USER`S MANUAL - Boxboro Systems
Contents
1. 15 DAS trigger connector pinouts and trigger 21 Copyright 2011 Boxboro Systems LLC 2 Figure No 1 c CON OOF C U aOR WOM Table No 1 2 4 1 April 2011 List of Figures and Tables Page FIDE VC COMPONC RIEN NNNM 5 RibEye components mounted on spine box front view 6 RibEye components mounted on spine box rear view y LED connectors on left side of spine 8 LED connectors on left side of spine 8 LEDs mounted on rib 0 9 Trunk box interlace DOX xu sacs 9 10 Diagrams for mounting RibEye components 11 LEDiraaiauor AUS Tzu 13 RibEye coordinate system definition 15 FIDE VS XZ VAN 16 RIDE YS TE E Um TEES 17 2 Tee 22 Alternate trigger switch CONNECTION 23 TTL trigger source2. 14 1 CAREANCHORB O O 33 1 90598 ACCEL MOUNT e u 1 se RONTBALASTWEGHT O 1 1 BALLAST WEIGHT 3 Pio 2 mm amp 8 4 ADAPTOR PLATE 8 t CENTER MOUNTING Lock 7 1 PROCESSOR POWER BOARD HOUSING 6 S845 SENSORHEADASSEMRY 25 FE 5 2 35952 22 DEGREE LED ASSEMELY 53 1 4 2 oi 2DEGREELED ASSEMBLY 3 3 sns nari a 2 1 868s ALTERED ADAPTOR ASSEMBLY 1 1 t 968 ALTERED HII XITH SPINE BOX HITI 50th RIBEYE ASSEMBLY 3 AXIS HII 50th MALE DUMMY r i SHEET 1 a DO NOT SCALE DRAWING 12 4 e uM CL aas SMUT 15 E 5 hel 4 ROBERT A DENTON 1587 WATERNTOW DE SILC Koc Figure 9 Diagrams for mounting RibEye components Copyright 2011 Boxboro Systems LLC 11 April 2011 2 0 Mounting the RibEye Diagrams for mounting the RibEye controller sensor heads and LED connector blocks are shown in Figure 9 The controller sensor head assembly and connector blocks should be mounted to the dummy s spine prior to assembling the ribs onto the spine The following moun
3. 36 02 005 04 006 056 005 Power requirements The RibEye can be powered by any DC voltage source from 12 to 36 Volts The power cable from the RibEye s interface trunk box to the power source has two conductors the red wire is positive and the black wire is negative The interface box has an internal self resetting polymer fuse It can take up to 1 2 hour to reset after an overload The power draw depends on the RibEye s operating conditions as shown in Table A3 Table A3 RibEye power requirements Operating Interface Box Controller LEDs Conditions Watts On idling Collecting data typical Maximum 9 9 13 When all LEDs are out of view of both sensors and driven to power Data acquisition and storage Sample rate 10 000 samples per second per LED Acquisition time 30 000 ms 30 seconds in D RAM 2 Seconds in Flash Data is collected to RAM memory and stored post test in flash memory Copyright 2011 Boxboro Systems LLC 18 April 2011 Control signals The DAS trigger interface cable has 8 conductors used for trigger inputs and control hand shaking signals to an external data acquisition system The trigger and control signals are listed in Table A3 All unused control wires should be individually insulated and protected The Trigger output signal 15 not used on this model Table A3 RibEye trigger and control signals Pinf ColorCode Function ground 5V 5
4. Controller S LED 6 Spine Box Communications Power Cable Cable Status Manual Arm Light Button Interface Trunk Box J Ethernet T Jack DAS Power Trigger Input Cable Cable Figure 8 RibEye connections Copyright 2011 Boxboro Systems LLC 10 4 3 y 2 1 RIGHT SIDE 1 Wi 3 79 p _ RIB i4 RB 05 V RIB Wo USE NYLON TIE WRAPS SECURE LED S WIRES RIRS SECTION 36 1 24 PIN COMMUNICATION CABLE GCALE 1 2 35 1 7594 2PINPOWERSUPPINCABIE 0 3 1 7583 CARL 33 1 755214 PIN COMMUNICATION CABLE 32 1 TROBE 31 2 assists 1875 DIA X 1 2 LG DOWEL 30 amp 31534105 44D X 04 EG FRCS 4 312534077 42 56 X 1 4 LG FRCS mj 28 10 912554537 14 208 L2 LG 010 32 X 1 2 LG BHCS 35 1 ansa 4 40 X 14 LIS 25 912558075 82 58 X 3 15 BHCS e 4 912514540 1 4 20 x 3 4 LG Pas 812514539 1 4 21 5 8 LG iced z2 2 912514535 120K 3 8 1G 2 2 910518344 1032 5 165 5 we WE 10 32 X 1 2 LG SHES Ca UM 9 asme amp 32 1 21 D qu I 2 ansam 53 sam 256 ess E yi 16 amp asua 40 0 316 5 5 6 ey 15 2 785185 MOLDED STOP P nd
