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USER`S MANUAL FOR THE WORLDSID 50TH PERCENTILE MALE

1. Drawing number Description Electronic file format Por sre lws0 41022 Lumbar upper clamping plate x wso aroae Lumbar mounting wedge x wso aroso Weldment lower lumbar mounting bracket x lws0 41031 Lower lumbar mounting bracket x wso at032 Dummy lifting socket x wso atoat DAS cover x lws0 41042 Docking station pelvis AG lws0 42002 Sacroiliac load cell backing plate x 42005 Hip joint socket x lws0 42007 Inner ring hip joint x jwso a2008 Hip socket retainer x wso a2010 Pelvis bone left hand x wso azo11 Pelvis bone right hand x x wso azo12 Insert iliac wing wso azo16 Sacroiliac load cell interface left hand x 5 2017 Sacroiliac load cell interface right hand x 22019 Pelvis flesh x x wso a2030 Instrumentation bracket pelvis x wso a2031 Instrumentation cover plate pelvis x wso a2510 Pubic buffer moulded x wso aze16 End plate medial x lws0 42617 End plate lateral x 5 2521 Cowrench for hip joint x wso s1000 Upper leg assembly right x wso stoo Modification of small spanner wrench 25mm 28mm x wso s1002 Unmodified large spanner wrench 40mm 42mm x wso s1003 Modified 4mm hexagon key wrench wso s1004 Modified 22mm open end wrench x lwso 51017 Trochanter 50 51022 Trochanter tube assembly right x 50 51023 Trochanter assembly left x FA Drawing number Description Electronic file format Por sre lws0 s1034 Femoral
2. Figure 3 18 Lower arm flesh 136 Figure 3 19 Upper arm flesh 137 Figure 3 20 Lower arm suit 137 igure 3 21 Lower leg cables 138 jure 3 22 Knee area cable routing igure 3 23 Knee area cable routing Figure 3 24 Knee area cable routing and flesh jure 3 25 Femoral neck cable routing Figure 4 1 Cable attachment to the upper neck load cell Figure 4 2 Spine box cable routing Figure 4 3 Spine box cable attachment Figure 4 4 Spine box cable attachment igure 4 5 Lumbar cable attachment jure 4 6 Pelvic load cell cable attachment igure 4 7 Knee cable attachment Figure 4 8 Cable attachment jure 4 9 Tibia cable attachment Figure 5 1 Location of temperature sensors used for internal temperature survey 151 igure 7 1 Lateral head drop angle 157 Head bracket installation for lateral drop 158 Frontal head drop angle 159 xi Figure 7 4 Head bracket installation for frontal drops 159 Figure 7 5 Front view of setup for full dummy certification tests 168 Figure 7 6 Side view of setup for full dummy certification tests 168 Figure 7 7 Using an inclinometer with the H point tool to check pelvis angle 169 Figure 7 8 Shoulder test dummy and arm position 171 Figure 7 9 Thorax test without arm dummy and arm position 176 Figur
3. 2171 Shoulder rib mounting bracket struck side WorldSIO x lws0 32172 Thorax and abdominal rib accelerometer mounting bracket WorldSID X lwso 32173 Thorax and abdominal rib clamping bracket WorldSID x wso azizs Shoulder rib sternum mounting strip threaded x lws0 32176 Thorax and abdominal rib mounting strip threaded x lws0 32177 Shoulder rib sternum mounting strip x lws0 32178 Thorax and abdominal rib sternum mounting strip x fws0 32179 Screw rib IRTRACC mount x 32180 Clamp damping x wso aso21 Rib coupler abdominal WorldSIO x x wso aso22 Sternum thorax rib x x wso a5023 1 Shoulder pad left WorldSIO x x wso aso23 2 Shoulder pad right WorldSID sci oc 35022 Pad thorax x 37011 Battery mounting bracket x 37012 Battery structural replacement x wso a7022 Backup plate mounting bracket x wso a7023 Angular accelerometer sensor mount bracket x wso s7024 T12 accelerometer mount WorldSID x lws0 37029 Bracket rotational accelerometer mount x 000 Battery assembly x 00 Back plate battery enclosure x wso aeo02 Enclosure cover batte x ws0 38004 Foam pad 3 mm thick x wso 40000 Pelvis assembly x lwso a1018 Lumbar spine rubber x x lws0 41019 Bushing lumbar x lws0 41020 Bushing lumbar spine top x 41021 Lumbar lower clamping plate x F3
4. Figure 1 11 Neck dampers are free to be removed when interface plates are removed 1 2 3 Assembling When assembling the neck mount the neck buffers with the circular cross sections on the lateral sides of the neck and mount the neck buffers with the square cross sections on the front and rear of the neck As shown in Figure 1 12 the lateral locations for the buffers in the interface plates are farthest from the holes for mounting the neck to the head and torso 11 Lael postion atersi postion Figure 1 12 Lateral positions for neck buffers The circular cross section buffers have a cylindrical end and a mushroom shaped end Press the mushroom ends firmly into the top and bottom interface plates so that the mushroom cap protrudes into the counterbore on the flat face of the interface plate A turning action during assembly helps to get the circular buffers positioned correctly Tune the correct response of the neck in lateral bending by using three different hardnesses of lateral circular cross section buffers When installing the flexion extension buffers in the interface plates position them as shown in Figure 1 13 so the end that sticks out farther is facing the moulded neck 12 fS Molded rubber neck Lateral buffers Fore buffer cylindrical end Aft buffer Lateral buffers mushroom end A Half spherical screw Figure 1 13 Asseml 9 of neck buffers Position the interface plate with the inst
5. lt 15 Maximum percentage subsequent to main peak lt 10 155 7 1 3 Cer ication test procedures 7 1 8 1 Principle Certify the dynamic response of a head assembly by performing a 200 mm lateral drop on each side of the head and a 376 mm drop on the forehead 7 1 3 2 Apparatus 49 CFR Part 572 Subpart E horizontal head impact surface chrome plated rigidly supported horizontal steel plate 50 8 mm x 610 mm x 610mm 8 80 rms micron mm surface finish Head drop tool assembly drawing W50 82100 pdf Instrumented head assembly drawing W50 10000 pdf including the instrumentation insert and upper neck load cell or structural replacement Two SHCS M6 x 12 7 1 3 3 Sensors Use triaxial linear accelerometers as described in Section 1 7 1 3 4 Preparation Expose the head assembly to an environment with a temperature of 21 4 degrees C 0 8 degrees C and a relative humidity between 10 and 70 for a period of at least four hours prior to a test Clean the head skin surface and the surface of the impact plate with 1 1 1 trichlorethane or equivalent Install the triaxial accelerometer in the head assembly 156 Install the upper neck load cell angular accelerometers and dual axis tilt sensor or their structural or mass replacements Attach the head drop tool to the bottom of the upper neck load cell or its structural replacement with the two SHCS M6x12 Mount the tool for left or right lateral or fro
6. Figure 1 29 The rib and abdominal couplers are attached to the ribs after instrumentation is plugged in Figure 1 30 Installation of G5 modules Figure 1 31 WorldSID rib instrumentation Figure 1 32 G5 DAS module Figure 1 33 Interposer connector Figure 1 34 DAS connector Figure 1 35 Arrangement of DAS interposer connector and connector 44 Figure 1 36 Full arm exploded Figure 1 37 Shoulder arm detail Figure 1 38 Upper arm exploded Figure 1 39 Elbow section Figure 1 40 Lower arm exploded Figure 1 41 Wrist Figure 1 42 2 Pivot and upper arm tube vii Figure 1 43 Elbow potentiometer 60 Figure 1 44 Elbow potentiometer wiring Figure 1 45 Arm joint rotation 62 Figure 1 46 Arm joint tension points 63 Figure 1 47 Elbow adjustment 66 Figure 1 48 Elbow friction adjustment 67 Figure 1 49 Change over components 69 Figure 1 50 Arm assembly 70 Figure 1 51 WorldSID pelvis components 74 75 Figure 1 52 Rear view of pelvis assembly Figure 1 53 Front view of pelvis assembly 75 Figure 1 54 Close up view of pubic assembly 76 76 Figure 1 55 Close up view of lumbar assembly Figure 1 56 Removing spine box from the pelvis 77 Figure 1 57 Detaching the femur assemblies 78 79
7. Velocity change at 4 ms 0 77 mis to 1 04 mis Velocity change at 8 ms 1 60 mis to 2 16 m s Velocity change at 12 2 43 m s to 3 29 mis T 0 s at initial contact with honeycomb or alt shown to lead to the same results ative products which can be 7 2 3 7 Calcula n procedures Filter the data according to ISO 6487 or SAE J211 as given in Table 7 6 Integrate the filtered and adjusted acceleration time histories Calculate the flexion angle of the head form using the following equation 5 76 8 where angular displacement of head form relative to the pendulum Angular displacement of forward pendulum to head form sliding rod positive when doing a right side impact Lateral angular displacement of head form about forward pendulum to head form sliding rod positive when doing a right side impact After performing this calculation digitally filter all angular displacements using ISO 6487 or SAE J211 CFC 180 Calculate the moment about the occipital condyle as Moc My F x 0 0195m where the My and F polarities are in accordance with the SAE J211 sign convention 164 Table 7 6 Filter speci ion for neck test Variable Fiters Pendulum acceleration CFC 60 Pendulum velocity No digital filtering Angular displacement of forward rod 14 CFC 1000 Angular displacement rear rod CFE 1000 Angular displacement
8. 1 Upper rod x 4112 Lower rod x 113 Middle bar x Wedge x 000 2001 Tinsert x 734 0800 Temperature logger assembly x kr Neck compression tool x 2 20123 Neck intermediate plate x Potentiometer assembly x FDA Potentiometer housing assembly x Potentiometer clamp x Foe Bearing x For Potentiometer housing x e Coupling assembly x 5 Coupling E Bearing x Drawing number Description Electronic file format PDF sre FGA Arrow shaft pivot assembly A x Arrow shaft pivot assembly x Fec Arrow shaft assembly x Feo Pivot inside assembly x F Ge Pin machined x Fen Pivot outside x Dm Pivot inside x Coupling x rer Arrow shaft x FHC Spat x FIA Rotary potentiometer x F 263 IR TRAGC specification sheet x Table F 2 WorldSID fasteners Description Fastener number Ball nose spring plunger MCM 84895421 5000257 Ball nose spring plunger MCM 84895A73 5000256 SHES MIO X 1 5 X 20mm 5000176 BHCS M2 5 X 10 5000208 BHCS M2 5 X 3 5000248 BHCS M2 5 X 6 5000244 BHCS M3 X 0 5 X 10mm 5000178 BHCS M3 X 0 5 X 6mm 5000171 BHCS M4 X 0 7 X 10mm 5000010 BHCS MA X 0 7 X 12mm 5000005 BHCS M4 X 0 7 X 6mm 5000179 BHCS M4 X 16 5000153 BHCS MB X 8 X 25 5000466 BHCS MB X 0 8 X 10 0 5000003 BHCS MB X 20 5000210 Description Fastener
9. Installation of G5 modules 1 3 4 Instrumentation mounting 1 3 4 1 Thorax instrumentation The thorax instrumentation for the WorldSID includes an IR TRACC deflection measurement assembly for each struck side rib plus a triaxial accelerometer attached to the inner struck side of each rib Figure 1 31 illustrates the configuration for the assembly of the rib with instrumentation The IR TRACC assembly Figure 1 31 Item 14 is attached to the spine box with a BHCS M2 5 Figure 1 31 Item 11 and that the other end of the IR TRACC assembly is attached to the rib accelerometer mounting bracket Figure 1 31 Item 32 with an IR TRACC rib mount screw Figure 1 31 Item 40 19 accessed from the bottom of the rib A linear triaxial accelerometer Figure 1 31 Item 15 is secured to the rib accelerometer mounting bracket Figure 1 31 Item 32 with a cheese screw M2 x 16 Figure 1 31 Item 37 and that the rib accelerometer mounting bracket Figure 1 31 Item 32 is secured to the inner band of the rib Figure 1 31 Item 33 the thorax rib Figure 1 31 Item 28 and the rib clamping bracket Figure 1 31 Item 31 with four BHCS M5 x 10 Figure 1 31 Item 1 A battery to power the G5 modules is part of the thorax assembly and that additional instrumentation attached to the spine box is described in the disassembly assembly section for the spine box A shoulder load cell is also available for use with the WorldSID 41 IR TRACC assem
10. y axis acceleration G CFC 180 Peak T12 y axis acceleration CFC 180 Peak thorax rib 1 deflection mm CFC Pak thorax rib 2 deflection mm CFC 600 Peak thorax rib 3 deflection mm CFC 176 7 3 5 1 6 Test reports Document the results of the test 7 3 6 Abdomen When assembled according to Section 1 and tested using the procedure specified in 7 3 2 and 7 3 6 1 the abdomen without arm assembly shall meet the specifications given in Table 7 18 Table 7 19 WorldSID abdomen certification specifications Variable Absolute value Peak abdomen rib 1 deflection Imm 33041 Peak abdomen rib 2 deflection mm 31038 Peak pendulum force 261033 Peak T12 acceleration along y axis IG 151020 7 3 6 1 Abdomen test certification procedures 7 3 6 1 1 Principle Perform a test involving a lateral impact to the abdomen in order to certify the dynamic response of the abdomen ribs 7 3 6 1 2 Apparatus Use the following items 49 CFR Part 572 subpart E Hybrid Ill 50 percentile adult male pendulum 23 4 kg 152 4 mm face diameter Simulated armrest consisting of a rigid hardwood block as given in Table 7 20 attached to the impact face of the pendulum The centreline of the armrest simulator shall be aligned with the centreline of the pendulum 177 Table 7 20 Simulated armrest specifications Variable Value Width mm 150 05 Height immi 70
11. 05 Depth immi 60205 Comer radius Imm Tost Mass Ka 100 001 7 3 6 1 3 Sensors Install instrumentation in order to obtain data for the items given in Table 7 21 Table 7 21 Sensor specifications for abdomen test Variable Sensor Performance Pendulum acceleration G See Table 7 3 SAE 32570 Lower spine T12 y axis Triaxial linear accelerometer SAE 225701 acceleration G Endevco 7268C 2000M1 Abdomen rib 1 and 2 IRTTRACC See sensor specification details on deflections mm Model IF 363 electronic drawing number IF 363 Impact velocity m s Not specified Resolution 0 02 mis or better 7 3 6 1 4 Procedure Set up the dummy in standard test posture as described in 7 3 2 with the half arm in the driving posture as shown in Figure 7 5 Align the wood block face so it is aligned with and parallel to the middle of the two abdomen ribs Place the wood block in contact with the side of the dummy Raise the pendulum to achieve a 4 3 m s 0 1 m s impact velocity Release the pendulum to impact the dummy 178 7 3 6 1 5 Calculation procedures and expression of results Filter the data according to ISO 6487 or SAE J211 1 as given in Table 7 22 Calculate the pendulum impactor force by multiplying the pendulum acceleration time history by the combined measured mass of the pendulum and armrest simulator Graph the time histories of impactor force T12 y axis acceleration
12. Foot Assembly Cable Guide Knee Figure 3 21 Lower leg cables 3 8 2 Knee cable routing Route and secure cables in the area of the knee as show Figure 3 22 Figure 3 23 and Figure 3 24 138 Lower Leg Cables Knee Load Cell Knee Pad Upper Leg Assembly jure 3 22 Knee area cable routing Lower Leg Cables Knee Cover igure 3 23 Knee area cable routing 139 Lower Leg Flesh Upper Leg Flesh Lower Leg Cables Figure 3 24 Knee area cable routing and flesh 3 8 3 Femoral neck cable routing The femoral neck load cell cable should be routed as shown in Figure 3 25 140 Upper Leg Flesh Figure 3 25 Femoral neck cable routing 3 9 Wiring with an external DAS For sensor wiring in conjunction with an external DAS the procedures described in this Section which relate to the sensor end of the cable see for example Figure 3 1 should be followed when possible The routing of the cable or cables exiting the dummy may vary depending upon the DAS vehicle or test but in all cases the cable should be secured to the dummy such that the motion of dummy components of interest e g impact side ribs are not affected and also such that cable tension is not applied to sensors 141 Section 4 4 RECOMMENDED WORLDSID GROUNDING SCHEME 4 1 Parts list The parts given in Table 4 1 should be used to provide electrical continuity between the dummy components and an off dummy electric
13. Hex nut M2 5000216 Hex nut with nylon locking insert M14 5000219 BOLT M8 X 1 25 X 10 5000569 Locknut M6 HEX 5000143 Locknut nylon insert M12 X 1 75 5000462 LWSHCS M3 X 0 5 X 12mm 5000620 LWSHCS M6 X 1 0 X 12mm 5000194 Retaining ring 12mm St 5000249 Retaining ring 16mm Ste 5000250 Retaining ring 18mm Ste 5000251 Roll pin M1 5 X 8mm 5000189 Roll pin M3 X 10mm 5000199 Roll pin M3 X 12mm 5000166 Roll pin M3 X 14mm 5000196 Roll pin M3 X 20mm 5000188 Roll pin M3 X mm 5000195 Roll pin M4 X 10mm 5000182 Roll pin M4 X 14mm 5000197 SHES M1 6 X 0 35 X 5 5000338 SHES M1 6 X 6 CLASS 12 9 Alloy steel 5000343 Description Fastener number SHES M2 X 0 4 X 18mm 5000164 SHES M2 X 0 4 X 6mm 5000082 SHES M2 X 0 4 X 8mm 5000083 SHES M2 X 10 5000215 SHES M3 X 5X6 5000393 SHES M3 X 0 5 X 12mm 5000070 SHES M3 X 10 5000119 SHES M3 X 5000252 SHES MA X 7 X 10 5000151 SHES M4 X 0 7 X 8 0 5000024 SHES MB X 0 8 X 12mm 5000002 SHES 5 X 0 8 X 16mm 5000020 SHES MB X 18 5000112 SHES M6 X 1 0 X 16 5000081 SHES M6 X 1 0 X 20 0 5000001 SHES Me X 12 5000281 SHCS M6 X 50 5000324 SHCS X 18 5000209 SHES M3 X 0 5 X 8 5000388 SHES MAX 7 X 14 5000459 SHES M4 X 7 X 25 5000461 SHES M5 X X 30 5000471 SHES X 1 X 10 5000457 SHSS M6 X 25mm 5000163 Spring washer M6 5000134 SSCP M25 5000340 SSCP M3 X 0 5 X 5000470
14. Repeat steps 4 and 5 for the lower thorax station as shown in Figure 3 7 Figure 3 7 Cable routing for the thorax connector station 128 7 Bundle the cables at the upper thorax portion to a cable mount as shown in Figure 3 82 tie the rest of the cable as illustrated Figure 3 8b Figure 3 8 Thorax cable routing 8 Group and bundle the cables in the shoulder area as shown in Figure 3 9 129 Figure 3 9 Shoulder area final cable routing 9 Tie the pelvis cable and dummy exit cable as shown in Figure 3 10 The overall thorax cable routing will be as illustrated in Figure 3 11 Figure 3 10 Pelvis cable and dummy exit cable routing 130 Figure 3 11 Thorax cable routing 10 Install the sternum and the abdomen coupling make sure that the dummy exit cable and tilt sensor cables are routed between the abdomen ribs as shown in Figure 3 12 Loop a cable tie around the 2 abdomen rib Figure 3 12 then secure the cables to the loop with another cable tie Figure 3 12 131 jure 3 12 DAS exit cable and tilt sensor cables Figure 3 13 Shoulder load cell cable rounting 11 Route the shoulder load cell cable as shown in Figure 3 12 and tie it to the sternum with a cable tie The finished wiring looks as shown in Figure 3 14 132 Figure 3 14 WorldSID final dummy wiring 133 3 7 Instrumented arm cable routing 3 7 1 General considerations The following
15. 7 Arm tube assembly 1 W50 61012 8 BHCS M6 x 1 0 x 16 mm 1 5000072 9 sswrMe x 10x 6 mm 1 s000621 Figure 1 37 Shoulder arm detail 48 1 4 1 3 Parts list for upper arm Table 1 8 lists the parts required for assembling the WorldSID upper arm which is illustrated in Figure 1 38 Table 1 8 Parts for upper arm Item number Description ay Part number 1 Upper arm Z pivot assembly left 1 W50 61006 Upper arm Z pivot assembly right w50 61111 2 Upper arm tube assembly 1 ws0 61012 3 Modified button head cap screw 12 ws0 61042 4 Wrist washer 1_ ws0 61019 5 Spring washer 1 ws0 61022 6 BHCS M6 x 1 0 x 16 mm 1 5000072 7 Universal arm load cell 1 ws0 71070 not shown Arm load cell structural replacement 1 W50 61041 8 Upper arm extension tube assembly 1 W50 61004 E SHCS M2 x 0 4 x 18 mm 2 5000164 10 Accelerometer mass replacement 11 Elbow load cel 1 ws0 71060 Not shown Elbow structural replacement 1 ws0 61065 Not shown Triaxial linear accelerometer Endevco 7268c 2000M1 49 Figure 1 38 Upper arm exploded 1 4 1 4 Parts list for elbow Table 1 9 lists the parts required for assembling the WorldSID elbow which is illustrated in Figure 1 39 Table 1 9 Parts list for elbow Description Quantity Part number 1 BHCS M3 x 0 5 x 10 2
