORM
VERTICAL PLANE
STEERING WHEEL
TOP VIEW
WINDSHIELD
HEADFORM
VERTICAL PLANE
EXCLUDED AREA
LEFT SIDE VIEW
INSTRUMENT PANEL
FIGURE 1
SEATS WITHOUT HEAD RESTRAINTS
BUCKET SEAT
DSP
CENTERLINE
FRONT OF
BENCH SEAT
RIGHT
FRONT
4"
RIGHT
REAR
4"
4"
LEFT
FRONT
4"
DSP
CENTERLINE
4"
LEFT
REAR
BACK
4"
BUCKET SEAT
TOP VIEW
FIGURE 2
VEHICLE
CENTERLINE
13
12.
COMPLIANCE TEST EXECUTION....Continued
SEATS WITH HEAD RESTRAINTS
BUCKET SEAT
DSP
CENTERLINE
BENCH SEAT
RIGHT
FRONT
BACK
RIGHT
REAR
LEFT
FRONT
BACK
LEFT
REAR
BACK
FRONT OF VEHICLE
DSP
CENTERLINE
BUCKET SEAT
TOP VIEW
VEHICLE
CENTERLINE
FIGURE 2A
12.3
DETERMINATION OF THE AREA OF POSSIBLE HEAD IMPACT
12.3.1 INSTRUMENT PANEL AND SUN VISORS
A.
Using information provided by the COTR, locate the SRP for the right front
seating position.
B.
Place the base of the Head Impact Location Fixture in the right front seating
position as described in Sec. 12.10.1. A representative head impact location
fixture is shown in Figure 3.
C.
Adjust the base and the pivot until the pivot is located at the SRP.
D.
Assemble the arm to the base of the fixture.
E.
Adjust the head form to the 33 inch radius position.
F.
Adjust the arm to a position where it will swing in a plane parallel to the vehicle
centerline.
G.
Swing the arm forward until it contacts the instrument panel.
14
12.
COMPLIANCE TEST EXECUTION....Continued
WINDSHIELD
STEERING WHEEL
IMPACT
FIXTURE
HEADFORM
INSTRUMENT
PANEL
RIGHT SIDE VIEW
FIGURE 3
H.
Keeping the head form in contact with the instrument panel, rotate the arm about
the vertical axis through the pivot. Rotating to the left and right, find the locus of
points for head impacts. Only the points that fall within the "Area to investigated"
are permissible, as shown in Figure 1.
I.
With the fixture arm again in the plane parallel to the vehicle centerline, swing the
arm forward and the sun visor down to find a contact with the edge of the visor.
J.
Move the arm forward to left and right to find all possible contacts along the edge
of the visor.
Adjust head form to each value allowed by the device including the 29 inch
radius position and repeat steps F to J.
For seats that are ADJUSTABLE FORE AND AFT, move the pivot of the
measuring device to a point 5 inches horizontally forward and 0.75 inches
vertically above the SRP.
Repeat all above steps for the center and/or driver's DSP. Outline the
extremities of the loci found above on the instrument panel and sunvisor.
Photograph these areas of possible impact.
15
12.
COMPLIANCE TEST EXECUTION....Continued
INSTRUMENT PANEL
EXCLUDED AREA
5"
HEADFORM
VERTICAL PLANE
STEERING WHEEL
TOP VIEW
WINDSHIELD
HEADFORM
VERTICAL PLANE
EXCLUDED AREA
LEFT SIDE VIEW
INSTRUMENT PANEL
FIGURE 1
12.3.2
SEAT BACKS
12.3.2.1 SEATS WITHOUT HEAD RESTRAINTS
Repeat the above procedure by placing the head impact location fixture in the rear
DSPs and locating the areas of possible impact on the seat backs.
12.3.2.2 SEATS WITH HEAD RESTRAINTS
Place head restraint in its lowest adjustable position. Only points along the centerline of
the head restraint that are parallel to the vehicle longitudinal centerline, may be
considered.
In an instance where the impact on the seat back is not possible within the vehicle
interior because of space constraints, or otherwise, the COTR shall be notified. A
decision can be made in using a suitable laboratory fixture or the COTR may authorize
cutting up of the intruding vehicle structure or removal of vehicle parts to permit impact
test sequence.
16
12.
COMPLIANCE TEST EXECUTION....Continued
12.4
SELECTION OF THE POINTS OF IMPACT
12.4.1 INSTRUMENT PANEL
The points of impact shall be located on a line (maximum length of 33 inches) tangent to
the instrument panel surface. The origin of the line tangent to the instrument panel
surface shall be a point on a transverse horizontal line through the FORWARD SRP.