5. 24 Differential trigger source connection 25 Armed OUMU ONCU TETTE 26 Nominal unloaded LED 18 Measured accuracy for Model 7800B 3 s n 81 18 HibEye power 1 nennen nnne nnns 18 RibEye active trigger and control signals 0 19 ER 21 Copyright 2011 Boxboro Systems LLC 3 April 2011 USER S MANUAL RibEye Multi Point Deflection Measurement System 3 Axis Version for 50 Male Hybrid Hardware Manual for Model 7800B 3 1 0 Overview RibEye measurement system is made up of several hardware components described in this manual Detailed specifications appear in Appendix A This manual does not cover the RibEye control software The components of the 3 axis RibEye for the 50 Male ATD are identified in Figures 1 7 Not all of the components appear in every figure The components are The RibEye controller A located in the ATD spine sensor bar which contains three optical sensors The bar is mounted to the spine and is permanently wired to the controller Six light emitting diodes LEDs two sets of 3 each which are mounted on the rib stiffener bars on the sides of the sternum Some of the LEDs have an angled mounting surface that aims the LEDs toward the sensors to minimize p
6. 40 screws for each LED Some of the LEDs have an angled mounting surface that aims the LEDs toward the sensors to minimize power requirements The LED cables should be securely fastened to the ribs using black nylon cable ties The LEDs are plugged into the LED connector blocks as follows Left Side Right Side Top LED 1 Top LED 4 Middle LED 2 Middle LED 5 Bottom LED 3 Bottom LED 6 The RibEye uses different calibration curves to process the LED data depending on which Z axis location that the LED 15 mounted To obtain the guaranteed accuracy the LEDs must be mounted on the rib stiffeners at the locations specified above and must be plugged into the correct specified LED connector See the specifications Appendix A for more information on the calibrated range for each LED location Figure 10 shows the radiation pattern of the LEDs Note that the brightest light is directly in front of the LED on axis and the brightness gets lower at larger angles The RibEye controller continuously adjusts how hard it drives the LEDs to get a good signal from the sensors Copyright 2011 Boxboro Systems LLC 12 0 OHLO1660 PAPE IN LLL LI A N 1 0 6 LELLINLLELELS ASK PS i 2 0 AQ j Figure 10 LED radiation pattern 2 5 Interface box mounting 60 80 100 120 Apri
7. dummy Z mm 100 90 80 70 60 50 40 30 20 10 10 20 30 40 50 60 70 80 90 100 50th 3D XZ range and nominal LED positions looking from the side of the ribcage Par 10 20 30 40 50 60 70 80 90 100 110 120 130 dummy mm Figure A2 RibEye XZ range Copyright 2011 Boxboro Systems LLC 16 April 2011 Middle Bottom 140 dummy Y mm 110 100 100 110 50th 3D XY range and nominal LED positions looking down into ribcage 20 30 40 50 60 70 80 90 100 110 120 130 dummy mm Figure A3 RibEye XY range Copyright 2011 Boxboro Systems LLC 17 April 2011 140 April 2011 Table A1 Nominal Unloaded LED Positions 2 MiddeLeft 1219 37 3 00 Lc 4 Middle Right 121 9 373 00 6 Lower Right The guaranteed measurement accuracy for all LEDs for all axes is better than 1 mm for the worst case error The average error over the whole range for each axis 1s less than 0 2 mm The first model was tested by taking data points for each LED over the whole range at 5 mm increments in X Y and Z resulting in 11 905 measurements per LED for the upper and lower LEDs and 12 035 points for the center LEDs The maximum and average errors are shown in Table A2 Table A2 Measured Accuracy for Model 7800B 3 s n 81 XErrors mm YErrors mm ZErrors mm 14 042 006 038 005 06 004 25 2038 006 038 005 037 00
8. from the same link If you want to write your own software to control the RibEye you can download the RibEye Communications Protocol from this link Copyright 2011 Boxboro Systems LLC 4 April 2011 Wy I IN 2 re 1 RibEye comp Figure 1 ems LL ight 2011 Boxboro Syst Copyrig 5 April 2011 Dg Ag TP mrt am 7 WC 666 0 UR i Figure 2 RibEye components mounted on spine box front view Copyright 2011 Boxboro Systems LLC 6 April 2011 DENTON AT 2 2967 WATERVIEW ROCHESTER HILLS MI 48309 248 852 5100 DENTON j SERIAL D cud gt ee eee Figure 3 RibEye components mounted on spine box rear view Copyright 2011 Boxboro Systems LLC 7 April 2011 9695 1 LEFT RIB 9695 2 LEFT RIB S 4 lt lt C 4 O me Figure 4 LED connectors on left side of spine box Figure 5 LED connectors on right side of spine box Copyright 2011 Boxboro Systems LLC 8 April 2011 Figure 6 LEDs mounted on rib stiffeners HUMANE TICS INNOVATIVE SOLUTIONS 47460 GALLEON DRIVE je lt a PLYMOUTH MI 48170 PENTON C7 34 451 7878 Figure 7 Trunk box interface box Copyright 2011 Boxboro Systems LLC 9 April 2011 Middle Right Sensor Sensor LED 1 LED LED pens LED 2 Conn Conn LED 5 Block