16. Item 16 in the knee clevis Figure 1 75 Item 9 and push the knee pivot shaft Figure 1 75 Item 8 into the pivot hole Align the shaft locking hole with the SSHDP M6 x 1 x 12 Figure 1 75 Item 17 Tighten the SSHDP M6 that the knee pivot shaft is locked in place Note that if the pivot shaft is not locked into the knee bone the shaft will not rotate with the knee bone during testing Once the pivot shaft is in place install the friction compression and clamping washers Figure 1 80 Item 7 8 and 9 respectively The friction washer Figure 1 80 Item 7 is made up of two disks one disk is steel and the other is a commercial braking material Push the friction washer on to the pivot shaft pins so that the braking material side of the washer is against the knee clevis Install the compression and clamping washers and secure them with a BHCS M10 x 1 5 x 20 mm Figure 1 80 Item 10 which is the adjustment for the 1 to 2 g setting adjustment of the knee section To install the knee potentiometer place the potentiometer insert into the square hole end of the knee pivot shaft see Figure 1 82 Insert the two BHCS M3 x 0 5 x 6 mm Figure 1 75 Item 5 into the potentiometer clips 105 and thread them into the knee clevis Tighten these two BHCS M3 so that the potentiometer body is secure and will not rotate EXC si EXC Figure 1 81 Knee potentiometer wiring DETAIL VIEW Figure 1 82 Knee potentiome
17. Pelvis instrumentation cover plate ws0 42031 20 Unear triaxial accelerometer Endeveo 726 2000 1 21 Pelvis instrumentation bracket ws0 42030 71 Item Description ay Part number number 22 Right sacroiliac load cell interface wsoa2017 23 cover ws0 41041 24 Sacroiliac load cell structural replacement 1 wsoz1975 25 Lumbar spine load cell structural replacement 1 W50 71122 26 Sacroiliac load cell backing plate 2 W50 42002 27 Right pelvis bone wsoa2o11 28 Lumbar mounting wedge ws0 41026 29 Hip joint socket 2 W50 42005 Hip joint inner ring 2 W50 42007 31 Hip socket retainer 2 ws0 42008 32 Trochanter assembly right ws0 51022 Not numbered Trochanter assembly left wso s1023 FHCS M x 1x20 5000036 34 FHCS M x 30 5000265 35 _ SHCS Mex 1x 16 2 5000072 36 M3 x 0 5 x 10 5000203 37 SHCS MA x07 x 8 8000024 38 SHCS MA x07 x 14 5000549 39 Cheese screw M3 x 6 5000222 40 Flat washer M8 6 9 ID x 18 8 OD x 2 3 thick 2 5000123 41 SHES M2x0 4x10 5000215 42 SHCS M3 x05 x8 11 5000388 43 Flat washer M4 4 3 ID x 9 0 OD x 0 7 thick 6 5000155 44 BHCSM4x0 7x16 5000153 45 shes Mex 1x 10 16 5000457 46 Hex head screw 8 x 10 2 5000569 a7 BHCS M6
18. SSCP M3 X 16 5000212 SSCP M4 X 0 7 X 6mm 5000076 SSCP M6 X 1 0 X 8mm 5000622 SSCP nylon tip M4 X 7 X 10 5000260 SSFP flat point M4 X 6 5000464 SSFT X 10mm 5000226 Description Fastener number SSHOP M6 X 1 0 X 6mm 5000165 SSHDP M6 X 1 0 X 12mm 5000185 SENT X 0 5 X amm 5000190 SSNT M4 X 0 7 X 5000201 SSNT M6 X 1 0 X 6mm 5000621 Threaded rod M12 X 1 5 5000048 Washer fat ML X 17 X 4 X 25 5000428 Washer flat MB 6 9 ID X 18 8 OD X 2 3 THK 5000123
19. This was based on a study of the influence of temperature variations on the performance of the shoulder thorax abdomen and pelvis In addition in order to quantify air temperature variations within the chest cavity internal air temperatures were measured by placing a thermocouple on each of the inner ribs in the locations shown in Figure 5 1 which are in the vicinity of typical maximum bending stress From the results it was determined that the air temperature in the chest cavity has a relatively uniform distribution The WorldSID has a permissible i e optional chest cavity air temperature sensor mounted on the non impact side of the spine box which can be read directly through the TDAS G5 hardware and software This temperature sensor has an internal log function where it stores temperature variation data from the last 24 hours 150 Figure 5 1 Location of temperature sensors used for internal temperature survey 5 3 Effect of internal DAS on dummy temperature Extensive testing was performed to determine the effects on internal air temperature due to operation of the permissible internal TDAS G5 system Based on this testing changes were made to the pre production TDAS G5 design so that it would draw much less power The internal DAS heating was compared to heating created by running a typical external DAS with 10 V excitation and with the same set of sensors A summary of the results is given in Table 5 1 For the opti
20. WorldSID head instrumentation Figure 1 7 WorldSID neck components Figure 1 8 Removing lower neck bracket Figure 1 9 Removing upper neck bracket Figure 1 10 Using clamp to remove neck interface plate Figure 1 11 Neck dampers are free to be removed when interface plates are removed 11 Figure 1 12 Lateral positions for neck buffers 12 13 Figure 1 13 Assembling of neck buffers Figure 1 14 Neck triaxial accelerometer installation 15 Figure 1 15 Components of WorldSID thorax and abdomen 18 20 Figure 1 16 Shoulder Figure 1 17 WorldSID spine box assembly 22 Figure 1 18 Removing shoulder load cell assembly 23 25 Figure 1 19 Detaching shoulder rib at front from sternum Figure 1 20 Detaching the rib from the spine box at the rear 26 Figure 1 21 Battery assembly 28 vi Figure 1 22 Internal spine box assembly 29 30 Figure 1 23 Angular accelerometer assembling Figure 1 24 IR TRACC ball joint assemblies are mounted to the struck side plate of the spine box 32 Figure 1 25 Shoulder rib is grey the first thoracic rib is red and the al ribs are white second and tl thoracic ribs and abdo 33 Figure 1 26 Components of thorax rib Figure 1 27 Wire routing for rib instrumentation Figure 1 28 Plugging modules mounted in the spine box
21. in the right front chamber with screws accessed from the left front chamber Mount the z axis rotational accelerometer in the left rear chamber wi screws accessed from the top Mount the x axis rot the right rear chamber with screws accessed from the right front chamber The linear triaxial accelerometer is mounted in the right front chamber with one cheese screw M2 x 16 Figure 1 6 Item 8 that is accessed from the right Mount the tilt sensor in the right rear chamber with one SHCS M4 x 10 Figure 1 6 Item 9 accessed from the right front chamber The strumentation in the right rear chamber must be installed before the instrumentation in the right front chamber The upper neck load cell is also considered part of the head assembly instrumentation accelerometer in rviational near accelerometer Dual axis tit sensor triaxial jc accelerometer screw sues sues Head core rotational accelerometer x axis Dratational accelerometer z axis sues Figure 1 6 WorldSID head instrumentation 1 2 Neck 1 2 1 Parts list for neck Table 1 2 lists the parts required for assembling the WorldSID neck which are shown in drawing W50 20000 igure 1 7 Part numbers correspond to those found on Table 1 2 Parts list for WorldSID neck Description Part number number 1 Lower neck bracket 1 wso 20008 2 Up
22. 1050 54015 97 Item number Description Quantity Part number 12 Ankle joint assembly 1 W50 54045 13 Front bearing assembly 1 wso 54042 15 SHCS 5 x 0 8 x 12 mm 6 5000002 16 X axis potentiometer optional 1 ws0 54012 17 Cable clamp 1 8 4 5000191 18 BHCS M3 x 0 5 x 6 mm 4 71 19 X version assembly 1 Wso 54044 20 Rear bearing assembly 1 Ws0 54043 21 X version resistive element Ws0 54035 22 Resistive element Dorsi amp Plantar 8 W50 54036 23 Right flexion centre assembly 1 ws0 54049 24 z axis potentiometer assembly optional 1 Ws0 54051 26 Stop 4 Ws50 54022 27 Compression pad 2 50 54021 Not shown Ankle potentiometer mass replacement ws0 54013 98 igure 1 78 Ankle assembly 1 7 2 Disassembling 1 7 2 1 Femoral neck Disassemble the femoral neck by loosening the SSCP M4 x 0 7 x 6 mm Figure 1 73 Item 1 that holds the femoral ball in place and unthread the ball Figure 1 73 Item 2 from the femoral neck base Figure 1 73 Item 4 Use a spanner wrench to turn the ball modified 25 mm to 28 mm diameter 99 WS50 51001 and a spanner wrench 40 mm to 42 mm 50 51002 to hold the femoral neck base Figure 1 73 Item 4 Be careful not to damage the surface of the ball during disassembly and re assembly Remove the four LWSHCS M6 x 1 0 x 12 mm Figure 1 73 Item 3 that attach the assembly to the
23. 14 Sensor specifications for thorax with half arm test Variable Sensor Performance Peak pendulum acceleration See Table 7 3 SAE 12570 Peak upper spine T4 y axis Triaxial linear accelerometer SAE 42570 acceleration G Endevco 7268C 2000M1 Peak lower spine T12 y axis Triaxial linear accelerometer SAE 42570 acceleration 6 Endevco 7268C 2000M1 First second and third thorax IR TRACC See sensor specification details on rib deflections mm Model IF 363 electronic drawing number IF 363 Impact velocity m s Not specified Resolution 0 02 mis or better 7 3 4 1 4 Procedure Set up the dummy in standard test posture as described in 7 3 2 with the half arm parallel to the thorax Align the pendulum centreline with the centreline of the middle thorax rib Raise the pendulum to achieve a 6 7 m s 0 1 m s impact velocity Release the pendulum to impact the dummy 7 3 4 1 5 Calculation procedures and expression of results Filter the data according to ISO 6487 or SAE J211 as given in Table 7 15 Calculate the pendulum impactor force by multiplying the pendulum acceleration time history by the measured impactor mass Plot the time histories of impactor force T4 and T12 y axis accelerations and deflections of thorax ribs 1 2 and 3 173 Table 7 15 Filter specifications for thorax with half arm test Variable Fi Peak pendulum accel
24. 25 Figure 1 17 Item 25 that secure the Number 1 mounting brackets 30 Figure 1 17 Item 1 to the spine box Remove the middle or upper G5 module mass replacement assembly Figure 1 17 Item 22 Detach the spine box cover plate Figure 1 17 Item 19 from the back of each G5 module mass replacement Figure 1 17 Item 22 by removing two BHCS M6 x 18 Figure 1 17 Item 24 Slide the G5 module mass replacement Figure 1 17 Item 22 from between the two mounting brackets Figure 1 17 Item 1 and 21 Detach each interposer mass replacement Figure 1 17 Item 3 from the mounting brackets by removing the four SHCS M2 x 12 Figure 1 17 Item 17 Remove the two backup plate mounting brackets Figure 1 17 Item 11 from the spine box by removing the two SHCS M4 x 10 Figure 1 17 Item 12 that hold each in place Remove each connector housing mass replacement Figure 1 17 Item 10 from its backup plate mounting bracket Figure 1 17 Item 11 by removing three SHCS M3 x 8 Figure 1 17 Item 9 Remove the lower G5 module mass replacement Figure 1 17 Item 22 from the spine box by detaching two pin dowel M4 x 14 Figure 1 17 Item 30 Turn the spine box over and remove seven FHCS M6 x 10 Figure 1 17 Item 15 to remove the seven spacers Figure 1 17 Item 6 from the left side plate Figure 1 17 Item 4 Remove three more of the FHCS M6 x 10 Figure 1 17 Item 15 to separate the upper spine box bracket weldment Figure 1 17 Item 2 from th
25. 30 and the Figure 1 51 Item 29 before tightening the hip socket retainer Figure 1 51 item 31 Insert the hip joint assembly through the front access hole in the pelvis flesh Secure from the inside of the pelvis with a M8 x 10 bolt Figure 1 51 Item 46 Place the assembled spine box over the lumbar wedge Figure 1 51 Item 28 and secure with four SHCS x 18 Figure 1 51 Item 14 the 90 1 6 4 Instrumentation mounting The pelvis instrumentation for the WorldSID includes pubic sacroiliac and lumbar spine load cells and that a G5 module can be mounted to the bottom of the pelvis assembly The pelvis instrumentation cavity can be equipped with a linear triaxial accelerometer and a dual axis tilt sensor 1 7 Full leg assembly 1 7 1 Parts list 1 7 1 1 General The full leg assembly includes the femoral neck assembly the upper leg assembly the knee assembly the lower leg assembly and the ankle foot assembly 1 7 1 2 Parts for femoral neck assembly Table 1 14 lists the parts required for assembling the WorldSID femoral neck assembly which is illustrated in Figure 1 73 Table 1 14 Parts list for femoral neck W50 51034 Item number Description Quantity Part number 1 SSCP M4 x 0 7 x 6 mm 1 5000076 2 Femoral neck ball 1 W50 51038 3 LWSHCS M6 x 1 0 x 12mm 4 5000072 4 Femoral neck base 1 W50 51035 91 Figure 1 73 Femoral neck 1 7 1 3 Parts list for upp
26. 4 Spine box disassembling Detach the right side plate Figure 1 17 Item 8 from the spine box by removing ten FHCS M6 x 10 Figure 1 17 Item 15 Note that the internal components of the spine box will now be visible see Figure 1 23 Figure 1 22 Internal spine box assembly Remove the T12 accelerometer mount Figure 1 17 Item 7 from the igure 1 17 Item 5 that secure the mount Remove the accelerometer Figure 1 17 16 from spine box by removing the two SHCS M3 x 10 the mount by removing a cheese screw M2 x 16 Figure 1 17 Item 18 Note the rotational and linear accelerometer assembly shown in Figure 1 23 To detach the rotational accelerometer assembly from the spine box remove the three SHCS M3 x 10 Figure 1 17 Item 5 that secure it to 29 the spine box Remove the dual axis tilt sensor Figure 1 17 27 from the rotational accelerometer bracket by removing the SHCS from the back of the bracket Detach the two rotational accelerometers by removing the two FHCS that secure each to the bracket Rotational accelerometer Rotational and linear accelerometer assembly Figure 1 23 Angular accelerometer assembling Begin removal of the upper or middle G5 module mass replacements Figure 1 17 Item 22 by removing two SHCS M4 x 25 Figure 1 17 Item 25 that secure the Number 2 mounting brackets Figure 1 17 Item 21 to the spine box weldment Figure 1 17 Item 2 Remove two more SHCS M4 x
27. 5000178 2 3 flat washer 2 5000181 Elbow potentiometer assembly 1 ws0 61027 4 Elbow clevis assembly 1 ws0 61029 5 SSHDP M6 x 1 0 x 6 mm 1 5000165 6 Friction washer assembly 1 ws0 52064 7 Compression washer 1 ws0 61016 8 Clamping washer 1 ws0 61014 E BHCS M10 x 1 5 x 20 mm 1 5000176 10 Elbow load cell 1 wso 71060 11 Elbow shaft assembly 1 W50 61028 Not shown Elbow load cell structural replacement 1 wso e1065 50 Figure 1 39 Elbow section 1 4 1 5 Parts list for lower arm Table 1 10 lists the parts required for assembling the WorldSID lower arm which is illustrated in Figure 1 40 Table 1 10 Parts for lower arm Description ay Part number number 1 Elbow clevis assembly 1 ws0 61029 2 Modified BHCS wsosioaz 3 Arm load cell optional 1 wso riozo Not shown Arm load cell structural replacement 1 W50 61041 4 BHCSM6 x 1 0 x 16 mm 1 5000072 5 11 Spring washer 2 ws0 61022 Wrist washer 1 wsoeiois 7 Lower arm tube assembly 1 wso e1oss SHCSM3 xo x 12 mm 5000070 51 Description ay Part number number wrist pivot assembly 1 Wso 61020 10 Wrist clevis assembly 1 _ 12 SHSS x 25 mm 2 5000163 13 Wrist pivot bumper 2 ws0 61046 SSNT M6 x 1 0 x 6 mm 1 5000622 15 SHCSM2x0 4x 18 mm 1 5000164 16 Accelerom
28. 54023 10 M3 x 0 5 x 6 mm a 5000171 1 Cable guide 2 W50 61030 12 Leg flesh orienting block 1 W50 54038 13 sHcs M6 x 1 0 x 12 mm 1 5000281 95 Figure 1 76 Lower leg tube assembly 1 7 1 6 Parts list for ankle foot Table 1 18 lists the parts required for assembly of the WorldSID ankle foot which is illustrated in Figure 1 77 Table 1 18 Parts list for ankle foot Item Description Quantity Part number 1 Leg load cell optional 1 W50 71010 Not shown Leg load cell structural replacement 1 wso s1060 2 Ankle assembly 1 wso s4054 3 Moulded foot assembly right 1 wso sso05 Not shown Moulded foot assembly left W50 55004 4 SHCS 5 x 0 8 x 16 4 5000020 96 Figure 1 77 Foot and ankle 1 7 1 7 Parts list for ankle Table 1 19 lists the parts required for assembly of the WorldSID ankle which is illustrated in Figure 1 78 Table 1 19 Parts list for ankle Item number Description Quantity Part number 1 SSNT M6 x 1 0 x 6 0 1 6000621 2 Clevis assembly 1 Ws0 54047 3 SHCS M6 x 1 0 x 12 mm 6 5000281 4 Y axis potentiometer assembly optional 1__ ws0 54052 5 14 25 SSNT M3 x 0 5 x3 4 5000190 6 Left flexion centre assembly 1 W50 54048 7 SSCP M3 x 0 5 x 4 mm 1 5000470 8 SHCS M5 x 0 8 x 16 mm 4 5000020 9 Retainer bracket 2 50 54014 10 BHCS M4 x 0 7 x 10 mm 6 s000010 11 Ankle joint cover 1
29. Attach the x axis rotational accelerometer to the back of the bracket with two FHCS so it is parallel to the bottom of the bracket Attach the dual axis tilt sensor Figure 1 17 Item 27 to the back of the bracket with a SHCS Position the rotational accelerometer assembly Figure 1 17 Item 24 on the spine box and secure it with three SHCS M3 x 10 Figure 1 17 Item 5 Plug the cables for the rotational accelerometers sensors into G5 module but leave the connectors for the dual axis tilt sensor free to be plugged into the off board readout during dummy setup Attach the T12 accelerometer mount Figure 1 17 Item 7 to the spine box with two SHCS M3 x 10 Figure 1 17 Item 5 Attach the accelerometer Figure 1 17 Item 16 to the mount with a cheese screw M2 x 16 Figure 1 17 Item 18 Orient the accelerometer so that the cable points upward and can be routed between the middle G5 module and angular accelerometer assembly to be plugged into the G5 module Attach the linear triaxial accelerometer Figure 1 17 Item 16 to the top of the spine box weldment with a cheese screw 2 x 16 Figure 1 17 Item 18 Plug the cable for the upper accelerometer into the G5 module after the ribs are installed 39 Attach the other side plate Figure 1 17 Item 4 or 8 to the spine box with ten FHCS M6 x 10 Figure 1 17 Item 15 Make sure the cables from the T12 or angular accelerometer assembly are not pinched by the side plate igure 1 30
30. Figure 1 58 Pelvis flesh As shown in Figure 1 59 remove the sacroiliac load cell backing plates Figure 1 51 Item 26 by removing the four FHCS M6 x 30 Figure 1 51 Item 34 and three FHCS M6 x 20 Figure 1 51 Item 33 that secure them Separate the two pelvis bones Figure 1 51 Items 9 and 27 connected by the pubic buffers Figure 1 51 Item 5 and pubic load cell Figure 1 51 Item 6 from the lumbar instrumentation assembly 79 Figure 1 59 Removing sacroiliac backing plates to separate the pelvic bone pubis assembly Detach the moulded pubic buffers Figure 1 51 Item 5 from the moulded pelvis by removing the three M4 x 16 Figure 1 51 Item 44 and 4 flat washers Figure 1 51 Item 43 that hold each in place see Figure 1 60 Figure 1 60 Separating moulded pelvis bone from pubis assembly 80 Detach the pubic buffers from the pubic load cell structural replacement Figure 1 51 Item 6 by removing four SHCS M4 x 8 Figure 1 51 Item 37 from each side see Figure 1 61 jure 1 61 Separating pubic buffers from pubic load cell structural replacement As shown in Figure 1 62 detach the lumbar spine Figure 1 51 Item 13 remove the six BHCS M6 x 20 Figure 1 51 Item 47 and six lumbar bushings Figure 1 51 Item 10 that attach it to the lower lumbar mounting bracket weldment Figure 1 51 Item 17 Remove the two lower lumbar clamping plates Figure 1 51 Item 11 81
31. Figure 1 58 Pelvis flesh Figure 1 59 Removing sacroiliac backing plates to separate the pelvic bone pubis assembly 80 Figure 1 60 Separating moulded pelvis bone from pubis assembly 80 Figure 1 61 Separating pubic buffers from pubic load cell structural replacement 81 Figure 1 62 Detaching the lumbar spine 82 Figure 1 63 Separating the upper lumbar clamping plate and lumbar mounting wedge from the lumbar spine 82 viii Figure 1 64 Removing the lower lumbar mounting bracket weldment 83 Figure 1 65 Removing the sacroiliac load cell interface 84 Figure 1 66 Removing pelvis instrumentation cover plate 84 Figure 1 67 Removing the pelvis instrumentation bracket 85 Figure 1 68 Removing the DAS cover 86 Figure 1 69 Removing the docking station 86 Figure 1 70 Removing interposer mass replacement 87 Figure 1 71 Separating the sacroiliac and lumbar spine load cell structural replacements 87 90 Figure 1 72 Routing of wires for pelvis instrumentation Figure 1 73 Femoral neck 92 Figure 1 74 Upper leg assembly 93 94 Figure 1 75 Knee Figure 1 76 Lower leg tube assembly 96 97 Figure 1 77 Foot and ankle Figure 1 78 Ankle assembly Figure 1 79 Ankle Figure 1 80 Knee assembli g Figure 1 81 Knee potentiometer ing Figu