Construct a perpendicular at the point of tangency. The intersection is the location of
the point of impact.
NOTE: POINTS OF IMPACT MUST BE WITHIN THE IMPACT AREA.
12.4.2 SEAT BACKS
The points of impact shall be located on a line (maximum length of 33 inches) tangent to
the seat back frame. The origin of the line tangent to the seat back frame shall be on a
point on a transverse horizontal line through the SRP of the right rear DSP.
Construct a perpendicular at the point of tangency. The intersection is the location of
the point of impact.
Adjustable front seats shall be in their rearmost Design Driving Position.
Adjustable front seat backs shall be in their Nominal Design Driving Position
(information will be obtained from vehicle manufacturer and supplied by the COTR).
NOTE: POINTS OF IMPACT MUST BE WITHIN THE IMPACT AREA
12.5
DIRECTION OF IMPACT
Direction of impact shall be one of the following:
A.
In a vertical plane parallel to the vehicle longitudinal axis
B.
In a plane normal to the surface at the point of contact
Mark selected points for impact and number each point.
Photograph the impact points.
17
12.
COMPLIANCE TEST EXECUTION....Continued
12.6
IMPACT TEST FOR SEAT BACKS AND INSTRUMENT PANELS
12.6.1 GENERAL REQUIREMENTS
Maintain test samples and the head form at 72ºF ± 5ºF for 12 hours prior to test.
Statement of measurement requirements is in Section 12.10.3 and representative
components are shown below.
MANUFACTURE
R/
MODEL
SERIAL
NUMBER
Computer
486DX2/66Mz
Endevco 2735PQ
GP14
Accelerometer
Endevco 2272
PA49
Time Interval Meter
CMC915
09150116
Time Trap No. 1
MS 1"/01
1
Time Trap No. 2
MS 1"/02
2
Integrator Processor
Fine Engineering
Weather
Instrument
CALIBRATIO
N
DUE
486DX2-2203
Charge Amplifier
CALIBRATI
ON
DATE
BOOKD
ITEM
Temperature
FIGURE 4
Use a 6.5 inch diameter head form (cross-section shown in Figure 5) which weighs 14.7
pounds ± 0.2 pounds.
Impact velocity shall be 14.7 mph ± 0.2 mph. Deceleration shall not exceed 80g
continuously for more than 3 milliseconds (ms) to pass the test.
12.6.2 IMPACT TEST STEPS
The following steps will be followed in accomplishing the impact tests on seat backs and
the instrument panel:
A.
Install the head form actuator mount in the area of the test vehicle aft of the
impact area selected for the test.
18
12.
COMPLIANCE TEST EXECUTION....Continued
MOUNTING LIP
6.5" DIA. HEADFORM
CENTERLINE
ACCELEROMETER
MOUNTING HOLES
WEIGHT = 14.9 LBS. MAXIMUM
SIDE VIEW
FIGURE 5
B.
The test engineer will select approximately five "worse case" impact locations
within the head impact zone where the local area is hard or stiff. The COTR will
be consulted before finalizing the selection.
C.
Record X and Y coordinates of each impact location and angle of impact with
reference to a common reference axis system that will be selected by the test
engineer.
D.
Ensure that the accelerometer is properly mounted at the designated location on
the head form (SAE J984 Jun80) and that the accelerometer output is properly
connected to the recorder.
E.
Set the actuator pressure to previously calibrated level to achieve 14.7 mph ± 0.2
mph impact velocity. Activate the velocity timing trap. Fire the actuator and
verify that the specified velocity is achieved.
F.
Position the head form actuator as required and impact the selected impact point
at the locations/angles selected in step B and C, with the head form traveling at
14.7 mph ± 0.2 mph. Record the actual velocity from the speed trap.
G.
The same procedure will be repeated at each selected impact zone.
19
12.
COMPLIANCE TEST EXECUTION....Continued
H.
The test engineer will process the acceleration versus time data recorded from
the head form accelerometer by using "3 ms clip" computer routine to establish
the maximum (3 ms clip) value of head form acceleration data using SAE J211
recommended filter class 1000.
I.
The test engineer will process the accelerometer versus time head form
acceleration data to obtain the dynamic head form displacement. This will be
accomplished by double integrating the head form accelerometer data from time
zero to find the maximum value.
J.
Document each impact location photographically with pretest and post test still
black and white photographs.
K.
Note any unusual events, occurrence or anomalies in test log and the data sheet.
L.
Record all parameters and the results.