9. output of the receiver is internally connected to pin 10 the SWITCH OR TTL trigger input WARNING DO NOT EXCEED THE MAXIMUM INPUT RATING GIVEN IN THE SPECIFICATIONS SECTION Appendix A Figure B5 shows the armed output circuitry that you can use to monitor the state of the RibEye Copyright 2011 Boxboro Systems LLC 21 April 2011 5V RibEye Trigger Interface O ww Ja 10k Trigger Switch A gt v Figure B1 Trigger switch connection For this connection if the switch closes at the start of the event select SWITCH OR TTL FALLING EDGE TRIGGER If the switch opens at the start of the event select SWITCH OR TTL RISING EDGE TRIGGER Copyright 2011 Boxboro Systems LLC 22 April 2011 5V RibEye Trigger Interface O 2 Xe Trigger Switch D 10k Dho Or 27 Figure B2 Alternate trigger switch connection For this connection if the switch closes at the start of the event select SWITCH OR TTL RISING EDGE TRIGGER If the switch opens at the start of the event select SWITCH OR TTL FALLING EDGE TRIGGER Copyright 2011 Boxboro Systems LLC 23 5V RibEye Trigger Interface TTL TRIGGER SOURCE Figure B3 TTL trigger source connection For this connection if the input at pin 1 goes from OV to 5V at the start of the event select SWITCH OR TTL RISING EDGE TRIGGER If the input at pin goes from 5
10. using a clean lint free cloth 3 Dry the lenses with another clean lint free cloth Never remove the lenses from the case or loosen the lens cover screws If the lens are loosened the calibration will be invalid There are no user serviceable parts in the RibEye Copyright 2011 Boxboro Systems LLC 14 April 2011 Appendix A RibEye specifications RibEye coordinate system The coordinate system for the 3 axis 50 Male RibEye is shown in Figure 1 The Y axis 16 on the line between the center of the two outer left and right sensors The origin of the X axis 15 where the X line crosses the Y axis 10 34 mm in front of the center sensor The Z axis is positive downward to match the standard dummy coordinate system Figure A1 RibEye coordinate system definition Measurement accuracy and Iange The RibEye uses one set of calibration curves for each of the nominal Z positions of each LED Therefore there is a specified Z range of motion for each LED Figure A2 shows the XZ range for each LED The nominal unloaded LED positions are also shown overlaid on the range Figure A3 shows the XY range for each LED The nominal unloaded positions of the LEDS are also shown overlaid on the XY range The nominal unloaded LED positions are shown in Table A1 From the range graphs you can see that the RibEye can measure 70 80 mm of X compression 40 mm of Z motion and 60 130 mm of Y motion Copyright 2011 Boxboro Systems LLC 15
11. 0 milli amp maximum 8 2 20224 Differential trigger inputs pins 4 5 Maximum differential input voltage 12 VDC e Minimum differential input voltage 0 2 VDC Common mode input voltage 12 VDC Switch trigger input pin 1 with respect to 3 ground Maximum input voltage 5 0 VDC e Minimum on voltage 3 3 VDC Maximum off voltage 0 4 VDC e Current limited by resistor Copyright 2011 Boxboro Systems LLC 19 April 2011 Additional 5V for external power pin 6 e Output voltage 4 75 to 5 25 volts Limit external loads to 50 milli amp maximum e Short circuit will cause resettable fuse to trip Armed output pin 7 e Output voltage 4 75 to 5 25 volts at 0 5 ma max when armed e Output voltage 0 5 volts when disarmed e See Appendix B for a schematic of the armed output circuit Communication and power cables These cables connect the interface box in the vehicle trunk to the RibEye s controller The communication and power cables are internal to the RibEye system and should not be modified in any way No user connections are available on these cables Note that the input power cable is terminated at the user end in pigtails The red wire is connected to the DC power supply positive power connection The black wire is for the DC power supply negative ground connection The power cable shield should be tied to either the vehicle common ground point or the D