32. are recommended WorldSID instrumentation cable routing procedures There are two primary concerns with instrumentation cable routing 1 cable protection during dynamic testing 2 reducing the cable s influence on the motion of the dummy during dynamic testing 3 7 2 Lower arm cables Route and secure the lower arm cables as shown in Figure 3 15 Cable Guide M3 x 6 mm BHCS Figure 3 15 Lower arm cables 3 7 3 Upper arm cables Route and secure the upper arm cables as shown in Figure 3 16 134 Cable Guide 2 x 6 mm BHCS Elbow Figure 3 16 Upper arm cables 3 7 4 Elbow cables Route and secure cables in the area of the elbow as shown in Figure 3 17 Potentiometer Cable Elbow Accelerometer Cable Accelerometer Cable 3 Cable Guide M3 x 6 mm BHCS Figure 3 17 Cables in the elbow region 135 3 7 5 Routing wires through flesh component The instrumented arm flesh and suit components should be installed with wire routing as shown in Figure 3 18 Figure 3 19 and Figure 3 20 Velcro Lower Arm Flesh Figure 3 18 Lower arm flesh 136 Upper Arm Flesh Upper Arm Z Pivot Figure 3 19 Upper arm flesh Lower Arm Suit Piece Lower Arm Cables Upper Arm Cables Figure 3 20 Lower arm suit 3 8 Instrumented leg cable routing 3 8 1 Lower leg cable routing Route and secure the lower leg cables as shows ure 3 21 137 Velero Strap
33. as specified in 49CFR Part 572 Subpart E 7 2 3 4 Sensors Perform the test using the sensors given in Table 7 3 161 Table 7 3 Sensors for neck assembly Variable Sensor Performance Pendulum acceleration Single axis accelerometer SAE 42870 Endevco 7231 750 Pendulum velocity Not specified Resolution 0 02 mis or better Angular displacement of forward pendulum to Angular potentiometer SAE 12870 head form sliding rod positive when doing a right side impact 4 Angular displacement of rearward pendulum Angular potentiometer SAE 12870 to head form sliding rod positive when doing right side impact 4 Angular displacement of head form about Angular potentiometer SAE J2570 forward pendulum to head form sliding rod positive when doing a right side impact 4 Neck moment M Upper load cell SAE 12870 Denton W50 71000 Neck force F Upper load cell SAE 12570 Denton W50 71000 7 2 8 8 Preparation Expose the neck to the conditions specified in Table 7 4 for at least four hours prior to a test Table 7 4 Neck test preconditions Variable Specification Temperature degrees 214 Relative humidity 6 40 30 Attach the top of the neck to the head form Attach the bottom of the neck to the pendulum interface Ensure that the screws do not protrude into the neck rubber as this may influence the response If the screws a
34. cable lengths Table E 1 Specialized WorldSID support equipment Table E 2 Other standard support equipment Table F 1 WorldSID drawing Table F 2 WorldSID fasteners xv SECTION 1 WORLDSID 14 Head 1 1 1 Parts list for head PROCEDURES FOR DISASSEMBLING AND ASSEMBLING THE Table 1 1 lists the parts required for assembling the WorldSID head which are illustrated in Figure 1 1 Part numbers correspond to those on electronic drawing W50 10000 Table 1 1 Parts list for WorldSID head Tem number Description ary Part number 1 Head 1 W50 10007 2 Moulded head 1 W50 14014 3 Rotational accelerometer 3 Endevco 730274 4 Dual axis tilt sensor 1 Endevco 7302M4 5 Linear triaxial accelerometer 1 Endevco 7268C 2000MT 6 Neck load cell structural replacement 1 W50 71003 jj M3 x 0 5 x 6 6 5000383 g Cheese screw 2 x 18 1 5000254 9 SHCS x 0 7 x 10 1 5000151 10 SHES M6 x 1 x 18 4 5000081 11 Flat washer M8 8 9 ID x 18 8 OD x 2 3 thick 1 5000123 12 BHCS x 1 25 x 25 1 5000255 18 Neck shroud assembly 1 WS0 24103 14 SHCS x 12 4 8000281 15 BHCS M4 x 0 7 x 10 amp 5000010 Not shown Rotational accelerometer mass replacement 3 Ws0 10010 Not shown Linear triaxial accelerometer mass replacement 1 W50 61063 Not shown Dual axis tit sensor mass replacement 1 W80 10011 Not shown Unive
35. femoral neck load cell Figure 1 74 Item 3 Note that these screws can be removed without removing the ball using modified hex key wrench W50 51003 1 7 2 2 Upper leg Disconnect all the cable connectors and remove the cable guides Remove the femoral neck load cell Figure 1 74 Item 3 by taking out the four BHCS M6 x 1 0 x 16 Figure 1 74 Item 10 that attach it to the trochanter assembly Figure 1 74 Item 9 Remove the twelve modified BHCS Figure 1 74 Item 5 that respectively attach the trochanter Figure 1 74 Item 9 to the leg load cell Figure 1 74 Item 8 the leg tube assembly Figure 1 74 Item 7 to the leg load cell and the leg tube assembly Figure 1 74 Item 7 to the knee assembly Figure 1 74 Item 6 Separate these assemblies 1 7 2 3 Knee Detach the lower leg assembly by removing the four modified that attach the knee assembly to the leg load cell at the upper tibia position Figure 1 76 Item 1 Remove the knee covers Figure 1 75 Item 2 by removing the four SHCS M4 x 0 7 x 10 mm Figure 1 75 Item 1 holding each cover in place Remove the potentiometer assembly Figure 1 75 Item 4 by taking out the BHCS M3 x 0 5 x 6 mm Figure 1 75 Item 5 at each side of the potentiometer The knee contact load cell structural replacement 100 Figure 1 75 Item 3 positioned directly beneath the knee cover and is removed by taking out four SHCS M4 x 0 7 x 10 mm Figure 1 75 Item 1 for each l
36. number BHCS M5 X 6 5000214 BHCS M6 X 1X 18 5000465 BHCS X 1 0 X 16 5000072 BHCS M6 X 22 5000211 BHCS M2 5 X A5 X 5 5000429 BHCS M6 X 1 X 20 5000438 BHCS MB X 1 25 X 25 5000255 Cable clamp 5000191 Cheese screw M2 X 10 5000220 Cheese screw M2 X 12 5000253 Cheese screw M2 X 16 5000254 Cheese screw M2 X 18 5000221 Cheese screw M3 X 6 5000222 5000224 5000167 5000225 Dowel pin M3 X 12mm 5000183 Dowel pin M3 X 16mm 5000223 Dowel pin M3 X 6mm 5000385 Dowel pin M3 X 8mm 5000384 Dowel pin M4 X 10 5000414 Dowel pin M4 X 14 5000053 Dowel pin M5 X 16 5000331 Dowel pin M6 X 12mm 5000217 FHCS M2 X 12 5000207 FHCS M25 X 12 5000206 FHCS M25 X 6 5000202 FHCS M3 X 10 5000203 FHCS M4 X 0 7 X 12mm 5000177 FHCS MS X 8 X 16 5000467 FHCS M5 X 0 8 X 10 5000084 FHCS M6 X 1 0 X 20 0 5000036 FHCS M6 X 10 5000204 Description Fastener number FHCS M6 X 16 stainless stool 5000090 FHCS M6 X 30 5000265 Flat washer M3 5000181 Flat washer M4 5000155 Helicoil M4 X 0 7 X 8mm 5000047 Helicoil M4 X 12mm 5000205 M4 X Gmm 5000200 Helicoil M5 X 1mm 5000213 M6 X 1 X 6 5000049 Helicoil M6 X 1 0 X 6mm 5000087 Helicoil M6 X 1 0 X 8 5000088 Helicoil M6 X 12mm 5000175 Helicoil MB X 1 25 X 8 5000348
37. of the upper arm tube assembly Figure 1 42 2 Pivot and upper arm tube While the components are disassembled make a thorough inspection of bearing and mating surfaces Ensure that wear or damage will not affect the performance of the arm assembly Refer to Figure 1 42 Inspect the 1 5 roll pins in the end of the Z pivot Figure 1 42 Item 1 to make sure they are not bent 56 1 4 2 3 Disassembling elbow The elbow joint is disassembled by removing the BHCS M10 x 1 5 x 20 mm Figure 1 39 Item 9 at the elbow pivot This BHCS M10 provides the tension necessary for the 1 to 2 G setting in the elbow When this screw is removed the clamping compression and friction washers Figure 1 39 Items 8 7 and 6 respectively can be pulled from the assembly Loosen or remove the SSHDP 6 x 1 x 6 mm Figure 1 39 Item 5 from the elbow load cell and the elbow shaft assembly Figure 1 39 Item 11 can be pulled from the elbow joint With the shaft assembly removed the elbow load cell and clevis assembly can be pulled apart The elbow potentiometer Figure 1 39 Item 3 can be removed by taking out the two BHCS M3 x 0 5 x 10 mm Figure 1 39 Item 1 and the associated M3 flat washers Figure 1 39 Item 2 14 2 4 Disassembling lower arm Before disassembling the lower arm assembly remove the triaxial linear accelerometer located in the wrist assembly Remove the accelerometer mounting bracket Figure 1 40 Item 17 Hold the bra
38. pelvis test Variable Sensor Performance Pendulum acceleration G _ See Table 7 3 SAE 12870 Lower spine T12 y axis Triaxial linear accelerometer SAE 32570 acceleration G Endevco 7268 2000 1 Pelvis acceleration GI Triaxial linear accelerometer SAE 22670 Endevco 7268C 2000M1 Impact velocity m s Not specified Resolution 0 02 mis or better 7 4 3 4 Procedure Set up the dummy with half arm in standard test posture as described in 7 3 2 Align the pendulum centreline with the H point 180 Raise the pendulum to achieve a 6 7 m s 0 1 m s impact velocity Release the pendulum to impact the dummy 7 4 3 5 Calculation procedures and expression of results Filter the data according to ISO 6487 or SAE J211 1 as given in Table 7 24 Calculate the pendulum impactor force by multiplying the pendulum acceleration time history by the measured impactor mass Graph the time histories of impactor force pelvis and T12 y axis accelerations Table 7 25 Filter specifications for pelvis test Variable Fitter Pendulum acceleration GI CFC 180 T12 y axis accleration G CFC 180 y axis acceleration G CFC 180 7 4 8 6 Test reports Document the results of the pelvis test 181 FASTENER TORQUE VALUES Table A 1 Screw torques Annex A Screw Type Screw Size
39. potentiometer assembly x lws0 61028 Elbow shaft assembly x lws0 61029 Elbow clevis assembly x wso eroso Cable guide x wso eros Elbow leg load cell structural replacement body wso e1032 Wrist clevis x wso e103a Wrist levis assembly x lwso 61034 Lower arm assembly x lws0 61035 Wrist assembly x wso erose Lower arm tube assembly x lws0 61037 Hand moulded assembly left x ws0 61038 Bumper x wso eroso Accelerometer mount bracket assembly x lwso 61040 Accelerometer mount bracket x lws0 61041 Arm leg load cell structural replacement assembly x lws0 61042 Modified button head screw x wso eroas Bumper x w50 61045 Bumper x Drawing number Description Electronic file format PDF sre lws0 61046 Bumper wrist pivot lws0 61047 Modified IGUS bearing lws0 61088 Bumper hand lws0 61089 Pivot shaft lws0 61050 Pivot washer lws0 61051 Shoulder clevis assembly lws0 61052 Bumper moulded assembly lws0 61053 Shoulder assembly lws0 61054 Flexion extension stop assembly jwso eross Flexion extension stop wso erose Stop bumper lws0 61057 Shoulder bumper plate wso 61058 sheet 1 Wso 61058 sheet 2 wso eross Shoulder load cell abduction bumper wso eroeo Friction pad lws0 61062 Elbow ballast for structural replace lws0 61063 7268 C accelerometer structural replacement w
40. radial limit screw Figure 1 76 Item 5 to remove the lower tibia leg load cell Figure 1 76 Item 1 Loosen the NTSS M6 x 6 mm Figure 1 78 Item 1 Use this set screw to adjust the z axis rotational friction for the lower tibia load cell isconnect the cables from both of the 101 tibia loads Using a modified 22 mm open end wrench W50 51004 hold the z axis nut Figure 1 76 Item 9 in place while rotating the leg tube and load cell assembly until the lower tibia leg load cell can be pulled from the ankle assembly Remove the anti rattle and rotational washers Figure 1 76 Items 7 and 8 from the assembly Remove the four SHCS M5 x 0 8 x 16 mm that secure the foot to the ankle assembly Figure 1 77 Item 4 to remove the moulded foot 1 7 2 5 Ankle Remove the Y Axis potentiometer Figure 1 78 Item 4 if equipped by loosening the SSNT M3 x 0 5 x 3 mm Figure 1 78 Item 5 holding it in place Pull the potentiometer from the assembly Remove the six BHCS M4 x 0 7 x 10 mm Figure 1 78 Item 10 that attach the ankle joint cover Figure 1 78 Item 11 to the ankle joint assembly Figure 1 78 Item 12 Figure 1 79 Ankle Lift the Y version assembly off the X version assembly Note that when the two assemblies separate the resistive elements Figure 1 78 Item 22 will fall out of the assembly With the two assemblies separated take apart 102 each assembly Check the resistive elements for signs of permanent defor
41. the inside edge of the knee and placed 102 mm from the seat centreline 153 If either knee of the dummy is in contact with the vehicle interior rotate the entire contacting leg s at the hip joint away from the obstruction until contact occurs Record any variation in the knee separation distance 6 2 3 3 Place both feet with the heel on the floor pan and as far forward as permitted by foot contact thigh cushion contact or leg contact with the forward seat structure For the rotation of the ankle joint allow the feet to remain in a neutral position Align the feet parallel to the vehicle centreline 6 2 3 4 Rear seats with adjustable seat backs 6 2 3 5 Fully recline the seat back 6 2 3 6 Hold the ATD s thighs down and push rearward on the upper torso to maximize the ATD s pelvic angle 6 2 3 7 While holding the thighs in place rotate the torso forward until the torso recline angle the angle of a side view line from the ATD H point to the head s center of gravity is set to 12 degrees 1 degree While supporting the ATD rotate the seat back forward until the ATD torso is supported in the 12 degrees 1 degree torso recline position 6 2 3 8 Gently rock the upper torso relative to the lower torso laterally in a side to side motion three times through a 5 degree arc approximately 50 mm side to side to reduce friction between the ATD and the seat 6 2 3 9 Reposition feet if necessary 6 2 3 10 Rotate the arms to 45 d
42. 027 5 BHCS M3 x 0 5 x 6 mm 2 5000171 6 BHCS M3 x 0 5 x 6 mm 2 5000171 7 Cable guide 1 ws0 61030 8 Knee pivot shaft assembly 1 ws0 82008 Knee clevis assembly right 1 wso s2008 shown Knee clevis assembly left 1 wsosaozi 93 Item number Description Quantity Part number 10 Friction washer 1 W50 52064 11 Compression washer rubber 1 ws0 61016 12 Clamping washer steel 1 ws0 61014 13 BHCS M10 x 1 5 x 20 mm 1 5000176 n Knee pad mould assembly 1 ws0 62010 15 BHCS M4 x 0 7 x 12 mm 5000005 16 Knee bone assembly 1 wso s2002 17 SSHDP M6 x 1 0 x 12 mm 1 5000185 Not shown Rotary potentiometer mass replacement wsoenzs Figure 1 75 Knee 94 1 7 1 5 Parts list for lower leg tube assembly Table 1 17 lists the parts required for assembling the WorldSID lower leg tube which is illustrated in Figure 1 76 Table 1 17 Parts list for lower leg tube Item number Description Quantity Part number 1 Leg load cell optional 2 ws0 71010 not shown Leg load cell structural replacement 2 ws0 51060 2 Modified button head cap screw ws0 61042 3 Lower leg tube 1 ws0 53001 4 SSCP M6 x 1 0 x 8 mm a 500022 5 z axis radial limit screw 1 wsosaon 6 Z pivot pin 1 ws0 54009 7 z axis anti rattle washer 1 Wso 54024 8 z axis rotational washer 1 j W5o 54010 9 z axis nut 1 W50
43. 12 Figure 1 1 Item 14 Torque the screws to 6 Nm Mount the neck shroud assembly Table 1 1 Item 13 to the moulded head Figure 1 1 Item 2 using five BHCS M5 x 10 Place the head neck shroud assembly over the instrumented core making sure that all wires are free Place the flat washer into the recess at the top of the head and connect the head to the instrumented core using the BHCS M8 x 25 Figure 1 1 Item 12 Tighten the screw 1 4 1 2 turn after engagement of the screw head and the skull As shown in Figure 1 5 bundle the wires from the head instrumentation together at the rear with cable ties and route down the back of the neck over to the non struck side of the dummy Pass the cables between the shoulder rib and first thoracic rib to be plugged into the DAS modules from the other wiring so it can be plugged into an off board readout during setup As shown in Figure 1 5 make sure that the cable has some slack See Section 1 3 for more detailed wiring information Figure 1 5 Wire routing for head instrumentation 1 1 4 Instrumentation mounting As shown in Figure 1 6 the head core can be instrumented with three rotational accelerometers Figure 1 6 Item 3 one linear triaxial accelerometer Figure 1 6 Item 5 and one dual axis tilt sensor Figure 1 6 Item 4 Each rotational accelerometer is secured with two SHCS M3 x 6 Figure 1 6 Item 7 and that the y axis rotational accelerometer is mounted
44. 50 82244 W50 82245 Modified spanner wrench 25 mm to 28 mm dia Assembly W50 51001 Spanner wrench 40 mm to 42 mm dia Assembly _ wso 51002 Modified hex key wrench Assembly wso 51003 Modified 22 mm open end wrench Assembly wso s1004 Shortened 6 mm hex key 15 mm long Assembly W50 20018 Cowrench for hip joint Assembly W50 42521 Lifting mechanism Handling w50 84100 a This equipment may need to be customized for each lab EA E 2 Other support equipment typically available in test laboratories Other dummy support equipment needed for WorldSID certification and typically available in test laboratories are given in Table E 2 Table E 2 Other standard support equipment Description Use 5 1 49 CFR Part 872 Subpart E horizontal head impact surface Certification 5 1 Quick release mechanism Certification 5 2 49 CFR Part 572 Subpart neck pendulum apparatus Certification 5 2 CFR Part 572 Subpart E pendulum decelerating aluminium Certification honeycomb or alternative products which can be shown to lead to tho results 5 2 Neck bending pendulum accelerometer Endevco 7231 750 Certification 5 3 49 CFR Part 572 subpart E Hybrid Ill 50th percentile adult male Certification dummy pendulum 23 4 kg with 6 in dia 5 3 49 CFR Part 572 subpart E Hybrid Ill 50th percentile adult male Certification dummy pendulum acceleromet
45. 6 Item 33 is attached to the spine box with damping clamps Figure 1 26 Item 10 and FHCS The rib Figure 1 26 Item 28 is attached to the spine box Figure 1 26 Item 13 at the rear with BHCS and to the thorax rib sternum Figure 1 26 Item 3 at the front using BHCS and the sternum mounting strip Figure 1 26 Item 4 and threaded sternum mounting strip Figure 1 26 Item 7 Attach the IR TRACC assembly Figure 1 26 Item 14 with a BHCS to the ball joint components which are attached to the spine box Secure the IR TRACC to the rib accelerometer mounting bracket Figure 1 26 Item 32 with a special mounting screw accessed from the bottom A linear triaxial accelerometer Figure 1 26 Item 15 is attached to the rib accelerometer mounting bracket Figure 1 26 Item 32 which is then secured to the inner rib rib and rib clamping bracket Figure 1 26 Item 31 with a BHCS 34 D linear triaxial pinebox assembly accelerometer 62 Rib accelerometer mounting bracket Damping clamp 9 clamping bracket S rhorax rib sternum IR TRACC assembly G3 Inner band thorax rib A g Thorax rib 1 Reference drawing 9 Threaded sternum mounting strip W50 30000 DSternum mounting strip Figure 1 26 Components of thorax rib 35 Figure 1 28 Plugging rib instrumentation cables into the front of the G5 modules mounted in the spine box 36 Continue installing the ribs with the preceding procedure At
46. 71987 246 Pubic a 5 7 Mid spine 1 w50 71987 435 Femoral neck 3 408060 Les 2 ws0 71984 406 Femoral neck 3 1080 142 61 Pelvis 2 W50 71984 1080 Mid temur e 254100 Les 2 wso risst 264 Knee contact 1 35614 01 Leo 4 wso 71020 356 Knee pot 1 3564 Leg 2 wso 71162 Upper tibia e Les 2 ws0 71981 608 Lower tibia s ies 2 ws0 71981 686 Ankle pot a 9140360 Les 2_ ws0 71161 Upper arm 6 127 61 Upper spine 1 w50 71981 700 co Position No of Length Dase Pare number channels mm inches location Lower arm 1100143 3 Upper spine 1 Ww50 71981 1100 Wrist accelerometer a 12001472 Upper spine 1 w50 71164 1200 Elbow 2 800081 8 Upper spine 1 w50 71992 800 Elbow accelerometer 1200072 Upper spine 1 ws0 71164 1200 Elbow potentiometer 1 950374 Upper spine 1 ws0 71163 Shoulder a Upper spine 2 W50 71986 355 Annex D OPTIONAL DTS G5 DAS LOW POWER MODE HEAT BUILDUP MITIGATION D 1 General To help address temperature concerns inherent when sensors and DAS are installed in dummy TDAS CONTROL has a Low Power Mode option for use with iDummy Low Power Mode is only available when using Recorder Mode for data collection D 2 What is Low Power Mode In the standard Recorder Mode the system starts to collect data when it receiv
47. 7379 55 Set screw cup point 150 4029 SSFP Set screw flat point 150 4026 SSHDP Set screw half dog point SSNP Set screw nylon point SSNT Set screw with nylon tip B 1 OVERVIEW OF AN EXAMPLE INTERNAL DATA ACQUISITION SYSTEM C 1 General This annex gives an overview of the main functional components of and cable pinout scheme for the WorldSID G5 DAS which is an example internal data acquisition system for the WorldSID Users of an internal data acquisition system should contact the manufacturer to request operating procedures and specifications for the system WorldSID Task Group document N397 contains some geometric mass and performance characteristics for permissible internal data acquisition systems The WorldSID G5 DAS is an example of a system which conforms to these normative specifications and was used in the 11 pre production WorldSIDs C 2 System components The basic components of the WorldSID G5 DAS system are shown in Figure C 1 Table C 1 lists parts and part numbers A description of each item is given below for the convenience of users of this example system Table C 1 WorldSID G5 DAS parts list Description Part number TOAS G5 Module TDASS M32 TOAS 65 TDASS DB TDAS G5 DB Dog Bone connector clamp TDASS DBCON CL TOAS G5 DB Dummy exit cable TDASS C DBDE Dummy exit to TDAS status box cable TDASS C DESB