The details of the instrumentation required are provided in Section 11.10, Test
Equipment. A representative list of measurement system components is shown in
Figure 4.
MANUFACTURE
R/
MODEL
SERIAL
NUMBER
Computer
486DX2/66Mz
486DX2-2203
Charge Amplifier
Endevco 2735PQ
GP14
Accelerometer
Endevco 2272
PA49
Time Interval Meter
CMC915
09150116
Time Trap No. 1
MS 1"/01
1
Time Trap No. 2
MS 1"/02
2
Integrator Processor
Fine Engineering
Weather
Instrument
CALIBRATI
ON
DATE
BOOKD
ITEM
Temperature
FIGURE 4
A representative recording setup is shown in Figure 6 on the next page.
CALIBRATIO
N
DUE
20
12.
COMPLIANCE TEST EXECUTION....Continued
ACCELEROMETER
TIME TRAP NO. 1
TIME TRAP NO. 2
TIME
INTERVAL
METER
NO. 2
DATA FROM
ACCELEROMETER
AMPLIF./
SIGNAL
CONDIT.
DATA
COLLECTTION
TIME
INTERVAL
METER
NO. 1
DATA
PROCESSING
DATA
PLOTS
COMPUTER SYSTEM
FIGURE 6
12.7
SUN VISOR EVALUATION
A.
B.
Determine areas of sun visor mounting that are contactable by a spherical 6.5
inch diameter head form.
C.
Measure the edge radii that were found to be contact areas with the head form.
Radius must equal or exceed 0.125 inch to be acceptable. Mark edges that are
not acceptable and photograph.
D.
12.8
Check that the sun visor is covered with energy absorbing material.
Disassemble the sun visor and identify the construction material.
ARMREST EVALUATION
This evaluation includes attached armrests, such as on door panels, and folding
armrests that fold into the seat back.
12.8.1 REQUIREMENTS
The armrest shall conform to at least one of the following:
21
12.
COMPLIANCE TEST EXECUTION....Continued
A.
It shall be constructed with energy absorbing material and shall deflect or
collapse laterally at least 2 inches without permitting contact with any underlying
rigid material.
B.
It shall be constructed with energy absorbing material that deflects or collapses
to within 1.25 inches of a rigid test panel surface without permitting contact with
any rigid material. Any rigid material between 0.5 and 1.25 inches from the panel
surface shall have a minimum vertical height of not less than 1 inch.
C.
Along not less than 2 continuous inches of its length, the armrest shall, when
measured vertically in side elevation, provide at least 2 inches of coverage within
the pelvic impact area.
If the armrest folds into the seat back or in between the two seat backs it shall conform
to at least one of the following requirements:
A.
One of the three requirements identified in items A, B, C as they apply to fixed
armrests
B.
Be constructed of or covered with energy absorbing material
12.8.2 ARMREST EVALUATION PROCEDURE
A.
Test engineer will inspect each armrest to establish if its of a fixed configuration
or a folding configuration.
B.
Each armrest will be further evaluated to record if it is constructed or covered
with energy absorbing material, such as foam, padding, soft fabric or other
material designed to absorb impact energy.
C.
Mark the pelvic impact area as defined in Section 10. A cardboard or sheet
metal cutout may be required to identify the pelvic impact area. A representative
cutout is shown in Figure 7.
D.
Place the pelvic area cutout in proper orientation in a vertical plane next to the
armrest under evaluation.
E.
Mark the outline of the armrest on the cutout (representative sample shown on
previous page).
F.
Examine the armrest outline on the cutout to record if at least 2 inches of vertical
coverage has been provided by the armrest along at least 2 inches of its
continuous length.
G.
Use a scale graduated in 1/32 inch to make the measurements.
22
12.
COMPLIANCE TEST EXECUTION....Continued
7"
2"
SRP
4"
8"
FIGURE 7
H.
Record the results.
I.
Document the measurement using black and white photographs.
J.
Position a portapower or equivalent device with which to load the armrest along a
lateral axis at the center point of the armrest. A representative device is shown
in Figure 8.
K.
Load the armrest laterally until a deflection of the 1-1/4 inches is observed.
L.
Examine if any underlying rigid material has been contacted. If the answer is no
go to step M. If the answer is yes go to step N.
M.
Continue loading until a deflection of 2 inches is reached. At each 1/4 inch
deflection repeat step L.
N.
At any stage, in step L or M, if underlying rigid material is contacted, stop the
loading test, examine the armrest construction to establish if the underlying rigid
material between 0.5 inches to 1.25 inches from the end has a minimum height
of 1 inch. Record the actual height. The examination may require tearing down
of the armrest.