12. 2 168 0 240 This IP address can be changed to work with your local area network LAN You can also communicate with the RibEye Copyright 2011 Boxboro Systems LLC 13 April 2011 directly using a PC without connecting toa LAN To directly connect a PC to the RibEye your PC must be set up with a fixed IP address on the same subnet as the RibEye Please refer to the RibEye Software Manual for instructions on how to change the RibEye IP address 3 2 LED flashing on power up When the RibEye is powered on it will flash each of the LEDs for about 1 second The LEDs will flash in the following order 1 Upper Left 2 Middle Left 3 Lower Left 4 Upper Right 5 Middle Right 6 Lower Right 4 0 RibEye software As footnoted earlier instructions for installing and operating the RibEye PC software can be found in the RibEye Software User s Manual The software manual can be found on the disk shipped with the RibEye or it can be downloaded from the Boxboro Systems website at http www boxborosystems com servicepage html Updates to the RibEye PC software can be downloaded from the website as they become available 5 0 RibEye maintenance The RibEye lenses must be kept clean for accurate measurements Dust and smudges from fingers will affect the instrument s accuracy To clean the lenses 1 Blow the lenses off with canned compressed air not shop air to remove any grit 2 Wipe the lenses with lens cleaning solution or alcohol
13. April 2011 BOXBORO System 5 USER S MANUAL RibEye Multi Point Deflection Measurement System 3 Axis Version for 50 Male Hybrid Hardware Manual for Model 7800B 3 April 2011 Boxboro Systems LLC 978 257 2219 www boxborosystems com Copyright 2011 Boxboro Systems LLC 1 April 2011 Table of Contents Page WO Atencio nts utes ted cuti else 4 20 nen te Nt reece 12 2 4 Gontroller MOUNING xui vids studie 12 2 2 SENSO head assembly mobi sess adea bend a 12 2 9 LED connector DIOCK IMOUNUNG int Anta Qua peur adler Aiea 12 2 4 LED MOUNINO Renard dotes ded 12 2 b jntertace DOX MOUNTING dba ele ud Ve Rev Ras ue iini seta 13 3 0 Operating the HIDEVe chara boi Hot etg d Sepe VERD pr Bedv Fue pu 13 2211 IBIDEVE IP adOl SS 13 32 aan 14 4 0 HIDEye 14 5 0 neta 14 Appendixes A
14. C power supply negative ground connection or both depending on the configuration of your DC power grounding scheme We recommend that you try the various shield connection options and see which option provides the lowest noise on the RibEye data Copyright 2011 Boxboro Systems LLC 20 April 2011 Appendix B Trigger Inputs and Armed Output circuits The DAS trigger interface connector on the RibEye s interface box is an 8 pin Lemo connector A mating cable terminated in a pigtail is supplied with the RibEye At this time 7 of the connector s 8 pins can be used for triggering and status The trigger output is not programmed on this model Table B1 lists the pinouts pigtail color code and signal function Refer to the specifications sections for maximum voltages applied to these connections Table B1 Trigger signals Pinf ColorCode Function 5V 50 milli amp maximum 8 frggeroupt Figures 1 4 show how to connect trigger switches active TTL level trigger sources and differential trigger sources Where a trigger switch is shown you can use the same configuration for open collector transistor output trigger sources If you want to use a photo interrupter type trigger source you can power it from the 5V supply on pin 8 Figures 1 4 also show the input circuitry in the interface box Note that the differential receiver connected to pins 6 and 11 is enabled when a differential trigger is selected The
15. V to OV at the start of the event select SWITCH OR TTL FALLING EDGE TRIGGER Copyright 2011 Boxboro Systems LLC 24 April 2011 April 2011 5V RibEye Trigger Interface Differential Trigger Source Figure B4 Differential trigger source connection In this configuration if the differential driver transitions from HIGH pin 4 voltage gt pin 5 voltage to LOW pin 4 voltage lt pin 5 voltage at the start of the event select DIFFERENTIAL FALLING EDGE TRIGGER If the differential driver transitions from LOW pin 4 voltage lt pin 5 voltage to HIGH pin 4 voltage gt pin 5 voltage at the start of the event select DIFFERENTIAL RISING EDGE TRIGGER Note that when differential triggering is selected the output of the differential receiver can be monitored at pin 10 Copyright 2011 Boxboro Systems LLC 25 April 2011 Trunk Box 7 BLACK Armed Output Figure 5 Armed output circuit Copyright 2011 Boxboro Systems LLC 26