48. 77 Denton COE tilt sensor adaptor block head x wso rto7s Denton COE tik sensor adaptor block x lws0 71080 Femoral neck load cell assembly optional x wso 71090 Shoulder load cell assembly optional x lws0 71092 Shoulder load cell structural replacement assembly x wso 71094 Denton COE tilt sensor adaptor block head x lws0 71097 Bushing x wso z1098 Slug x lws0 71120 Lumbar spine load cell assembly optional x 71122 Lumbar spine load cell structural replacement assembly x lws0 71123 Lumbar spine load cell structural replacement body x fws0 71130 Sacroiliac load cell assembly optional x lws0 71701 Temperature logger mass replacement x wso 71965 Femoral neck load cell structural replacement assembly x lws0 71875 Sacroiliac load cell structural replacement assembly x w50 74307 G5 DAS structural replacement body x 75001 Interposer replacement x Drawing number Description Electronic file format por sre lws0 75002 Connector housing replacement x 50 75102 sheet 1 Linear trax accelerometer cable head x 50 75102 sheet 2 Linear triax accelerometer cable head x lw50 75108 sheet 1 Rotational accelerometer cable universal x 5075108 sheet 2 Rotational accelerometer cable universal x wso 75201 sheet 1 Linear accelerometer cable universal x wso 75201 sheet 2 Linear trax accelerometer cable univ
49. 8C 2000M1 Variable Sensor Performance Peak pendulum acceleration GI See Table 7 3 SAE 12570 Peak upper spine 4 y axis SAE 12570 acceleration 61 Endeveo 7268C 2000M1 Peak lower spine T12 y axis Triaxial linear acce SAE 12570 First second and third thorax IR TRACC See sensor specification details on rib deflections imm Model IF 263 electronic drawing number IF 363 Impact velocity m s Not specified Resolution 0 02 mis or better 7 3 5 1 4 Procedure Set up the dummy without arm in standard test posture as described in 7 3 2 Raise the arm to a vertical orientation as shown in Figure 7 9 Align the pendulum centreline with the centreline of the middle thorax rib Raise the pendulum to achieve a 4 3 m s 0 1 m s impact velocity Release the pendulum to impact the dummy 175 Figure 7 9 Thorax test without arm dummy and arm po 7 3 5 1 5 Calculation procedures and expression of results Filter the data according to ISO 6487 or SAE J211 as given in Table 7 18 Calculate the pendulum impactor force by multiplying the pendulum acceleration time history by the measured impactor mass Graph the time histories of impactor force T4 and T12 y axis accelerations and deflections of thorax ribs 1 2 and 3 Table 7 18 Filter specifications for thorax without half arm test Variable Filter Peak pendulum acceleration 81 CFC 180 Paak
50. CC mass replacement wsotoeo Ne moun Linear triaxial accelerometer mass replacement ws0 61083 mown Temperature logger assembly mass replacement ws0 71701 7 Figure 1 15 Components of WorldSID thorax and abdomen 18 1 3 1 2 Parts list for shoulder Table 1 4 lists the parts required for assembling the WorldSID shoulder electronic drawing W50 61053 which is illustrated in Figure 1 16 Table 1 4 Parts list for shoulder assembly Tem Description Quantity Part number number 1 Shoulder load cell structural replacement 1 50 71092 2 Shoulder pivot shaft 1 ws0 61049 3 Shoulder pivot washer 2 ws0 61050 4 Shoulder clevis assembly 1 wso 61117 5 M6 hex locknut 1 5 6 SSNT M4 x 0 7 x 4 mm 2 5000201 Not shown Shoulder load cell 1 wso 71090 Not shown SSFP M4 x 0 7 x 4 mm 2 5000618 Not shown SSFT M6 x 10 1 5000226 19 Figure 1 16 Shoulder 1 3 1 3 Parts list for spine box assembly Table 1 5 lists the parts required for assembling the WorldSID spine box Part numbers correspond to those on drawing W50 31000 and shown in Figure 1 17 Table 1 5 Parts list for WorldSID spine box hem Description Part number number 1 Mounting bracket 1 2 wso 31042 2 Upper bracket weldment spine box WorldSID 1 ws0 31010 a Interposer replacement 2 wso zsoor 4 Sid
51. Dual axis tilt sensor mass replacement 1 21 Figure 1 17 WorldSID spine box assembly 1 3 2 Disassembling 1 3 2 1 Separation of upper and lower torso To separate the upper and lower torso first make sure all the cables running between the upper and lower torso are detached these would normally include communication cables if the pelvis DAS is installed sensor cables that were routed to the DAS in the thorax and a ground cable This 22 step may require disassembling of the sternum to access the sensor collector Thereafter remove the four SHCS MB two on each side of the bottom of the spine box to separate the upper and lower torsos 1 3 2 2 Shoulder As shown in Figure 1 18 remove the shoulder assembly Figure 1 15 Item 23 by removing the four FHCS M5 x 16 Figure 1 15 Item 20 that hold each in place Figure 1 18 Removing shoulder load cell assembly To remove the clevis assembly Figure 1 16 Item 4 take off the M6 hex nut Figure 1 16 Item 5 with the nylon washer Figure 1 16 Item 3 at the threaded end Next loosen the two SSNT M4 x 0 7 x 4 Figure 1 16 Item 6 in the clevis assembly that hold the pivot shaft Figure 1 16 Item 2 and the two SSFT M6 x 10 mm in the load cell behind the clevis securing 23 the pivot shaft from the load cell structural replacement then pull the shaft out of the assembly NOTE shoulder load cell has two SSFP x 4 mm se
52. ECOMMENDED WORLDSID GENERAL PRACTICES 2 1 Cer ication test intervals The acceptable interval between WorldSID certification tests is highly dependent upon the type and severity of impacts to which the WorldSID is subjected Each user should determine their own requirements based on their existing policies regulatory requirements impact severity and experiences with the WorldSID Users should perform certification tests as follows before and after each series of sled tests after every three full scale vehicle tests after each high energy impact after any unusual impact if ribs exhibit more than 2 mm of permanent deformation when compared to their original shape 2 2 Recommended inspection pra As with the certification test interval discussed in 2 1 each WorldSID user should determine their own inspection requirements based on their existing policies regulatory requirements impact severity and their experience with the WorldSID When establishing appropriate inspection practices users should consider the following 116 All parts should be visually inspected during each assembly and disassembly process Before performing certification tests the involved parts should be visually inspected Components subjected to high energy impact should be inspected following the test Ribs should be inspected on a regular basis and after high energy impacts to determine if permanent deformation
53. Ethernet communication cable from status box to PC TDASS ETH SOPC Wireless Ethernet programming cable Wireless Ethernet jumper plug TDAS status box TDASS 58 Antenna TDASS SBAN TDAS power supply TDASS PS TDAS G5 User s manual and software TDASS Soft Allen wrench TOASS Wrench Rugged instrument case Pelican 1550 TOASS 1550 2 4 Amp power supply with 4Pin Lemo connector TDASS PS 2 Amp C 3 G5 module Each G5 module records data from as many as 32 sensors and has sensor ID capabilities The G5 system installed on the WorldSID pre production dummies had the provision for mounting five G5 modules on the dummy two in the spine one in the pelvis and one in each upper leg skin In addition if needed additional G5 units can be located in the dummy suit pockets to support full arm sensors See the manufacturer supplied G5 module hardware user s manual for additional information C 4 G5 docking station The docking station consists of a mechanical guide and connector for the G5 module flex cable and sensor input connectors As specified in the G5 documentation when attaching a G5 to the docking station the attachment bolt torque should be 1 6 to 1 8 Nm Additional information c2 regarding the docking station is found in the manufacturer supplied G5 module hardware user s manual 5 G5 DB The G5 DB is used to link up to five G5 Modules together inside the dummy Note that the in dummy tem
54. Figure 1 15 Item 9 Detach the inner band of the thorax rib Figure 1 15 Item 12 by removing the four BHCS M5 26 x 10 Figure 1 15 Item 10 that hold them in place Remove the two damping clamps Figure 1 15 Item 24 Detach the rib from the spine box at the rear by removing two BHCS M5 x 6 Figure 1 15 Item 26 that hold them in place Repeat this procedure for the second and third thorax ribs and the two abdominal ribs with the few differences in parts described here Note that the two abdominal ribs are attached at the front to the abdominal rib coupler Figure 1 15 Item 6 and that the inner rib bands of the two abdomen ribs Figure 1 15 Item 13 are different than the inner bands of the three thorax ribs Figure 1 15 Item 12 The damping material on the abdominal ribs is thicker than that on the thoracic ribs Also the first thorax outer rib Figure 1 15 Item 3 is different from the thorax ribs 2 and 3 and the abdominal ribs Figure 1 15 Item 4 which are the same After the ribs are removed see Figure 1 15 detach the battery mass replacement Figure 1 21 Item 31 from the non struck side by removing two SHCS 5 x 18 Figure 1 21 Item 34 Then detach the battery mounting bracket Figure 1 21 Item 29 by removing the two SHCS M5 x 30 Figure 1 21 Item 30 that secure it to the spine box 27 S v Reference drawing Battery este W50 30000 replacement Figure 1 21 Battery assembly 28 1 3 2
55. Figure 1 62 Detaching the lumbar spine Remove the upper lumbar clamping plate Figure 1 51 Item 12 from the lumbar spine by removing the four BHCS 5 x 25 Figure 1 51 Item 15 that secure it see Figure 1 63 Remove the lumbar mounting wedge Figure 1 51 Item 28 Figure 1 63 Separating the upper lumbar clamping plate and lumbar mounting wedge from the lumbar spine 82 As shown in Figure 1 64 remove the lower lumbar mounting bracket weldment Figure 1 51 Item 17 from the lumbar load cell structural replacement Figure 1 51 Item 25 by removing four FHCS M6 x 16 Figure 1 51 Item 16 Figure 1 64 Removing the lower lumbar mounting bracket weldment Detach the left and right sacroiliac load cell interfaces Figure 1 51 Items 22 and Item 8 by removing the eight SHCS x 10 Figure 1 51 Item 45 that hold each in place see Figure 1 65 Figure 1 65 Removing the sacroiliac load cell interface As shown in Figure 1 66 remove the pelvis instrumentation cover plate Figure 1 51 Item 19 by removing four cheese screws M3 x 6 Figure 1 51 Item 39 Figure 1 66 Removing pelvis instrumentation cover plate 84 Detach the pelvis instrumentation bracket Figure 1 51 Item 21 from the sacroiliac load cell structural replacement Figure 1 51 Item 24 by removing three SHCS M4 x 14 Figure 1 51 Item 38 accessed from the back see Figure 1 67 Figure 1 67 Removing the pelvi
56. ISO TC22 SC12 WG5 WorldSID TG N393 USER S MANUAL FOR THE WORLDSID 50TH PERCENTILE MALE SIDE IMPACT DUMMY 24 3 3 34 BOND ONE BORE TABLE OF CONTENTS Parts list for heat Disassembling Assembling Instrumentation mounting Neck Parts list for neci Disassembling Assembling Instrumentation mounting Thorax abdomen and shoulder Parts list Disassembling Instrumentation mounting Full arm Parts list Disassembling Assembling the arm Adjusting arm Changing full arm from left to right side impact Half arm Parts list for half arm Disassembling Assembling Pelvis Parts list for pelvis Disassembling Assembling the peh Instrumentation mounting Full leg assembly Parts list Disassembling Assembling the leg Adjusting the leg Suit assembly BBESNNSSSSBOONSSS SOON Ou GOM wnn 7 ois Parts list for suit Disassembly Assembly RECOMMENDED WORLDSID GENERAL PRACTICES Certification test intervals Recommended inspection practices WorldSID thorax half width Avoiding possible connector damage 118 Temperature range 119 Dummy handling 119 General 119 Procedures for using the Dummy storage ing bracket are as follows SUGGESTED WORLDSID WIRING PROCEDURES Head Wiring Neck Shoulder rib and 1 thorax rib 2 and 3 Thorax ribs and abdomen Pe
57. Torque Nm SHES M2 X04 1 SHES M25 X 0 45 1 SHES M XOT 4 35 SHES M5 x08 n SHES M6x1 14 124 SHSS hand and wrist pivot screw X 25 mm 3 27 BHCS X08 1 SHES 2 Modified BHCS pin W50 61042 10 89 BHCS 2 pivot screw Me X1 E 18 BHCS Elbow pivot screw M10 X TS a 27 FHCS M XOT 3 27 LwsHEs M3X05 3 27 LWsHcS 15 133 cPsss 0 5 1 cPsss M6 x1 7 62 SSCP M4 X 0 7 2 18 SSCP M6X1 7 62 SSFP M4 X 0 7 2 18 SSNT M3 x 0 5 1 SSNT M4 X 0 7 2 18 SSNT 2 pivot screw M6 X1 a 27 SSHOP Mex n Used for 1 t0 2 G setting Torque may vary with components Torques based on manufacturer s recommendation of 50 of yield strength 1 FASTENER ABBREVIATIONS Table B 1 gives a summary of fasteners abbreviations descriptions and ISO references for the convenience of users of this document Table B 1 Summary of fasteners abbreviations descriptions and ISO references Abbreviations Descriptions 150 references BHCS Button head cap screw 150 7380 Cheese screw Cheese head screw 150 1207 CPNT Cone point nylon tip set screw CPSs Cone point set screw 150 4027 558 Cone point socket set screw 150 4027 FHCS Flat head cap screw 150 10642 LHSHCS Low head socket head cap screw NTSS Nylon tip set screw SHCS Socket head cap screw 150 4762 SHSS Socket head shoulder screw 150
58. ables in front of the connector station and determine the final plug and connector positions 3 The following cable groupings are recommended Dummies with a pelvis DAS will be different DAS number 1 upper thorax 1 Upper neck load cell 6 channels 2 Lower neck load cell 6 channels 3 Shoulder load cell 3 channels Head rotational accelerometer x 126 10 11 12 Head rotational y Head rotational accelerometer 2 Head triax accelerometer T1 triax accelerometer 4 triax accelerometer Shoulder triax accelerometer Shoulder IR TRACC Thoracic rib 1 IR TRACC DAS number 2 lower thorax 10 11 12 13 Thorax rib 1 triax accelerometer Thorax rib 2 triax accelerometer Thorax rib 3 triax accelerometer Abdominal rib 1 triax accelerometer Abdominal rib 2 triax accelerometer Thorax rib 2 IR TRACC Thorax rib 3 IR TRACC Abdominal rib 1 IR TRACC Abdominal rib 2 IR TRACC T12 accelerometer Pelvis triax accelerometer Pubic load cell 1 channel Lumbar load cell 6 channels 127 NOTE Special care is needed when plugging in the sensor connectors to prevent pin damage A flash light is helpful for better visibility 4 Plug in the connectors along one side for the upper thorax station as shown in Figure3 6a and then the other side as shown in Figure 3 6b 5 Connect the DAS communication cable and secure the retaining bar shown in Figure 3 6b with an SHCS M1 6 6
59. al ground point Table 4 1 List of ground cables Cable number Part number Description Quantity 1 W50 75801 head to thorax 1 2 W50 75802 torso to sacrum 1 3 W50 75803 sacrum to pubic 1 4 W50 75804 sacrum to upper leg 2 5 W50 75805 upper leg to lower leg 2 6 W50 75806 torso to external ground 1 4 2 Grounding procedures The WorldSID dummy should be grounded as follows 1 Attach cable 1 to the right side rear mounting screw of the upper neck load cell as shown in Figure 4 1 142 Figure 4 1 Cable attachment to the upper neck load cell 2 Route cable one with the other cables around the neck and through the spine box as shown in Figure 4 2 Figure 4 2 Spine box cable routing 143 3 Attach the other end of cable 1 and one end of cable 2 to the spine box with a SHCS x 6 mm as shown in Figure 4 3 In addition attach one end of cable 6 not shown to this same screw Figure 4 3 Spine box cable attachment 4 Route cable 2 through the spine box as shown in Figure 4 4 144 Figure 4 4 Spine box cable attachment 5 Attach the other end of cable 2 to the front lumbar to sacrum attachment screw on the non struck side along with one end of cable 3 and one end of cable 4 as shown in Figure 4 5 145 Figure 4 5 Lumbar cable attachment 6 Attach the other end of cable to the top inner pubic load cell attachment b
60. alled buffers over one end of the neck Lubricate the surface of the half spherical screw with the Never Seez high pressure grease which is provided in the toolbox Attach the interface plate to the neck by tightening the half spherical screws to 10 Nm using the neck compression tool Repeat for the other end of the neck Place the upper neck bracket Figure 1 7 2 over the lower neck bracket Figure 1 7 Item 1 and engage the teeth in the desired orientation Insert the neck bracket nut Figure 1 7 Item 6 into the slot on one side and orient it so the hole in the nut lines up with the hole accessed from the back 13 of the lower neck bracket Insert the SHCS M6 x 50 Figure 1 7 Item 5 to secure the brackets together Repeat with the second neck bracket nut and SHCS on the other side Mount the neck load cell or its structural replacement Figure 1 7 Item 3 to the neck bracket with four SHCS M6 x 12 Figure 1 7 Item 7 Tighten the screws to 6 Nm Attach the neck assembly Figure 1 7 Item 4 to the neck bracket load cell assembly with four SHCS M6 x 12 Figure 1 7 Item 7 accessed from the bottom Tighten the screws to 6 Nm 1 2 4 Instrumentation mounting The neck assembly includes a lower neck load cell the upper neck load cell is considered part of the head assembly In addition a triaxial accelerometer can be mounted in a recess in the back of the lower neck bracket Install the triaxial accelerometer or its ma
61. and 1st thorax ribs 1 Lay the cables of the IR TRACCS and rib accelerometers as shown in Figure 3 3a 2 Group these four cables and bundle them together with tie wrap as shown by Item in Figure 3 3 3 4 2 and 3 Thorax ribs and abdomen ribs Second and 3 thorax ribs and abdomen ribs wiring should be installed as follows 123 Figure 3 4 Cable routing for IR TRACC and linear triax accelerometers of the 2nd 3rd thorax ribs and abdomen ribs 1 Layout the IR TRACC and rib accelerometer cables similar to the shoulder as shown in Figure e 3a 2 Route sensor cables of the 2nd and 3rd thorax ribs thorough the gap between 2nd and 3rd thorax ribs and bundle them as shown by Item 1 in Figure 3 4 3 Route the sensor cables of the 1st and 2nd abdomen ribs as shown by Item 2 in Figure 3 4 124 3 5 Pelvis cable routing Pelvis wiring should be installed as follows Figure 3 5 Pelvis cable routing 1 Tie the T12 and ground cable to the back of spine box as shown in Figure 3 5a 2 Route the pelvis cable as shown in the Figure 3 5b 3 6 Installation of sensor connectors to the thorax connector station Thorax connector station wiring should be installed as follows 125 Figure 3 6 Installations of sensor connectors to the thorax connector station 1 Route all cables from the head neck cables to the non impact side through the gap between the shoulder rib and 1 thorax rib 2 Sort all the c
62. and deflections of abdomen ribs 1 and 2 Table 7 22 Filter specifications for abdomen test Variable Fit Pendulum acceleration GI CFC 180 712 y axis acceleration G CFC 180 Abdomen rib 1 deflection mm CFC Abdomen rib 2 deflection mm CFC 7 3 6 1 6 Test reports Document the results of the abdomen test 7 4 Lumbar spine and pel 7 4 1 General description The lumbar spine and pelvis assembly shall consist of the components and assemblies listed in lumbar spine and pelvis assembly drawing W50 40000 pdt When assembled according to Section 1 and tested using the procedure specified in 7 3 2 and 7 6 3 the pelvis assembly shall meet the specifications given in Table 7 23 179 Table 7 23 WorldSID pelvis certi ication specifications Variat Absolute value Peak acceleration along y axis IG 411051 Peak pelvis pendulum force kN 63107 8 Peak T12 acceleration along y axis G 101014 7 4 3 Pelvis certification test procedure 7 4 8 1 Principle Perform a test involving a lateral impact to the pelvis in order to certify the dynamic response of the pelvis 7 4 3 2 Apparatus Use 49 CFR Part 572 subpart E Hybrid 50 percentile adult male dummy pendulum 23 4 kg 152 4 mm face diameter 7 4 3 3 Sensors Install instrumentation to obtain data for the items given in Table 7 24 Table 7 24 Sensor specifications for