23
12.
COMPLIANCE TEST EXECUTION....Continued
FLAT STOCK
ROUND
TUBE
STOCK
3/8" DIA. ROD STOCK
1" SQ. TUBE STOCK
SIDE VIEW
FIGURE 8
O.
12.9
Use collected data in steps A to N to evaluate PASS/FAIL performance of the
tested armrest.
INTERIOR COMPARTMENT DOORS
Doors located in the instrument panel, console assembly, seat back or side panel area
adjacent to a designated seating position shall be evaluated for unlatching due to
inertial loads developed during an accident
12.9.1 LOADING CONDITIONS
A.
Inertial load of 10 g in a horizontal transverse direction.
B.
Inertial load of 10 g in a vertical direction.
C.
Inertial load of 30 g in a horizontal longitudinal direction.
12.9.2 EVALUATION
Each latch assembly evaluation shall be conducted mathematically by using the
algebraic method described in SAE Recommended Practice J839b Section 5 and
shown in the Appendix C or equivalent. The latch assembly evaluation method must be
approved by the COTR.
24
12.
COMPLIANCE TEST EXECUTION....Continued
INTERIOR COMPARTMENT DOOR LATCH DATA:
COTR will provide manufacturer's data that will be used as input to the analysis. Such
data will include:
A.
Geometric details of the latch/lock configuration.
B.
Mass data for each element in the linkage.
C.
Spring rates for each spring element in the configuration.
D.
Any additional details unique to the design yet necessary for the calculations.
12.10 TEST EQUIPMENT REQUIREMENTS
The test equipment requirements for S201 testing in terms of overall performance
guidelines are outlined in this section. Two designs are described: one for the Head
Impact Location Fixture and the other for the impact fixture. Measurement equipment is
also identified.
12.10.1 HEAD IMPACT LOCATION FIXTURE
The fixture consists of a head form rigidly attached to an arm that pivots about the SRP
with both horizontal and vertical axes of rotation.
The length of the arm must be infinitely adjustable between 29 and 33 inches,
measured from the pivot to the top of the head.
Provision must be made for placing the pivot at the SRP and also at a position five
inches in front of and 0.75 inch above the SRP.
The lower end of the pivot has a threaded shaft that serves two purposes. It permits
height adjustment of the pivot to align it with the SRP. Rotation of the shaft also
provides the vertical axis of rotation.
12.10.2 IMPACTOR FIXTURE
The impactor fixture can be installed by removing the side doors of the vehicle and by
setting up the base of the impactor test setup frame going across the test vehicle at
right angles to vehicle longitudinal centerline. The fully adjustable impactor setup then
can be mounted and operated from this base. The type of impact fixture shown in
Figure 11 on the next page can be utilized. The head form, rod and actuator would be
mounted on a ball-joint attached to a frame member extending through the vehicle. The
accumulator and controls would be mounted outside the vehicle.
25
12.
COMPLIANCE TEST EXECUTION....Continued
HEADFORM
IMPACTOR ASSEMBLY
FRONT BUCKET
SEAT
LEFT SIDE VIEW
FIGURE 11
The impactor shown above is not suitable for an impact on almost horizontal surfaces of
the instrument panel. A swinging type impactor end as shown in Figure 10 on the next
page or equivalent could be used to accomplish the impact sequence.
12.10.3 MEASUREMENT SENSORS
VELOCITY SENSORS
Two noncontacting optical velocity sensors are required to obtain a redundant
measurement of the impact speed. The sensors should be capable of measuring
velocity of 14.70 mph to an accuracy of plus or minus 0.05 mph. The sensors should be
operated from independent power supplies such that no single failure results in a loss of
both speed measurements.
ACCELEROMETER
An accelerometer suitable for impact testing with full scale range of at least 200g's will
be required. The frequency response of the accelerometer shall be consistent with the
requirements of SAE J211.
26
12.
COMPLIANCE TEST EXECUTION....Continued
HEAD IMPACT LOCATION FIXTURE
ADJUSTABLE
29" to 33"
HEADFORM DIA. = 6.5"
WT. = 14.7 lbs ± 0.2 lbs
BALL JOINT
SIDE VIEW
5"
FIGURE 10
ZERO TIME MARKER
A trigger switch capable of accurately signaling the first contact of the impactor with the
impacted part will be used.
TEMPERATURE
The temperature will be continuously recorded on a "Hyrothermograph" by Weather
Measurement Corp. or a similar device.