16. l 2011 The interface box or trunk box 15 intended to be mounted in the trunk of the vehicle near the DAS and the power source Four holes are provided in the base of the box for mounting The interface box can be mounted in any orientation but we recommend that it be mounted such that the side of the box with all of the connectors is easily accessible The communications and power cables from the spine box are connected to jacks on the interface box An Ethernet cable is used to connect the interface box to a router hub or directly to a laptop PC Jacks are provided for incoming power and DAS trigger connections 3 0 Operating the RibEye The RibEye operates as a stand alone smart sensor that collects and stores data In this stand alone mode a PC program 15 used to control the RibEye and to download data In addition to controlling the RibEye with the PC program the interface box has a status light and a manual Arm button The status light blinks at different rates depending on the state of the RibEye 0 5 Hz idle with data in memory 1 0 Hz idle with memory erased 2 0 Hz acquiring data 5 0 Hz storing data in flash memory 10 Hz erasing flash memory The Arm button can be used to manually arm the RibEye when it is idle and the memory is erased You must press the Arm button for at least 3 seconds to arm the RibEye 3 1 RibEye IP address The RibEye ships from the factory with its IP address set to 19
17. ower requirements DANGER The LEDs are very bright when driven at full power Do not look directly at the LEDs Two LED connector blocks D which are mounted on the sides of the spine box e The interface box also called the trunk box because it is typically placed in the trunk of the vehicle A power cable and a communication cable that are bundled together The cables connect the RibEye controller to the trunk box A power input cable which connects the trunk box to customer s power supply e A data acquisition system DAS interface cable H which connects trunk box to the customer s DAS for trigger and control signals Appendix B contains the DAS trigger connector pinouts and trigger circuits Modified Hybrid III 50 spine 1 that the RibEye components mount to e Controller cable removal tool J that allows removal of the power and control cables without unbolting the controller from the spine Figures 8 and 9 show how the components are interconnected and mounted The RibEye Software User s Manual describes the installation and operation of the RibEye software The software manual can be found on the disk shipped with the RibEye or it can be downloaded from the Boxboro Systems website at http www boxborosystems com servicepage html RibEye Software Release Notes provide updates in between revisions to the software manual and can also can be downloaded
18. ting instructions are for application in the 50 Male Hybrid III ATD Model 7800 3 2 1 Controller mounting The RibEye controller is mounted inside the top of the dummy spine in the rectangular opening The power and communication cables can be connected to the controller before or after the controller is mounted in the spine The controller slides into the spine and is attached with four screws shown at the top of Figure 3 The power and communication cables come out from the back of the spine and then down under the skin to exit at the bottom of the jacket These cables are then routed to the interface box 2 2 Sensor head assembly mounting The sensor head assembly is mounted to the spine weight inset with four screws and two dowel pins as shown in Figure 9 Note that the sensor assembly is oriented such that the cables are pointed downwards The sensor head assembly is also shown in Figures 1 3 2 3 LED connector block mounting The two LED connector blocks mount on the sides of the spine box with two screws for each Figures 4 and 5 show the connector block mounted on the left and right sides of the spine Note that the LED connectors have a locking tab that must be pressed to remove them from the connector block 2 4 LED mounting After the controller sensor heads and connector block are mounted the ribs can be assembled onto the spine and sternum The LEDs are mounted to the rib stiffeners as shown in Figures 6 and 9 using two 14
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