63. ble 7 12 Calculate the pendulum impactor force by multiplying the pendulum acceleration time history by the measured impactor mass Graph the time histories of impactor force and shoulder deflection Table 7 12 Filter specifications for shoulder test Filter CFC 180 Shoulder deflection mm 600 7 3 3 1 6 Test reports Document the results of the test 171 7 3 4 Thorax with half arm When assembled according to Section 1 and tested using the procedure specified in 7 3 2 and 7 3 4 1 the thorax with half arm assembly shall meet the specifications given in Table 7 13 Table 7 13 WorldSID thorax with half arm certi Variable Absolute value Peak pendulum force kN 41164 Peak T4 acceleration along y axis G 241033 Peak T12 acceleration along y axis GI 20 16 28 Peak thorax rib 1 deflection imm 351047 Peak thorax rib 2 deflection imm 42157 Peak thorax rib 3 deflection imm 40154 7 3 4 1 Thorax with half arm certification procedures 7 3 4 1 1 Principle Perform a test involving a lateral impact to the thorax with the half arm order to certify the dynamic response of the thorax 7 3 4 1 2 Apparatus Use 49 CFR Part 572 subpart E Hybrid 50 percentile adult male dummy pendulum 23 4 kg 152 4 mm face diameter 7 3 4 1 3 Sensors Install instrumentation in order to obtain data for the items given in Table 7 14 172 Table 7
64. bly 3 linear triaxial accelerometer Rib accelerometer mounting bracket D Rib clamping bracket Bsucs 1 19 IR TRACC rib mount screw SPONSOR Reference drawing 50 30000 G3 Inner band thorax rib Figure 1 31 WorldSID rib instrument 1 3 4 2 Spine box instrumentation The spine box includes mounting positions for two G5 DAS modules one of which is shown in Figure 1 32 Note that for both of these an interposer connector see Figure 1 33 is attached to the mounting brackets and the DAS module is plugged into this connector The connector for each DAS see Figure 1 34 which is linked to the interposer connector is secured to a bracket mounted to the spine box The arrangement of the DAS and connectors is shown in Figure 1 35 Note that for the lower G5 module 42 the connector is mounted adjacent to the module so the module plugs in directly to the connector and no interposer is used Figure 1 33 Interposer connector Figure 1 34 DAS connector 43 Figure 1 35 Arrangement of DAS interposer connector and connector Other instrumentation in the spine box includes a linear triaxial accelerometer mounted directly to the spine box near the top and that a second linear triaxial accelerometer is mounted to a bracket attached to the spine box near the location of the T12 thoracic vertebra An angular accelerometer assembly which includes rotational accelerometers to meas
65. cket in place by four SHCS M2 5 x 0 45 x 8 mm Figure 1 40 Item 18 and one SHCS M3 x 0 5 x 12 mm Figure 1 40 Item 8 Hold the 7268C triaxial linear accelerometer in position using a SHCS M2 x 0 4 x 18 mm Figure 1 40 Item 15 To begin disassembly after disconnecting all cables remove the modified BHCS Figure 1 40 Item 2 that secure the elbow clevis Figure 1 40 Item 1 and arm load cell Figure 1 40 Item 3 and separate these two components Remove the modified BHCS screws that attach the arm load cell and the wrist assembly pull the two sections apart 14 2 5 Disassembling wrist The wrist assembly W50 61035 is shown in Figure 1 41 57 To remove the wrist pivot and clevis assemblies take out the BHCS 6 X 1 x 16 mm Figure 1 41 Item 10 that holds the wrist pivot assembly in the wrist assembly Remove the wrist washer Figure 1 41 Item 8 and the spring washer Figure 1 41 Item 9 These two washers are the same as the parts in the upper arm assembly Figure 1 38 Items 4 and 5 Loosen the SSNT M6 in the wrist assembly Figure 1 41 Item 4 and pull the wrist pivot assembly Figure 1 41 Item 2 from the wrist assembly Take out the SHSS M6 x 25 mm Figure 1 41 Item 12 and the rubber washer Figure 1 41 Item 9 Separate the wrist pivot and wrist clevis assemblies Figure 1 41 Items 2 and 1 respectively Inspect the rubber bumpers W50 61038 on the wrist clevis to ensure there is no damage to the material and t
66. croiliac load cell or its mass replacement Figure 1 51 Item 24 using four SHCS M6 x 30 Figure 1 51 Item 34 The connectors are at the bottom of the load cells and face the front of the dummy Install the interposer or its mass replacement Figure 1 51 Item 2 to the pelvis docking station Figure 1 51 Item 4 with four SHCS M2 x 10 Figure 1 51 Item 41 Secure the docking station to the bottom of the sacroiliac load cell with four FHCS M3 x 10 Figure 1 51 Item 36 Slide the DAS unit Figure 1 51 Item 3 into the docking station and connect it to the interposer Install the DAS cover Figure 1 51 Item 23 with two BHCS M6 x 16 Figure 1 51 Item 35 Secure the connector or its mass replacement Figure 1 51 Item 7 to the front of the sacroiliac load cell with three SHCS M3 x 8 Figure 1 51 Item 42 Mount the linear triaxial accelerometer Figure 1 51 Item 20 to the pelvis instrumentation bracket Figure 1 51 Item 21 using a cheese screw M2 x 16 Figure 1 51 Item 48 accessed from the back Attach the dual axis tilt sensor Figure 1 51 Item 18 with an SHCS M4 x 8 Figure 1 51 Item 37 accessed from the top Secure the pelvis instrumentation bracket Figure 1 51 Item 21 to the sacroiliac load cell or its structural replacement Figure 1 51 Item 24 with three SHCS M4 x 14 Figure 1 51 Item 38 Mount the pelvis instrumentation cover plate Figure 1 51 Item 19 with four cheese screws M3 x 6 Figure 1 51 Item 39 Ensure tha
67. cular to the upper arm Tighten the elbow pivot screw see Figure 1 47 so that the lower arm remains parallel to the floor until a downward force of about 1 to 2 G is applied 65 Figure 1 47 Elbow adjustment If tightening the elbow pivot screw does not provide enough friction to maintain the 1 2 G adjustment inspect the joint to ensure that it is properly assembled Note that the locking screw see Figure 1 48 must be installed that it secures the elbow pivot shaft assembly to the elbow assembly and the locking hole in the elbow pivot shaft assembly must be aligned with the locking screw Inspect the three washers used with the elbow pivot screw The washers must be installed in the order shown in Figure 1 48 and the friction washer must have the friction material toward the elbow clevis assembly Check the compression washer neoprene material for deformation or other damage and replace as necessary 66 Cu Friction Washer Shatt Assembly Btw A ee j 9 Locking hole 6 0m ssor 79 oching serew igure 1 48 Elbow fri adjustment 1 4 4 6 Adjusting the wrist and hand pivot rotations Note the following The wrist adjustments are not easily done due to the lack of mass of the components This joint is adjusted to approximate a 1 to 2 G setting Rotate the hand and tighten the modified SHSS M6 x 25 mm until there is an appropriate fricti
68. curing the pivot shaft instead of the one SSFT M6 x 10 in the load cell structural replacement 1 3 2 3 Thorax and abdomen Remove the thorax pad Figure 1 15 Item 36 by removing it from the Velcro that holds them in place Remove the shoulder pads Figure 1 15 Items 27 and 28 by lifting them off of the dummy Remove the lower neck bracket from the spine box by removing four SHCS M6 x 16 Figure 1 15 Item 37 Remove the shoulder rib mounting brackets Figure 1 15 Item 14 Detach the shoulder rib IR TRACC Figure 1 15 Item 2 from the shoulder rib mounting bracket by removing the IR TRACC rib mount screw Figure 1 15 Item 21 accessed from the bottom of the shoulder rib mounting bracket Remove the linear triaxial accelerometer Figure 1 15 Item 16 from the shoulder rib mounting bracket by removing the cheese screw M2 x 16 Figure 1 15 Item 38 Detach the shoulder IR TRACC assembly from the spine box by removing the BHCS M2 5 x 10 Figure 1 15 Item 32 As shown in Figure 1 19 disconnect the shoulder rib Figure 1 15 Item 17 at the front by removing the two BHCS M5 x 10 Figure 1 15 Item 10 that attach the left and right shoulder ribs to the sternum thorax rib Figure 1 15 Item 3 Removing a shoulder rib sternum mounting strip Figure 1 15 Item 7 and a threaded shoulder rib sternum mounting strip Figure 1 15 Item 18 which are removed from each side 24 Figure 1 19 Detaching shoulder rib at front fr
69. ded with the test data Ifa different temperature sensor and recording method is used it is recommended that the internal chest cavity air temperature be measured and monitored during the test 152 Section 6 6 RECOMMENDED WORLDSID SEATING PROCEDURE 6 1 Placement procedures for the driver seat position 6 1 1 General The WorldSID should be positioned following the IIHS UMTRI seating procedure Guidelines may be downloaded from http www highwaysafety org vehicle ratings tech info htm 6 1 2 Electronic spreadsheets Accompanying templates for position calculations may be downloaded from http www highwaysafety org vehicle_ratings tech_info htm 6 2 Placement procedures for the rear seat posi 6 2 1 ATD preparation Adjust the dummy as recommended in Section 1 This adjustment should include joint placement like the neck bracket and joint torque specifications for the arms and legs 6 2 2 Position the seat If the seat position is adjustable on a track in the fore aft direction place the seat in the rearmost locking position 6 2 3 Dummy placement 6 2 3 1 Install the dummy into the vehicle such that the midsagittal plane is vertical and coincident with the seat centreline The buttocks and torso should be in contact with the seat back 6 2 3 2 Adjust the knee position such that the distance between the knees is 330 mm measured at the knee centrelines Alternatively the knee separation distance can be measured from
70. den Start Record and Trigger buttons This can be done from within TDAS CONTROL the Advanced window accessible by Edit TDAS INI or by editing your tdas i i file directly and changing the two entries below ves C After these changes made every test performed Power Mode Enable Software mrigger stert Record D wo 1 be armed using Low D 2 SUPPORT EQUIPMENT E 1 Specialized WorldSID support equipment Specialized WorldSID support equipment needed for WorldSID assembly handling or certification testing consists of the items given in Table E 1 Table E 1 Specialized WorldSID support equipment Reference Description Use Part number 5 1 Head drop tool Certification W50 82100 52 Head form Certification w50 83000 5 1 Head sensor extension cables for head drop test Certification Custom 5 2 Head form rotational potentiometers quantity of three Certification 5 2 Carbon rods for potentiometers Certification F GL 5 2 Circular section neck buffers with different hardness Certification WS0 20006 5 2 Neck and head form sensor extension cables for neck Certification Custom Won tool Test set up WS0 82500 5 3 Tellon covered dummy certification test bench Certification W50 82200 5 3 Smal Teflon sheets for the seat and back Certification w
71. dy and then connect the potentiometer to the data acquisition system to be used for testing Loosen the two BHCS M3 Figure 1 39 Item 1 securing it to the elbow clevis and rotate the potentiometer body until O volts output is achieved If there is not sufficient angular displacement available to achieve O volts remove the two BHCS M3 and their associated washers then lift the potentiometer assembly out of the elbow shaft Rotate the potentiometer insert see Figure 1 43 90 replace the unit on the elbow clevis and check the output again Bod Insert d meter wiring 60 1 4 3 4 Assembling lower arm Attach the arm load cell Figure 1 40 Item 3 or structural replacement to the elbow clevis assembly Figure 1 40 Item 1 using four modified BHCS M6 torque to 10 Nm The wrist assembly is attached to the arm load cell using four modified BHCS M6 Figure 1 40 Item 2 torqued to 10 Nm 1 4 3 5 Assembling wrist Inspect the hand bumpers W50 61048 If they are loose or missing reinstall using Loctite 414 Super Glue or equivalent cyanoacrylate based adhesive The wrist assembly see Figure 1 41 has the same type of joint as the upper arm Z pivot Re assemble the wrist assembly by installing the wrist pivot Figure 1 41 Item 2 into the lower arm tube Figure 1 41 Item 3 and then aligning the wrist washer Figure 1 41 Item 8 on to the M1 5 pins After the wrist washer is installed insert the spring washer F
72. e movement along the z axis at the load cell while allowing for free rotation about the z axis Adjust the set screw M6 in the ankle assembly such that there is consistent stiffness in the joint to approximate 1 to 2 G setting as the foot is rotated about the lower leg 113 Load Cel N xB mms 7 Mo x6 mms 7 anite Figure 1 89 Ankle adjustment 1 8 Suit assembly 1 8 1 Parts list for suit The part number for the WorldSID suit is W50 80100 1 8 2 Disassembly Unzip all suit zippers and carefully remove the suit by reversing the assembly procedures 1 8 3 Assembly Install the dummy lifting bracket and lift the dummy with a hoist Open all the zippers on the suit including the front and rear of the thorax and both legs If working with a full arm set the full arm sleeves aside at this point Insert the arms through the short sleeves and close the zipper on the rear side of the dummy Straighten the legs pull the suit tight around the legs 114 and close both leg zippers Make sure the shoulder pads are in the proper position and zip the front thorax zipper half way Note the front thorax zipper cannot be fully zipped due to the lifting bracket Install full arm sleeves if needed Move the dummy to the bench or inside the vehicle remove the lifting bracket by removing the M8 bolt on the top and M12 bolt on the bottom and then close the front thorax zipper 115 SECTION 2 2 R
73. e C 1 WorldSID G5 DAS system diagram Figure Dummy exit to TDAS status box cable 2B 19 lemo connector wiring side view pins c8 xii Table 1 Table 1 Table 1 Table 1 Table 1 Table 14 Table 1 Table 1 Table 1 9 Parts list for elbow Table 1 10 Parts for lower arm Table 1 11 Parts list for wrist Table 1 12 Parts list for WorldSID Table 1 13 Parts list for WorldSID pelvis Table 1 14 Parts list for femoral neck W50 51034 Table 1 1 Table 1 Table 1 Table 1 Table 1 Table 2 Table 4 3 Parts list for the WorldSID thorax abdomen and shoulder 4 Parts list for shoulder assembly 5 Parts list for WorldSID spine box 8 Parts for upper arm 17 Parts list for lower leg tube LIST OF TABLES 1 Parts list for WorldSID head 2 Parts list for WorldSID neck 6 Parts list for full arm 7 Parts list for shoulder arm 5 Parts for upper leg 16 Parts list for knee 18 Parts list for ankle foot 19 Parts list for ankle 1 Parts list for lifting bracket assembly 1 List of ground cables xiii Table 5 1 Effect of internal and external DAS on WorldSID temperature Table 7 1 WorldSID head certification specifications Table 7 2 WorldSID neck certification specification
74. e left ide plate Figure 1 17 Item 4 As shown in Figure 1 24 the six IR TRACC ball joint assemblies Figure 1 17 Item 14 are secured to the struck side plate each with four FHCS M2 5 x 6 Figure 1 17 Item 13 31 Figure 1 24 IR TRACC ball joint assemblies mounted to the struck side plate of the spine box 1 3 3 Assembling 1 3 3 1 Assembling thorax and abdomen Figure 1 25 shows the color coding scheme for the WorldSID ribs and that the shoulder rib is grey the first thoracic rib is red and the remaining ribs thorax number two and three both abdominal are white jure 1 15 Item 13 have a thicker layer of damping material than the inner bands of the thoracic ribs Figure 1 15 12 and that the inner band of the shoulder rib Figure 1 15 Item 11 is different from the other inner bands Note that the inner bands of the two abdominal ribs 32 Figure 1 25 Shoulder ri second and ti is grey the first thoracic rib is red and the d thoracic ribs and abdominal ribs are white Begin assembly of the thorax by attaching the battery mounting bracket Figure 1 15 Item 29 with two SHCS M5 x 30 Figure 1 15 Item 30 that secure it to the spine box on the non struck side Attach the battery mass replacement Figure 1 15 Item 31 with two SHCS M5 x 18 Figure 1 15 Item 34 Begin assembly of the ribs from the bottom Attach the lower abdominal rib Figure 1 15 Item 4 to the spine box a
75. e plate left WorlaSID 1 wsostozo s sucsmsxosxio 7 5000119 6 Spacer WordSID wso s1041 7 T2 accelerometer mount WorldSID 1 weo 37024 Side plate right WorldSIO wso s1030 SHCS M3 x 0 5 x8 5000388 10 Connector housing mass replacement 2 W50 75002 20 Description Part number numb 11 Backup plate mounting bracket 2 ws0 37022 12 x10 4 5000151 1 x 0 45 x6 24 5000202 14 Ball joint assembly IRTRACC wsostoso 15 FHCS Mx 1 x10 18 5000204 16 Accelerometer linear triaxial 2 Endeveo 7268C 2000M1 17 sues M2 x 0 4 x 12 0 12 9 alloy steel 5000382 18 Cheese screw M2 x 16 2 5000254 19 x18 a 5000465 20 Rotational accelerometeritit sensor mount bracket 1 W50 37023 21 Mounting bracket 2 2 Wso 31043 22 G5 mass replacement a ws0 74307 23 Cover plate spine box 2 ws0 s1085 24 Accelerometer rotational 2 Endeveo 730284 25 SHCS M4 x25 8 5000461 26 Bracket rotational accelerometer mount 1 wsoazozs 27 Ti sensor dual axi ref 1 See dummy manufacturer information 28 FHCSM3x0 5x10 2 5000203 29 SHCSM4x0 7 x8 1 5000024 30 Pin dowel M4 x 14 2 5000053 Not shown Linear accelerometer mass replacement 2 ws0 61063 Not shown Rotational accelerometer mass replacement 2 ws0 10010 Not shown
76. egrees 1 degree 6 2 3 11 Rear seats with non adjustable seat backs 6 2 3 12 Hold the ATD s thighs down and push rearward on the upper torso to maximize the ATD s pelvic angle 6 2 3 13 Gently rock the upper torso relative to the lower torso laterally in a side to side motion three times through a 5 degree arc approximately 50 mm side to side to reduce friction between the ATD and the seat 154 6 2 3 14 Reposition feet if necessary 6 2 3 15 Rotate the arms to 45 degrees 6 2 3 16 If applicable place the adjustable head restraint such that the vertical centerline of the head restraint is aligned with the c g of the dummy head 7 Mechanical Requirements and Certification Test Procedures for WorldSID 7 1 Head 7 1 1 General descri The head assembly shall consist of the components and assemblies listed in head assembly drawing W50 10000 pdf 7 1 2 Certification specification When assembled according to Section 1 and tested using the procedure specified in 7 1 3 the head assembly shall meet the specifications given in Table 7 1 Table 7 1 WorldSID head certification specifications Frontal drop Variable Absolute value Peak resultant acceleration G 225 to 275 Peak lateral acceleration aj lt 15 Maximum percentage subsequent to main peak lt 10 Lateral drop Variable Absolute value Peak resultant acceleration at CG GI 9919 121 Peak longitudinal acceleration a
77. endent upon the location of the sensor and the location of the G5 ca used to record the sensor data Cable lengths for example G5 and sensor system are shown in Table Table C 3 Example instrumentation cable lengths Position No of Length pas ory Partnumber channels mm inches location Head accelerometer a 30 2 Upper spine 1 W50 71164 767 Head rotation accelerometer 1 750129 Upper spine 3 W50 71165 750 Upper neck 6 692127 2 Upper spine 1 ws0 71982 692 Lower neck s 3140124 Mid spine 1 ws0 71981 314 Thorax accelerometer 5530218 spine 1 _ w50 71164 553 Thorax rotation accelerometer 1 23419 2 Midspine 1 ws0 71165 234 T1 accelerometer a 416164 Mid spine 1 ws0 71164 416 accelerometer a 326128 Mid spine 1 w50 71164 326 Rib accelerometers a 3940155 Midspine 6 W5o 71164 394 T12 accelerometer a spine 1 ws0 71164 947 Pelvis accelerometer a sezuso Pelvis 1 ws0 71164 382 IR TRACC shoulder 280110 Upper spine 1 ws0 74411 IR TRACC thorax 1 280 11 0 Mid spine W5o 24411 IR TRACC abdominal 1 Mid spine 2 2441 Sacroiliac amp L e 290 11 4 Pelvis 2 ws0 71983 20 Lumbar 4750187 Mid spine 1 wso 71983475 Lumbar swuzs Pelvis 1 ws0 71983 318 Pubic 1 ason Pelvis 1 ws0
78. ension points Figure 1 45 shows the feasible rotations at each joint Perform the following procedures while the arm is attached to the dummy 1 44 2 Adjusting the shoulder x axis pivot Note the following The shoulder clevis pivots about the x axis on the shoulder pivot shaft Figure 1 16 Item 2 The full arm assembly should be able to support itself in the horizontal position parallel to the floor and perpendicular to the A light force 1 to 2 G applied to the hand should move the arm assembly to the at rest position against the upper torso 63 Adjust the shoulder assembly movement by tightening the M6 hex locking nut Figure 1 16 Item 5 until the arm almost stays fixed when raised to the side horizontally parallel to floor perpendicular to torso side Make the final 1 to 2 G setting by means of the two SSNT M4 x 0 7 x 4 mm Figure 1 16 Item 6 1 4 4 3 Adjusting the arm z axis pivot rotation Ensure that the upper arm z axis pivot is properly assembled prior to undertaking the adjustment procedure Note that the spring washer Figure 1 38 Item 5 in the z axis pivot joint can cause some variability from assembly to assembly Extend the complete arm laterally until it is parallel to the floor Tighten the shoulder arm joint until the arm is locked in this position Bend the arm at the elbow so that the lower arm is perpendicular to the upper but still parallel to the floor If the z axis pivot is pr
79. er Endevco 72316 750 EBF Neck compression wrench Assembly E 2 Annex DRAWING LIST This annex lists the WorldSID drawings in Table F 1 and fasteners in Table F 2 for the convenience of users Table F 1 WorldSID drawing list Drawing number Description Electronic fi format PoF sre wso oooo0 WorldSID ATD xc wso 10000 Head assembly tested and certified x jwso 10007 Head core x wso 1oo1o Rotational accelerometer replacement Endevco 73028M4 wso 10011 Tilt sensor mass replacement x wso 14014 Head moulded tested and certified xs e lws0 20000 Neck assembly x lws0 20002 Neck head torso interface plate x lws0 20006 Neck buffer assembly x lws0 20007 Screw half spherical x 20009 Lower neck bracket wso 20010 Upper neck bracket x wso 20011 Nut neck bracket x wso 20016 Flexion extension buffer x wso 2oo18 Shortened 6 mm hex x 21001 Neck assembly tested and certified x 22003 Neck moulded x x ws0 24013 Neck shroud assembly x wso zao14 Neck shroud ring aa Pe lws0 24015 Neck shroud x lws0 30000 Torso shoulder thorax abdomen WorldSID w50 31000 Spine box assembly x FA Drawing number Description Electronic file format Por sre wso atoto Upper bracket weldment spine box WorldSID 31011 Shoulder mounting plate 31012 Middle plate wso ato
80. er leg assembly Table 1 15 lists the parts required for assembling the WorldSID upper leg which is illustrated in Figure 1 74 Table 1 15 Parts for upper leg Item number Description Quantity Part number 1 LWSHCS M6 x 1 0 x 12 mm 4 5000194 2 Femoral neck assembly 1 ws0 s1034 3 Femoral neck load cell optional 1 ws0 71080 not shown Femoral neck load call structural replacement wso 71965 4 DAS mass replacement assembly W5O 51053 5 Modified BHCS 12 ws0 61042 Knee assembly right 1 not shown Knee assembly left 1 wsoszors 7 Leg tube assembly 1 ws0 51068 8 Leg load cell optional 1 ws0 71010 not shown Leg load structural replacement 1 ws0 s1060 E Trochanter assembly right 1 wsoss1022 not shown Trochanter assembly left 1 wsosrozs 10 BHCS M6 x 1 0 x 16 mm 4 5000072 92 Figure 1 74 Upper leg assembly 1 7 1 4 Parts list for knee assembly Table 1 16 lists the parts required for assembling the WorldSID knee which is illustrated in Figure 1 75 Table 1 16 Parts list for knee Item number Description Quantity Part number 1 SHCS M4 x 0 7 x 10 mm 16 5000151 2 Knee cover 2 ws0 62004 3 Knee contact load cell structural replacement 2 50 52015 Not shown Knee contact load cell optional 2 5071020 4 Rotary potentiometer optional 1 ws0 61
81. eration G CFC 180 Peak y axis acceleration G 180 Peak T12 y axis acceleration G 180 Peak thorax rib 1 deflection mm 600 Peak thorax rib 2 deflection mm 600 Peak thorax rib 3 deflection mm CFC 600 7 3 4 1 6 Test reports Document the results of the test 7 3 5 Thorax without arm When assembled according to Section 1 and tested using the procedure specified in 7 3 2 and 7 3 5 1 the thorax without arm assembly shall meet the specifications given in Table 7 16 Table 7 16 WorldSID thorax without arm certi Variable Absolute value Peak pendulum force kN 32039 Peak acceleration along y axis GI 121017 Peak T12 acceleration along y axis G 151921 Peak thorax rib 1 deflection imm 34 to 43 Peak thorax rib 2 deflection imml 34 to 43 Peak thorax rib 3 deflection imml 34 to 43 7 3 5 1 Thorax without arm certification procedures 7 3 5 1 1 Principle Perform a test involving a lateral impact to the thorax without the arm order to certify the dynamic response of the thorax 174 7 3 5 1 2 Apparatus Use 49 CFR Part 572 subpart E Hybrid Ill 50 percentile adult male dummy pendulum 23 4 kg 152 4 mm face diameter 7 3 5 1 3 Sensors Install instrumentation to obtain data for the items given in Table 7 17 Table 7 17 Sensor specifications for thorax without arm test acceleration Endevco 726
82. ersal wso 75801 Head to thorax x 75802 Torso to sacrum x 75803 Sacrum to pubic x 75804 Sacrum to upper leg x wso 75805 Upper leg to lower leg x wso 75806 Torso to external ground x lws0 801001 WorldSID suit x wsosoroo 2 wonasio suit x wsosoroo Wondsib sui x wsosoroo 4 WortdSID sui x fws0 82100 Head drop bracket assembly WorldSID x wso a2101 Base plate x wso a2102 Joint bracket x wso a2103 Head drop bracket x wso a2104 Joint bracket top x lws0 82105 Plate magnet x wso a2200 WorldSID bench x wso a2245 Teflon sheet x wso a2246 Teflon sheet wso a2500 Hcpoint tool x wso a2601 tool plate x lws0 82502 Hcpoint tool rod lws0 82600 C wrench x ws0 82601 C wrench head x Drawing number Description Electronic file format PoF sre lws0 82602 C wrench handle x Headform assembly WorldSID x wso estor Centre plate x wso 83102 Disc A WorldSID headform x wso e103 Disc B WorldSID headform x lwso 8a104 Upper neck interface plate x wso aa201 Lower neck interface plate x lws0 83202 Shaft x lws0 83205 Shaft coupling Xx wso sa206 Mounting base 8207 Potentiometer mounting bracket x lws0 84100 Lifting bracket assembly WorldSID x wso sato4 Handle threaded hole x lws0 84106 Handle threaded rod x lws0 84110 Lifting bracket weldment x
83. ertification test procedure Annex A FASTENER TORQUE VALUES Annex B FASTENER ABBREVIATIONS Annex C OVERVIEW OF AN EXAMPLE INTERNAL DATA ACQUISITION SYSTEM C 1 General C 2 System components G5 module G5 docking station c5 C6 C 7 In dummy battery and cable C 8 G5 DB to battery and temperature sensor cable C 9 G5 DB to dummy exit cable C 10 Dummy exit to TDAS status box cable C 11 TDAS status C 12 DC DC converter C 13 AC DC converter 14 TDAS power supply C 15 TDAS software C 16 Status box to PC cable C 17 Notebook PC C 18 Dummy exit to status box cable pinout C 19 Sensor cable length Annex D OPTIONAL DTS G5 DAS LOW POWER MODE HEAT BUILDUP MITIGATION D 1 General D 2 What is Low Power Mode D 3 to Implement Lower Power Mode 0 3 1 Update your tdas ini fil D 4 Enable Software Triggering and Low Power Mode Annex E SUPPORT EQUIPMENT E 1 Specialized WorldSID support equipment E 2 Other support equipment typically available in test laboratories Annex F DRAWING LIST LIST OF FIGURES Figure 1 1 WorldSID head components Figure 1 2 Removal of moulded head Figure 1 3 Separa ig the head core from the neck strumented head core Figure 1 4 Removing upper neck load cell from i Figure 1 5 Wire routing for head instrumentatio Figure 1 6
84. es the software ARM signal and it continues to collect data until a hard wired Start Record input is received Once received the system will collect data until the test time expires Low Power Recorder Mode is a little different When the system receives the software ARM signal it readies for data collection but does not actually start collecting data Instead the system goes to sleep it shuts off excitation to all sensors and waits until it receives a hard wired or software driven Start Record signal When it does the TDAS G5 DAS wakes up turns on all excitation circuits quickly powering up the sensors and begins to collect data The delay between the Start Record request and the start of data collection is 100 milliseconds The system acknowledges that it is now collecting data visible via the status box lights and will continue to do until the test time expires Currently the user is not able to change the delay time between the Start Record request and the start of data collection D 1 D 3 How to Implement Lower Power Mode 0 3 1 Update your tdas ini file This can be done by changing the Default Data Collection Mode to Recorder from within TDAS CONTROL either Edit TDAS INI or Setup gt Options windows ile directly and changing the entry below Collesticn node OIRCULAR EUPFERC RECORDERS MULTIPLE D 4 Enable Software Triggering and Low Power Mode This will enable the hid
85. eter mass replacement 1 wso e1oes 17 Accelerometer mount bracket 1 ws0 61039 18 SHCS M2 5 x 0 45 x 8 mm 4 5000458 Not shown Triaxial linear accelerometer Endevco 7268c 2000M1 ES Qi SS wea V hs 9 d Figure 1 40 Lower arm exploded 1 4 1 6 Parts list for wrist Table 1 11 lists the parts required for assembling the WorldSID wrist which is illustrated in Figure 1 41 52 Table 1 11 Parts list for wrist Item number Description Quantity Part number 1 Wrist clevis 1 W50 61033 2 Wrist pivot assembly 1 W50 61020 3 Lower arm tube assembly 1 W50 61036 4 SSNT M6 x 1 0 x 6 mm 1 5000621 5 SHCS M2 x 0 4 x 18 mm 1 5000164 6 Wrist accelerometer mount 1 W50 61039 7 SHCS M2 5 x 0 45 x 8 mm 4 5000458 8 Wrist washer 1 W50 61019 9 Spring washer 2 wso 61022 10 BHCS M6 x 1 x 16 mm 1 5000072 11 SHCS M3 x 0 5 x 12 mm 1 5000173 12 SHSS M6 x 25 mm 1 5000163 53 D bo a 5 Figure 1 41 Wi 1 4 2 Disassembling 1 4 2 1 Full arm To remove the arm assembly from the shoulder assembly loosen the two friction adjustment set screws SSFP M4 x 0 7 x 6 mm Figure 1 37 Item 5 in the shoulder bumper Figure 1 37 Item 4 Unthread the shoulder bumper from the shoulder clevis Remove the SSNT M3 x 0 5 x mm on the top of the Z pivot assembly Separate the arm assembly from the shoulder assembly Remove the hand a
86. exceed 2 mm The rib doubler to rib joint should be inspected on a regular basis and after high energy impacts to determine if there has been any separation of the doubler from the rib Flesh components should be inspected for tears Sensor and DAS cables should be inspected for cuts and excessive wear Joint tension should be checked and adjusted as described in Section 1 Sensor and DAS functions should be verified prior to each test 2 8 WorldSID thorax half width When calculating thorax injury indices a WorldSID thorax half width of 170 mm should be used 24 Aw g possible connector damage When using the optional G5 DAS each WorldSID sensor cable has a connector with exposed pins which can be damaged during installation removal or handling To prevent damage the user should consider the following preventative measures 117 1 Use extreme care when the connectors are installed handled or routed in the dummy 2 Install available connector covers any time the pins are exposed removing them only immediately before plugging the connector into the interposer 2 8 Temperature range The WorldSID dummy temperature when measured by the optional internal temperature sensor should be 20 6 degrees C to 22 2 degrees The test environment temperature should be 20 6 degrees C to 22 2 degrees 2 6 Dummy handling 2 6 1 General A lifting bracket assembly and fasteners part number W50 84100 as s
87. f the elbow shaft assembly Figure 1 36 Item 2 Remove the BHCS M10 x 1 5 x 20 mm Figure 1 36 Item 13 from the elbow shaft assembly along with the three joint friction adjustment washers Figure 1 36 Item 14 15 and 16 Remove the SSHDP M6 x 1 0 x 6 mm Figure 1 36 Item 23 securing the elbow shaft assembly in the elbow joint and slide the elbow shaft assembly out of the elbow and separate the upper and lower arm assemblies 1 4 2 2 Disassembling upper arm Disconnect the cables to the arm and elbow load cells and remove the accelerometer To remove the elbow load cell Figure 1 38 Item 11 take out the four modified BHCS Figure 1 38 Item 3 that attach it to the upper arm 55 extension tube Figure 1 38 Item 8 The elbow load cell also contains the mounting position for the triaxial linear accelerometer Note that the accelerometer is held in place using a SHCS M2 x 0 4 x 18 mm Figure 1 38 Item 9 on the rear side of the load cell Remove all the modified BHCS s and separate the arm load cell Figure 1 38 Item 7 from the arm extension tube Figure 1 38 Item 8 and the upper arm tube assembly Figure 1 38 Item 2 from the arm load cell To remove the Z pivot Figure 1 38 Item 1 loosen the SSNT M6 x O x 6 mm friction adjustment screw Figure 1 37 Item 9 and take out the BHCS M6 x 1 x 16 mm Figure 1 38 Item 6 and the spring washer Figure 1 38 Item 5 and wrist washer Figure 1 38 Item 4 Pull the pivot out
88. gure 1 17 Item 4 or Item 8 using seven FHCS M6 x 10 Figure 1 17 Item 15 Attach the upper spine box bracket weldment Figure 1 17 Item 2 to the struck side plate with three more FHCS M6 x 10 Figure 1 17 Item 15 As shown in Figure 1 30 attach the lower G5 module or its mass replacement Table 1 5 Item 22 to the spine box with four SHCS M4 x 25 Figure 1 17 Item 25 Attach each backup plate mounting bracket Figure 1 17 Item 11 to the spine box with two M4 x 14 pin dowels 38 Figure 1 17 Item 30 Connect each interposer its mass replacement Figure 1 17 Item 22 to the mounting brackets Number 1 Figure 1 17 Item 1 and Number 2 Figure 1 17 Item 21 with four SHCS M2 x 12 Figure 1 17 Item 17 Secure the mounting brackets interposers to the spine box with four SHCS x 25 Figure 1 17 Item 25 Slide the G5 modules or their mass replacements Figure 1 17 Item 22 into the mounting brackets and connect them to the interposers Attach the spine box cover plate Figure 1 17 Item 23 to the back of each G5 module or its mass replacement with two BHCS M6 x 18 Figure 1 17 Item 19 Attach each connector housing or its mass replacement Figure 1 17 Item 10 to its backup plate mounting bracket Figure 1 17 Item 11 with three SHCS M3 x 8 Figure 1 17 Item 9 Next assemble the angular accelerometer assembly Figure 1 17 Item 24 Attach the z axis angular accelerometer to the bottom of the bracket with two FHCS
89. hat they are securely fixed in position If the bumpers should come loose or fall off re glue with Loctite 414 Super Glue or equivalent cyanoacrylate based adhesive 1 4 3 Assembling the arm 1 4 3 1 General In general the procedure for assembling the arm is substantially the opposite of the procedure for disassembling it The following descriptions are provided to assist the user to more efficiently assemble the WorldSID arm 14 3 2 Assembling the upper arm To assemble the arm to the upper torso install the arm on the shoulder load cell clevis Push the arm onto the shoulder clevis Figure 1 37 Item 2 until it fully contacts the clevis face Thread the shoulder bumper Figure 1 37 Item 4 onto the shoulder clevis Thread the bumper as coarse adjustment for the arm s 1 to 2 g setting Tighten the SSNT M3 x 0 5 x 3 mm Figure 1 37 Item 3 to fine adjust 58 that inside the upper arm tube there are three components that involved in the adjustment of Z pivot joint the wrist washer Figure 1 38 Item 4 spring washer Figure 1 38 Item 5 and a BHCS M6 x 1 x 16 mm Figure 1 38 Item 6 Slide the Z pivot assembly Figure 1 38 Item 1 into the upper arm tube Figure 1 38 Item 2 Install the wrist washer into the tube as shown in Figure 1 42 orient the washer so that the through holes for the M1 5 pins are aligned with the pins on the Z Pivot Place the spring washer on the BHCS M6 Figure 1 42 Ite
90. hown in Figure 2 1 containing the parts listed in Table 2 1 is included with each dummy for handling Table 2 1 Parts list for lifting bracket assembly Item Quantity Part number Description number 1 1 5000537 Screw SHCS M8 x 1 25 x 80 2 1 W50 84106 Handle threaded rod 3 1 W50 84104 Handle threaded hole 4 1 W50 84110 Litting bracket weldment 5 1 5000538 Screw SHCS M12 x 1 75 x 150 118 Figure 2 1 Lifting bracket assembly 2 6 2 1 2 3 4 5 6 7 8 27 Procedures for using the lifting bracket are as follows Insert the lifting bracket Figure 2 1 Item 4 through a hole on the pelvis flesh and align it with the threaded hole inside the pelvis Thread bolt Figure 2 1 Item 5 a few threads into the pelvis so that it is engaged but not tight Bend the dummy forward to align the upper portion of the lifting bracket with the hole on the top front of the spine box assembly Loosely install bolt Figure 2 1 Item 1 Tighten both bolts Figure 2 1 Items 1 and 5 If needed some soft webbing can be used to loop around the upper leg above the knee area and attached to the lifting bracket to help support the legs Handles Figure 2 1 Items 2 and 3 can be used for handling of the dummy inside the vehicle When the dummy is positioned remove the bracket from the dummy before conducting any test Dummy storage The dummy should be st
91. ht 1 wso eroes Spring washer 1 wso eto22 12 SHSS M6 x 26 mm 1 5000163 13 BHCS MIO x 1 5 x 20 mm 1 5000176 14 Clamping washer steel wseerois 45 Item number Description Part number 15 Compression washer rubber 1 wso 61016 16 Friction washer 1 wso s2064 17 Cable guide 4_ ws0 61030 18 BHCS 3 x 0 5 x 6 mm 5000171 19 Shoulder bumper assembly 1 wso 61110 20 LASHES M3 x 0 5 x 12 mm 2 5000620 21 SSNT M3 x 0 5 x 3 mm 1 5000190 21 Flexion extension stop assembly 1 wso 61054 22 Full arm clevis assembly ws061051 23 SSHDP M6 x 1 0 x 6 1 5000165 Not shown Upper arm flesh left 1 wso eross Not shown Upper arm flesh right 1 wso eross Not shown Lower arm flesh 1 wso ertoo Not shown Elbow potentiometer optional 1__ wso 61027 46 Figure 1 36 Full arm exploded 1 4 1 2 Parts list for shoulder arm Table 1 7 lists the parts for assembling the WorldSID shoulder arm which is illustrated in Figure 1 37 47 Table 1 7 Parts list for shoulder arm Tem Description Qty Part number number 1 Shoulder load cell 1 ws0 71090 mot Shoulder load cell structural replacement 1 Wwso 71092 shown 2 Shoulder clevis assembly 1 W50 61051 3 SSNT M3 x 0 5 x 3mm 1 5000190 4 Shoulder bumper 1 ws0 61110 5 SSFP M4 x 0 7 x6 mm 2 so00464 6 Spring plunger 1 5000256
92. ib accelerometer mounting bracket Worlasi 10 ws0 32172 16 _ Accelerometer linear triaxial 6 _ Endevco 7268C 2000M1 17 _ Rib assembly shoulder 2 ws0 32001 18 Shoulder rib sternum strip threaded 2 ws0 32175 19 Thorax and abdominal rib clamping bracket WorldSID 10 w50 32173 20 FHCS MS x0 8x 16 5000467 21 Screw rip IRTRACC mount ws0 32179 22 Rib doubler shoulder 2 ws0 s2010 23 shoulder assembly 2 ws0 61053 24 Clamp damping 24 ws0 32180 25 FHES MS x0 8x 10 48 5000084 26 eHcs ms xo 8 x6 24 5000214 2 shoulder pad teft WorasID 1 _ w50 35023 1 16 Description Part number number Shoulder pad right WorldsiD 1 w50 35023 2 29 Battery mounting bracket 1 wso szont sHcs ms 30 2 5000471 31 Battery mass replacement 1 ws0 a7012 32 5 x 0 45 x 10 _ 5000208 Fics M25 x 0 45 x6 24 5000202 sucess x18 2 5000112 5 locknut M12 1 75 2 000462 thorax pad 2 wso aso24 7 sucsmex1x16 5000081 38 Cheese screw M2 x 16 5000254 Cable tie mount 0 50 x 0 50 nylon adhesive backed 10 6002035 40 Cable tie mount 4 screw nylon 1 6002026 sHcsM3x0 5 x6 1 5000399 42 Cable tie 7 4 inch not shown 6000004 Temperature logger assembly 1 Datas ost92Hiz Nu moun IR TRA
93. igure 1 41 Item 9 and an BHCS M6 x 1 x 16 Figure 1 41 Item 10 into the tube and the screw is tightened until the BHCS and spring washer contact the wrist washer Then turn the screw one eighth 1 8 turn tighter Use the SSNT M6 x 1 x 6 mm Figure 1 41 Item 4 to control rotational friction for the 1 t0 2 g setting Fit the wrist mounted triaxial linear accelerometer on the accelerometer mount Figure 1 41 Item 6 The mount is secured in place with four SHCS M2 5 x 0 45 x 8 mm Figure 1 41 Item 7 and one SHCS M3 x 0 5 x 12 mm Figure 1 41 Item 11 Attach the accelerometer with an SHCS M2 x 0 4 x 18 mm Figure 1 41 Item 5 Attach the wrist clevis assembly Figure 1 41 Item 1 to the wrist pivot with a spring washer Figure 1 41 Item 9 and an SHSS M6 x 25 61 Figure 1 41 Item 12 Tighten this screw to approximately a 1 to 2 g setting so that there is some stiffness to the joint without locking the joint 1 4 4 Adjusting the arm 14 4 1 General The arm assembly friction is adjusted at several points along the arm to ensure the biomechanical performance of the assembly during testing and that all joints are adjusted to a 1 to 2 G setting Figure 1 45 Arm joint rotation 62 shoulder levis Pivot Sot Screw 7 shoulder Arm Pivo Arm Pivot Set Sero merom Tam pivot i Tension Screw Hand Pot jas Elbow Y Pivot Wrist Piet Wrist Pivot Tension screw Figure 1 46 Arm joint t
94. lvis cable routing Installation of sensor connectors to the thorax connector st Instrumented arm cable roi General considerations Lower arm cable Upper arm cable Elbow cables Routing wires through flesh component Instrumented leg cable routing Lower leg cable routing Knee cable routing Femoral neck cable routing Wiring with an external DAS 134 134 134 134 135 136 RECOMMENDED WORLDSID GROUNDING SCHEME Parts list Grounding procedures WORLDSID TEMPERATURE INFORMATION Temperature sensitivity of WorldSID Monitoring of temperature variations of WorldSID Effect of internal DAS on dummy temperature Practical notes for full body testing related to temperature 6 RECOMMENDED WORLDSID SEATING PROCEDURE 6 1 Placement procedures for the driver seat position 6 1 1 General 6 1 2 Electronic spreadsheets 6 2 Placement procedures for the rear seat position 6 2 1 preparation 6 2 2 Position the seat 6 2 3 Dummy placement 7 Mechanical Requirements and Certification Test Procedures for WorldSID 74 712 7 1 3 Certification test procedures 7 2 Neck 7 2 1 General desci 7 22 7 2 3 Certification test procedures 7 3 Thorax abdomen shoulder 7 3 1 General description 7 3 2 Full body test setup 7 3 3 Shoulder 7 3 4 Thorax with half arm 7 3 5 Thorax without arm 7 3 6 Abdomen 7 4 Lumbar spine and pelvi 744 742 7 4 8 Pelvis c
95. m 5 and thread the screw into the base of the Z Pivot Tighten the BHCS 6 and spring washer until they contact the wrist washer and then turn it 1 8 turn tighter Do not over tighten this joint the wrist pivot must be able to rotate 1 4 3 3 Assembling elbow To reassemble the elbow section align the elbow load cell Figure 39 Item 10 and elbow clevis Figure 1 39 Item 4 so that the elbow shaft assembly Figure 1 39 Item 11 can be inserted into the elbow pivot hole Line up the shaft locking hole with the SSHDP M6 x 1 x 6 mm Figure 1 39 Item 5 This screw locks the elbow shaft to the elbow load cell so that the potentiometer attached to the elbow clevis can measure the angular displacement of the elbow load cell about the lower arm assembly Install the friction washer assembly Figure 1 39 Item 6 on the elbow shaft Press the washer over the pins onto the elbow shaft completely Install the next two washers Figure 1 39 Items 7 and 8 on the elbow shaft and secure all three in place with a BHCS M10 x 1 5 x 20 mm Figure 1 39 Item 9 Use this screw to adjust the joint tension to 1 to 2 9 setting Do this adjustment with the complete arm assembly Attach the elbow potentiometer assembly to the elbow clevis assembly using two BHCS M3 x 0 5 x 10 and two M3 flat washers Figure 1 39 Items 1 and 2 respectively To adjust the potentiometer zero position align 59 the elbow load cell body with the elbow clevis bo
96. mation crushing or cracks To remove the z axis potentiometer assembly Figure 1 78 Item 24 first loosen the SSNT M3 x 0 5 x 3 mm Figure 1 78 Item 25 that holds it in position If the potentiometer is connected to a cable first release the cable from the cable clamps located along the side of the clevis assembly Figure 1 78 Item 2 Then move it downward out of the clevis assembly NOTE When reinstalling each potentiometer do not over tighten the set screw on the body of the potentiometer or the device may be damaged Tighten it just enough to hold it in position securely To disassemble the X version assembly start by taking out the four SHCS 5 x 0 8 x 16 mm Figure 1 78 Item 8 that secure the retainer brackets Figure 1 78 Item 9 With the retainer brackets removed remove the ankle joint assembly Figure 1 78 Item 12 from the assembly Note that while removing the retainer brackets the X version resistive elements Figure 78 Item 21 could fall out Check the resistive elements for crushing deformation or cracks Check the stop pads Figure 1 78 Item 26 and compression pads Figure 1 78 Item 27 for tears and deformation Re secure the pads using Loctite 414 Super Glue or equivalent cyanoacrylate based adhesive if they come loose 1 7 3 Assembling the leg In general the procedure for assembling the leg is substantially the opposite of the procedure for disassembling it The following descriptions are pro
97. n neck assembly drawing W50 20000 pdf 7 2 2 Cer ication specification When assembled according to Section 1 and tested using the procedure specified in 7 2 3 the neck assembly shall meet the specifications given in Table 7 2 Table 7 2 WorldSID neck ation specifications Variab Absolute value Maximum angular displacement of the head form relative to the pendulum 501001 degrees Decay time of f to 0 degrees ms 58 to 72 Peak moment at occipital condyle Nm 55 to 68 160 Peak moment decay time ta O Nm Tite 87 Peak forward potentiometer angular displacement degrees 3210 39 Time of peak forward potentiometer angular displacement msi Peak rearward potentiometer angular displacement r degrees 301937 56 to 68 Time of peak rearward potentiometer angular displacement 0 ms 7 2 3 Certification test procedures 7 2 8 1 Principle Certify the dynamic response of the neck assembly by performing lateral pendulum tests 7 2 3 2 Materials For the pendulum stop use aluminium honeycomb of density 28 8 kg m 4 90 kg m and dimensions 102 0 mm minimum x 102 0 mm minimum with a thickness along the cells of 76 2 mm 4 mm or alternative products which can be shown to lead to the same results 7 2 3 3 Apparatus Neck assembly as specified in 7 2 1 WorldSID head form drawing W50 83000 pdf Neck pendulum apparatus
98. neck assembly 51035 Femoral neck 51038 Femoral ball lws0 51050 Upper log assembly left wso s1052 G5 DAS log docking station wso s1053 G5 DAS structural replacement assembly lwso s1058 Upper log flesh right velcro application lws0 51059 Upper leg flesh left velcro application 51060 Leg structural replacement assembly wso st067 Leg extension tube assembly ws0 51068 Leg extension tube Wso 52001 sheet Knee assembly right Wso 52001 sheet2 Knee assembly right part list lws0 52002 Knee bone assembly lws0 52004 Knee cover 52005 Knee clevis right w50 52005 Knee clavis right w50 52006 Knee clevis stop lws0 52007 Knee pivot shaft wso s2008 Knee pivot shaft assembly lws0 52009 Knee clevis assembly right wso s2010 Knee pad moulded assembly 52011 Side plate 52015 Knee contact load cell structural replacement assembly 52019 Knee assembly oft 52019 Knee assembly eft parts list wso s2020 Knee clevis left wso s2021 Knee clevis assembly left wso s2024 Knee bone 52063 Knee washer wso s2064 Fiction washer assembly xf xf x px fe oe oe oe oe o oe o F 5 Drawing number Description Electronic file format PDF sre wso s2065 Braking washer x wso
99. ntal drops as shown in Figures 2 3 4 and 5 When mounted for lateral drops position the head such that its midsagittal plane has an angle of 35 1 with the impact surface and its anterior posterior axis is horizontal to within 1 degree Suspend the head above the drop table using the head drop tool and a quick release mechanism For lateral tests position the head so its lowest point is 200 mm 0 25 mm above the impact surface and drop the head For a frontal test position the head so the lowest point on the forehead is 376 mm 0 25 mm above the impact surface igure 7 1 Lateral head drop angle 157 Figure 7 2 Head bracket installation for lateral drops 158 Figure 7 3 Frontal head drop angle SHCS M6 x10 Figure 7 4 Head bracket installation for frontal drops 159 7 1 3 5 Procedure Record and filter the head accelerations from the triaxial accelerometer according to SAE J211 and ISO 6487 Channel filter class 1000 Drop the head onto the rigid plate from the specified height by means that ensure quick release Visually inspect the head for damage to the skin or skull and note any such damage in the test report Allow at least 2 hours between successive tests on the same head 7 1 8 6 Test report Document the results of both the left and right lateral and the frontal drop tests 7 2 Neck The neck assembly shall consist of the components and assemblies listed i
100. oad cell Note that the screw used to secure the knee covers is the same size screw used to secure the knee contact load cell or its structural replacement Remove the knee bone Figure 1 75 Item 16 by taking out the SSHDP M6 x 1 0 x 12 mm Figure 1 75 Item 17 Remove the BHCS M10 x 1 5 20 mm Figure 1 75 Item 13 along with the associated washers Figure 1 75 Item 12 11 and 10 Inspect these washers for damage and wear The middle washer Figure 1 75 Item 11 is the compression washer and is made from a soft neoprene rubber Note that because it is a soft material permanent compression and or tearing could occur If the part is permanently compressed or damaged in any way it should be replaced Remove the knee pivot shaft Figure 1 75 Item 8 by sliding it out of the assembly Slide the knee bone out of the knee clevis assembly Remove the knee pad Figure 1 75 Item 14 from the knee bone by taking out the six BHCS x 0 7 x 12 mm Figure 1 75 Item 15 three on each side that hold it in position Inspect the knee pad for tearing and or cuts in the material 1 7 2 4 Lower leg Remove the BHCS M3 x 0 5 x 6mm Figure 1 76 Item 10 Remove the cable guides Figure 1 76 Item 11 and disconnect the cables from the load cells Remove the upper tibia load cell by removing four modified BHCS Figure 1 76 Item 2 and separating the leg load cell Figure 1 76 Item 1 from the lower leg tube Figure 1 76 Item 3 Remove the z axis
101. of head form 1007 CFC 1000 Neck moment M CFC Neck force Fy CFE 1000 a 1506487 or SAE J21T 7 2 8 8 Test reports Document the results of the test 7 3 Thorax abdomen shoulder 7 3 1 General description The thorax abdomen shoulder assembly shall consist of the components and assemblies listed in thorax abdomen shoulder assembly drawing W50 30000 pdf 7 3 2 Full body test setup 7 8 2 1 Materials Use Teflo heets of sufficient size to cover seat 7 3 2 2 Apparatus H Point tool drawing W50 82500 pdf Tilt sensor or inclinometer Dummy certification test bench 165 Seat and back Teflon sheets described in Annex 1 7 3 2 3 Preparation Expose the dummy clothed in its suit to the conditions given in Table 7 7 for at least four hours prior to a test Table 7 7 Dummy full body test preconditions Variable Value Temperature degrees C 214 08 Relative humidity 1 40 30 7 3 2 4 Setup procedure Install the H point tool Install dual axis tilt sensors in the head thorax and pelvis to check the angles about x and y direction Cover the seat back and base with Teflon sheets Seat the dummy on the rigid seat as shown in Figure 7 5 and Figure 7 6 Place the dummy on the seat and position it using either mechanical measurements on a dummy component or tilt sensors to verify the positions The relationship between mechanical angle measurements and the
102. olt on the non struck side as shown in Figure 4 6 Figure 4 6 Pelvic load cell cable attachment 146 7 Attach the other end of cable 4 to the non struck side knee clevis using a BHCS M3 x 6 mm along with one end of cable 5 as shown in Figure 4 7 Figure 4 7 Knee cable attachment 8 Attach one end of the second cable 4 to the front lumbar to sacrum attachment screw on the struck side as shown in Figure 4 8 147 9 10 igure 4 8 Cable attachment Attach the other end of the second cable 4 to the struck side knee clevis using a BHCS M3 x 6 mm along with one end of the second cable 5 as shown in Figure 4 7 For each of the legs attach the other end of cable 5 to the strain relief attachment screw just below the upper tibia load cell as shown in Figure 4 9 148 Figure 4 9 Tibia cable attachment 11 Attach the other end of cable 6 to an off dummy earth ground point The same ground point should be used as for the DAS 149 Section 5 5 WORLDSID TEMPERATURE INFORMATION 5 1 Temperature sensitivity of WorldSID It is believed that the WorldSID components with the most sensitivity to temperature change are the inner ribs as related to the energy absorbing material which covers the inner ribs 5 2 Moni ions of WorldSID g of temperature vari As specified in Section 2 the recommended chest cavity air temperature operating range for the WorldSID is 20 6 to 22 2 degrees C
103. om sternum Detach the left and right shoulder ribs from the spine box at the rear by removing two BHCS MB x 6 Figure 1 15 Item 26 that hold each in place see Figure 1 20 On the non struck side remove the two damping clamps Figure 1 15 24 25 Figure 1 20 Detaching the rib from the spine box at the rear The procedures for disassembling the remaining ribs are similar to those for the shoulder rib but details for the first thoracic rib are included here in order to include references to the correct item numbers Detach the rib clamping bracket Figure 1 15 Item 19 and the rib accelerometer mounting bracket Figure 1 15 Item 15 by removing the four BHCS 5 x 10 Figure 1 15 Item 10 Remove the triaxial accelerometer Figure 1 15 Item 16 from the rib accelerometer mounting bracket Figure 1 15 Item 15 by removing the cheese screw M2 x 16 Figure 1 15 Item 38 Remove the IR TRACC Figure 1 15 Item 2 by removing the BHCS M2 5 x 10 Figure 1 15 Item 32 that secures it to the spine box Detach it from the rib accelerometer bracket by removing the IR TRACC mount screw Figure 1 15 Item 21 wi accelerometer bracket accessed from the bottom of the rib Detach the thorax rib at the front by removing the four BHCS M5 x 10 Figure 1 15 Item 10 that connect it to the sternum Figure 1 15 Item 5 Remove the two sternum rib mounting strips Figure 1 15 Item 8 and the two threaded rib mounting strips
104. on in the Wrist Hand joint 1 4 5 Changing full arm from left to right pact To convert the instrumented arm from left side impact to right side pact or vice versa several parts have to be exchanged Replace the 2 pivot Figure 1 49 Item 1 hand Figure 1 49 Item 4 and upper arm flesh 67 not shown with their corresponding components For example replace the left hand with the right hand and so on Move the cable clamp Figure 1 49 Item 2 on the elbow load cell the potentiometer assembly Figure 1 49 Item 3 the BHCS M10 at the elbow joint Figure 1 49 Item 5 with its associated washers Figure 1 49 Items 6 7 8 and the lower arm assembly cable clamps Figure 49 Item 2 Attach the potentiometer on the inside surface of the arm closest to the torso Position Figure 1 49 Items 5 6 7 and 8 on the outboard side away from the torso 68 Figure 1 49 Change over components 1 5 Half arm 1 5 1 Parts list for half arm The half arm is moulded as one piece which consists of a plastic bone Vinyl skin and urethane foam The bone has a spring plunger for locating the arm position The locknut is used to adjust the 1 to 2 G settings The part number for the half arm is shown in Table 1 12 Table 1 12 Parts list for WorldSID Item number Description Quantity Part number 1 Half arm assembly 2 W50 62000 69 Figure 1 50 Arm assembly 1 5 2 Disassembling Rem
105. onal DTS TDAS control refer to Annex D regarding the low power mode intended to mitigate temperature concerns due to prolonged sensor excitation Table 5 1 Effect of ternal and external DAS on WorldSID temperature Condition Temperatura increase in thorax Production TDAS GS with 5 V excitation system in fully armed 1 34 degrees C por hour mode External DAS with 10 V excitation 1 32 degrees C per hour 151 5 4 Practical notes for full body testing related to temperature The following notes are provided for the information of users performing full body testing with the WorldSID Similar temperature increases occur when the same set of sensors is used regardless of whether a typical external DAS or the internal TDAS G5 system is used Since the temperature specification is 20 6 to 22 2 degrees C the dummy can be temperature soaked near the lower end of this range to allow for heating during a test Once the internal or external DAS is armed and sensor excitations are powered it is recommended that the test be performed within 30 minutes in order to minimize temperature effects i e there is an approximately 0 7 degrees C increase in 30 minutes If the permissible internal TDAS G5 system is used the software will provide a real time internal chest cavity air temperature measurement to the user The previous 24 hour temperature time history will also be automatically downloa
106. operly adjusted the lower arm should remain parallel to the floor but move easily when a downward force of 1 to 2 G setting is applied and if it does not the Z pivot must be adjusted using the friction adjustment screw Figure 1 37 Item 9 1 4 4 4 Adjusting the shoulder arm y axis pivot rotation Fully extend the arm from the dummy s upper torso toward the front of the torso so that the complete arm is straight and parallel to the floor Note the following The assembly should be approximately parallel to the dummy s midsagittal plane f properly adjusted the arm will maintain this position without support and will move freely if a downward force of 1 G is applied 64 Tighten the bumper on the arm pivot shaft to ensure proper engagement of the spring plunger mechanism see Figure 1 37 Item 6 Loosen the two set screws that lock the bumper in position see Figure 1 37 Item 5 Loosen the arm pivot set screw located at the top of the arm Z pivot Rotate the bumper in a clockwise direction until the arm is almost able to support its own mass without falling Adjust the set screw M3 Figure 1 37 Item 3 until the arm will not drop when moved to the horizontal but will fall with only a slight touch of the hand 1 4 4 5 Adjusting the elbow y axis pivot rotation Position the upper arm perpendicular to the floor and parallel to the upper torso Position the lower arm assembly so that it is parallel to the floor and perpendi
107. ored in a seating position with the lifting bracket installed 120 SECTION 3 3 SUGGESTED WORLDSID WIRING PROCEDURES 3 1 Head Wiring Head wiring should be installed as follows Figure 3 1 Cable routing for the head 1 Use a cable tie to mount z axis rotational accelerometer as illustrated by Item 1 in Figure 3 1a 2 Bundle the accelerometer and y axis rotational accelerometer cables with cable tie as shown by Item 1 in Figure 3 1b 3 Sort all the cables together and tie them together with cable tie as shown by Item 2 in Figure 3 1a 121 4 Lay all the cables from the head as shown and tie them together with the upper neck load cell cables as shown by Item 3 in Figure 3 1a 5 Small extra loops of wire inside the head core may be utilized as a precaution against cable pulls damaging the sensor 3 2 Neck Neck wiring should be installed as follows Figure 3 2 WorldSID neck cable routing 1 Install the head and install a cable tie mount on the back of the lower neck bracket as shown by Item 1 in Figure 3 2a 2 Bundle all the cables to the cable tie mount as shown 2 in Figure 3 2a make sure the cable has enough slack as illustrated by Item 1 in Figure 3 2b 122 3 3 Shoulder rib and 1 thorax rib Shoulder rib and 1 thorax rib wiring should be installed as follows Figure 3 3 IR TRACC and linear accelerometer routing for shoulder
108. ove the half arm from the shoulder by removing the locknut with a socket wrench 1 5 3 Assembling Attach the half arm to the shoulder using the locknut and a socket ig the joint to a 1 to 2 G sett wrench adju 70 1 6 Pelvis 1 6 1 Parts list for pelvis Table 1 13 lists the parts required for assembling the WorldSID pelvis Note that part numbers refer to those on drawing W50 40000 and in Figure 1 51 and that Figures 1 52 through Figure 1 56 illustrate different Views of the pelvis components Table 1 13 Parts list for WorldSID pelvis Item Description aw Part number number 1 Pelvis flesh ws0 42019 2 Interposer mass replacement ws0 75001 3 G5 module mass replacement ws0 74307 4 Pelvis docking station 1 ws0 41082 5 Moulded pubic buffer 2 W50 42510 6 Pubic load cell structural replacement wso 71052 7 Connector housing mass replacement ws0 75002 8 Left sacroiliac load cell interface wsoa2o16 9 Left pelvis bone 1 wsoa2o1o 10 Lumbar bushing ws0 41019 11 Lumbar lower clamping plate 2 W50 41021 12 Lumbar upper clamping plate wso41022 13 Rubber lumbar spine ws0 41018 14 SHCS x 18 4 5000209 15 BHCS M5 x 0 8 x 25 4 5000466 16 FHCSM6x1x16 4 5000090 17 Lower lumbar mounting bracket weldment wso 41030 18 Duataxis tilt sensor See dummy manufacturer information 19
109. per neck bracket 1 w50 20010 Neck load cell structural replacement 1 wso r1003 4 Neck column assembly 1 wsozz1001 s sucswex 50 2 5000324 6 Neck bracket nut 2 ws0 20011 7 sucsexi2 5000281 8 triaxial accelerometer 1 Endevco 7268 2000Mt 9 Cheese screw M1 5 x 16 1 5000227 Not shown Linear triaxial accelerometer structural replacement 1 wso eross Not shown Universal neck load cell wso r1000 Figure 1 7 WorldSID neck components 1 2 2 Disassembling Separate the upper Figure 1 7 2 and lower Figure 1 7 Item 1 neck brackets by removing two SHCS M6 x 50 Figure 1 7 Item 5 accessed from the rear of the dummy see Figure 1 8 Remove the two free neck bracket nuts Figure 1 7 Item 6 accessed from either side Figure 1 8 Removing lower neck bracket Remove the upper part of the neck bracket and lower neck load cell structural replacement from the neck assembly by removing four SHCS M6 x 12 Figure 1 7 Item 7 accessed from the bottom see Figure 1 9 Remove the lower neck load cell from the upper neck bracket by removing four SHCS M6 x 12 Figure 1 7 Item 7 Figure 1 9 Removing upper neck bracket To take apart the neck assembly use the neck compression wrench to remove the half spherical screw from the neck see Figure 1 10 After the interface plates come off remove the four dampers by pulling them out see Figure 1 11 10
110. perature sensor is also connected to the G5 DB The G5 DB also manages power input from the in dummy battery and external power sources See the G5 DB hardware user s manual for additional information C 6 Docking station to G5 DB cable The G5 docking station to G5 DB cable connects each G5 Module to the G5 DB Additional information regarding the cable is found in the G5 DB hardware user s manual Woridsib Deliverables Qty 2 G5 Modules Qty 2 Docking Stations 55 Qty 2 DS to DB Cables FTSS Qty 1 6508 Distribution Box Hub Qty 1 In Dummy Battery amp Cable 55 Qty 1 DB toBatt amp Temp Cable 55 Qty 1 DB to Dummy Exit Cable Qty 1 Dummy Exit to Status Box Cable Qty 1 TDAS Status Box 0 Qty 1 External Power Option 1 DC DC Converter 11 Qty 1 External Power Option 2 ACIDC Converter 12 Qty 1 External Power Option 3 TDAS Power Supply amp Cable NOT Crashworthy Qty 1 TDAS Software 14 Qty 1 Status Box to PC Cable 15 Qty 1 Notebook PC ordered separately Figure C 1 WorldSID G5 DAS system diagram C4 7 In dummy battery and cable The in dummy battery and integrated cable provide backup power for the G5 system This optional internal backup battery is provided however it is only for backup purposes and should not be relied upon for more than brief periods see manufacturers specification for battery capacities C 8 G5 DB to ba
111. re 1 76 Item 4 installed in the load cell and aligned with the drill points in the pin A fourth screw Figure 1 76 Item 5 is installed after the ankle assembly is installed along with the anti rattle washer rotational washer and nut Figure 1 76 Items 7 8 and 9 respectively The fourth screw is known as the z axis radial limit screw This limit screw is modified SHCS M6 and is installed on the anterior of the lower leg to control the radial travel of the ankle The ankle assembly Figure 1 77 Item 2 is attached to the lower leg assembly with the Z pivot pin anti rattle washer rotational washer and z axis nut Figure 1 76 Items 6 7 8 and 9 respectively see Figure 1 89 for a clearer diagram of the ankle to lower leg assembly These components must be in place in the ankle before the lower leg assembly can be attached Once the lower leg assembly is installed on the ankle the washers and nut can be tightened until the z axis movement is eliminated Then with the leg flesh orienting block Figure 1 76 Item 12 positioned toward the rear posterior of the assembly install the z axis radial limiting screw Figure 1 76 Item 5 or Figure 1 89 1 7 3 5 Assembling the ankle The ankle assembly is made up of two sections X version and version The upper section is the Y version assembly The lower section of the ankle assembly is the X version assembly see Figure 1 79 and Figure 1 85 Place the
112. re 1 82 Knee potentiometer installation Figure 1 83 Torquing the knee contact load cell Figure 1 84 Ankle potentiometer wiring Figure 1 85 X and Y version assembling Figure 1 86 Ankle assembly potentiometers Figure 1 87 Knee assembly Figure 1 88 Leg joint adjustments Figure 1 89 Ankle adjustment Figure 2 1 Lifting bracket assembly Figure 3 1 Cable routing for the head Figure 3 2 WorldSID neck cable routing Figure 3 3 IR TRACC and linear accelerometer routing for shoulder and 1st thorax ribs 123 Figure 3 4 Cable routing for IR TRACC and linear triax accelerometers of the 2nd 3rd thorax ribs and abdomen ribs Figure 3 5 Pelvis cable routing Figure 3 6 Installations of sensor connectors to the thorax connector station Figure 3 7 Cable routing for the thorax connector station Figure 3 8 Thorax cable routing Figure 3 9 Shoulder area final cable routing Figure 3 10 Pelvis cable and dummy exit cable routing Figure 3 11 Thorax cable routing 131 132 Figure 3 12 DAS exit cable and tilt sensor cables Figure 3 13 Shoulder load cell cable rounting 132 Figure 3 14 WorldSID final dummy wiring 133 134 Figure 3 15 Lower arm cables Figure 3 16 Upper arm cables 135 Figure 3 17 Cables in the elbow region 135
113. re too long insert washers under the head of the screw in order to prevent rubber contact Mount the pendulum interface to the pendulum such that the head 162 7 2 3 6 form s midsagittal plane is vertical and is perpendicular to the plane of motion of the pendulum s longitudinal centreline Slide the carbon fiber rods through the potentiometer housings on the pendulum First slide the pivot of the potentiometer closest to the pendulum over the central steel rod in the head form then install the small spacer ring and the second pivot Carefully tighten the second pivot Procedure Record and filter the data according to ISO 6487 or SAE J211 Channel filter class 1000 Release the pendulum and allow it to fall freely from a height such that the velocity at impact is 3 4 m s 0 1 m s measured at the centre of the pendulum mounted accelerometer Decelerate the pendulum arm using the 28 8 kg m aluminium products which can be shown to lead to the same results to achieve the pendulum pulse given in Table 7 5 honeycomb or alterna Allow the neck to flex without impact of the head or neck with any object other than the pendulum arm Conduct the test such that the time between raising the pendulum and releasing it does not exceed 5 minutes Conduct the test such that the time between any tests on the same WorldSID neck is not less than 30 minutes 163 Table 7 5 Pendulum arm deceleration pulse Variable Value
114. resistive elements two on each side Figure 1 85 Item 4 on the ankle joint assembly Figure 1 85 Item 5 slide the Y version assembly to the ankle joint assembly Check periodically for damage to the Teflon washers attached to the inner surfaces of the Y version left and right flexion centre assemblies Figure 1 78 Items 6 and 23 108 1K Figure 1 84 Ankle potentiometer wiring With the Y version assembly positioned on the ankle joint assembly place the remaining four resistive elements on top of the left and right flexion centre assemblies and install the ankle joint cover Figure 1 85 Item 3 In order to compress the resistive elements sufficiently to be able to insert the six BHCS M4 x 0 7 x 10 mm to attach to the cover two SHCS M4 x 0 7 x 18 mm are used Tighten the two SHCS M4 Figure 1 85 Item 1 until the BHCS x 0 7 x 10 mm can be installed and then replace the two SHCS with BHCS M4 109 Figure 1 85 X and version assembling Install the potentiometer W50 54012 into the X version assembly by loosening the three screws Figure 1 78 Item 15 and inserting the potentiometer into the hole at the front side of the ankle assembly see Figure 1 86 Do not over tighten the two SSNT M3 x 0 5 x mm set screws that secure the potentiometer body or there may be damage to the potentiometer Note that there is an SSCP M3 x 0 5 x 4 mm Figure 1 78 Item 7 tha
115. rsal neck load cell 1 W50 71000 Figure 1 1 WorldSID head components 1 1 2 Disassembling As shown in Figure 1 2 remove the BHCS 8 25 Figure 1 1 Item 12 and 8 flat washer Figure 1 1 Item 11 from the top of the head Lift the moulded head Figure 1 1 Item 2 off the head core assembly If the head sticks to the core tap the bottom edge of the head lightly with a plastic hammer Detach the neck shroud assembly not illustrated Item 13 from the head by removing five screws BHCS x 10 Figure 1 2 Removal of moulded head Remove the four SHCS M6 x 12 Figure 1 1 Item 14 that connect the head core assembly to the neck assembly see Figure 1 3 Figure 1 3 Separating the head from the neck Remove the four SHCS M6 x 16 Figure 1 1 Item 10 from the bottom of the upper neck load cell structural replacement Figure 1 1 Item 6 that attach it to the bottom of the head core see Figure 1 4 Figure 1 4 Removing upper neck load cell from instrumented head core 1 1 3 Assembling Install the head instrumentation as described in 1 4 Use four SHCS M6 x 16 Figure 1 1 Item 10 to attach the upper neck load cell to the bottom of the head core Figure 1 Item 1 Make sure the slot at the top front of the head core is lined up with the connector for the upper neck load cell Torque the screws to 6 Nm Attach the head core assembly to the neck assembly using four SHCS M6 x
116. s Remove the connector mass replacement Figure 1 51 Item 7 from the front of the sacroiliac load cell structural replacement by removing three SHCS M3 x 8 Figure 1 51 Item 42 As shown in Figure 1 68 detach the DAS cover Figure 1 51 Item 23 by removing two BHCS M6 x 16 Figure 1 51 Item 35 Slide out the G5 module mass replacement Figure 1 51 Item 3 85 Figure 1 68 Removing the DAS cover Figure 1 69 illustrates detachment of the pelvis docking station Figure 1 51 Item 4 by removing four M3 x 10 FHCS Figure 1 51 Item 36 Figure 1 69 Removing the docking station 86 As shown in Figure 1 70 detach the interposer mass replacement Figure 1 51 Item 2 by removing four SHCS M2 x 10 Figure 1 51 Item 41 Figure 1 70 Removing interposer mass replacement As shown in Figure 1 71 separate the structural replacements for the sacroiliac and lumbar spine load cells by removing the four SHCS M6 x 30 Figure 1 51 Item 34 accessed from the bottom Figure 1 71 Separating the sacroiliac and lumbar spine load cell structural replacements 87 1 6 3 Assembling the pelvis In general the procedure for assembling the pelvis is substantially the opposite of the procedure for disassembling it The following descriptions are provided to assist the user to more efficiently assemble the WorldSID pelvis Join the lumbar spine load cell or its mass replacement Figure 1 51 Item 25 to the sa
117. s Table 7 3 Sensors for neck assembly 162 Table 7 4 Neck test preconditions 162 164 Table 7 5 Pendulum arm deceleration pulse Table 7 6 Filter specification for neck test Table 7 7 Dummy full body test preconditions Table 7 8 Relationship between mechanical measurement indicators and the tilt sensors Table 7 9 Dummy set up cri Table 7 10 WorldSID shoulder certification specifications Table 7 11 Sensors for shoulder test Table 7 12 Filter specifications for shoulder test Table 7 13 WorldSID thorax with half arm certification specifications 172 Table 7 173 Table 7 174 Table 7 174 Table 7 175 Table 7 176 Table 7 19 WorldSID abdomen certification specifications 177 Table 7 20 ulated armrest specifications 178 Table 7 21 Sensor specifications for abdomen test 178 xiv Table 7 22 Filter specifications for abdomen test 179 180 Table 7 23 WorldSID pelvis certification specifications Table 7 24 Sensor specifications for pelvis test 180 Table 7 25 Filter spe ications for pelvis test 181 Table A 1 Screw torque 1 Table 1 Summary of fasteners abbreviations descriptions and ISO references Table C 1 WorldSID G5 DAS parts list Table C 2 Dummy exit to status box cable pinout Table Example instrumentation
118. s Variable Absolute value Paak pendulum force kN 261033 Paak shoulder rib deflection mm 351044 7 3 3 1 Shoulder certification test procedures 7 3 3 1 1 Principle Perform a test involving a lateral impact to the shoulder order to certify the dynamic response of the shoulders 169 7 3 3 1 2 Apparatus Use 49 CFR Part 572 subpart E Hybrid Ill 50 percentile adult male dummy pendulum 23 4 kg 152 4 mm face diameter 7 3 3 1 3 Sensors Install instrumentation to obtain data for the items given in Table 7 11 Table 7 11 Sensors for shoulder test Variable Sensor Performance Peak pendulum See Table 7 3 SAE 12870 acceleration GI Peak shoulder rib IR TRACC See sensor specification details on electronic deflection mm drawing number IF 363 Impact velocity m s Not spe Resolution 0 02 m s or better 7 3 3 1 4 Procedure Set up the dummy in standard test posture as described in 7 3 2 with the half arm aligned horizontal on the impact side as shown in Figure 7 8 Align the pendulum centreline with the centreline of the shoulder y axis rotation point Raise the pendulum to achieve 4 3 m s 0 1 m s impact velocity Release the pendulum to impact the dummy 170 Figure 7 8 Shoulder test dummy and arm position 7 3 3 1 5 Calculation procedures and expression of results Filter the data according to ISO 6487 or SAE J211 as given in Ta
119. s2066 Braking washer backing x 53001 Lower leg tube x wso sa002 Lower leg flesh ERES lws0 53007 Zipper assembly x lws0 53008 Vinyl strips x wso s4002 Ankle clevis right and left lower limb x wso sao04 Left flexion centre rotational piece x jwso saoos Ankle joint x jwso saoos Base plate x jwso saoos Thrust washer x wso saoos Z pivot pin x wso sao1o Z axis rotational washer x lws0 s4012 Potentiometer optional x wso saota Potentiometer structural replacement x jwso saota Retainer bracket x 51015 Ankle joint cover x wso sao1e version bushing x wso saoto Front bearing cover x wso sao20 Rear bearing cover x wso sao21 X version compression element x wso sao22 Dorsiflexion and plantarllexion hard stop x 50 54023 Zaxis nut x wso sao24 Zaxis anti ratlo washer x 51031 Zaxis rotation bearing m 50 54033 Right flexion centre rotational piece x lwso s4034 Foot sole locator pins x wso saoas X version resistive element x 50 54036 Resistive element x jwso saos7 Bumper x 50 54038 Orientation block x F 6 Drawing number Description Electronic file format Por sre wso saoat Zaxis radial limit screw x 50 54042 Front bearing assembly x 50 54043 Rear bearing assembly lws0 s4044 X version assembly x wso saoas Ankle joint assembly x lws0 s4046 X version assembly x lws0 s4047 Clovis a
120. so eroes Elbow load cel structural replacement assembly wso e1067 Moulded hand assembly right lws0 61068 Moulded hand assembly left wso eroes Hand moulded assembly right wso erozox IGUS bearing general table wso eroza Arm tube assembly wso eross Zpivot right wso eroso Modified IGUS bearing lws0 61098 Upper arm flesh right velero application wso eross Upper arm flesh left velcro application lws0 61100 Lower arm flesh velcro application wso errio Shoulder bumper assembly seen Zpivot assembly right x xf x x x ox o e o fe oe oe oe oe o F 9 Drawing number Description Electronic file format Por sre wso et113 sheet Shoulder clevis for half arm x W59 61113 sheet2 Shoulder clevis for half arm x 61117 Shoulder clevis assembly x lwso 61123 Structural replacement elbow potentiometer assembly x wso e2000 Half arm assembly x x lws0 62002 Half arm bone wso 71000 Neck load cell assembly optional x lws0 71003 Neck load structural replacement body x lws0 71010 Leg load cell assembly optional x lws0 71020 Knee contact load cell assembly optional x 71051 Pubic symphysis load cell x 71059 Pubic load cell structural replacement assembly x wso 71060 Elbow load cell assembly optional x lws0 71070 Arm load cell assembly optional x lws0 710
121. ss replacement to the upper neck bracket using a cheese screw M2 x 16 see Figure 1 14 14 Figure 1 14 Neck triaxial accelerometer installation 1 3 Thorax abdomen and shoulder 1 3 1 Parts list 1 3 1 1 Parts list for thorax abdomen and shoulder assembly Table 1 3 lists the parts required for assembling the WorldSID thorax abdomen and shoulder which are illustrated in Figure 1 15 Part numbers correspond to those on drawing W50 30000 15 Table 1 3 Parts list for the WorldSID thorax abdomen and shoulder Description Part number number 1 Spine box assembly 1 ws0 31000 2 IRTRACC displacement sensor assembly ribs 1 6 63 3 Thorax rib assembly 1 WorlaSID 2 wsoazii Thorax rib assembles 2 and 3 WorldSIO wso 32131 5 Sternum thorax rib 1 w50 35022 6 _ Rib coupler abdominal WorldSID 1 wso aso2t 7 shoulder rib sternum mounting strip 2 wsoa2177 Thorax and abdominal rib sternum mounting strip 10 wso 32178 9 Thorax and abdominal rib mounting strip threaded 10 wso 32176 Hes x 0 8 x 10 5000003 11__ Shoulder rib assembly inner band WorldSID 2 wsoazteo 12 Thorax rib assembly inner band WorldSID wsoaziso 13 Abdomen rib assembly inner band WorldSIO wsoaziss 14 Shoulder rib mounting bracket struck side WorldSIO 2 wsoazin 15 _ Thorax and abdominal r
122. ssembly AG wso sao4n Left flexion centre assembly x wso saoas Fight flexion centre assembly x wso saoso Y version assembly x wso saos Zaxis potentiometer assembly optional x wso saos2 Y axis potentiometer assembly optional x wso sao53 Lower leg assembly x wso saosa Ankle assembly x wso saoss Lower leg assembly right x jwso saose Lower leg assembly left x 55003 Sole plate x 55008 Left shoe x x wso ssoos Right shoe x lws0 61000 Arm assembly lef x lws0 61001 Full arm assembly right x lws0 61002 Upper arm left assembly x lws0 61003 Upper arm assembly right x wso eroos Upper arm extension tube assembly x wso eroos Upper arm z pivot loft x lws0 61006 Upper arm z pivot assembly left x wso e1007 IGUS bearing TEI 1214 08 x lws0 61008 Zstop pin x lws0 61010 Upper arm z stop 61011 Am tube x ws0 61012 Upper arm tube assembly x F 7 Drawing number Description Electronic file format Por sre lwso 61013 Elbow shaft x wso eroa Clamping washer x wso eroe Compression washer x lwso 61017 Elbow stop x wso erota Wrist pivot x lwso 61019 Wrist washer x lws0 61020 Wrist pivot assembly AG lws0 61021 Hand bone x lws0 61022 Spring washer x 61023 Elbow clevis x lws0 61024 Elbow clevis assembly x lws0 61025 Lower arm tube x lws0 61026 Upper arm extension bone x lws0 61027 Elbow
123. ssembly by taking out the SHSS M6 x 25 mm Figure 1 36 Item 12 at the hand wrist pivot joint Watch for the spring washer Figure 1 36 Item 11 to fall out of the assembly as the screw is removed This washer is made of soft plastic urethane and thus the screw head may damage it Inspect and replace as necessary Inspect the hand bumpers checking for cuts in the bumper material or signs that the bumper adhesive may be failing 54 Remove the upper arm flesh by opening the Velcro on the inboard side of the upper arm flesh and then pulling the arm flesh open and off of the arm Remove the lower arm flesh by opening the Velcro holding the flaps at the elbow closed and moving them over the potentiometer assembly and friction adjustment screw Hold the upper arm and pull the flesh towards the wrist to remove it from the lower arm Disassemble the lower arm from the upper by first disconnecting the connector from the lower arm load cell Remove the cable guides that are held Figure 1 36 Item 17 in position using two BHCS M3 x 0 5 x 6 mm Figure 1 36 Item 18 for each clamp Remove the potentiometer assembly from the elbow joint by taking out the BHCS M4 x 0 7 x 6 mm and 4 flat washer Figure 1 36 Items 6 and 7 holding the potentiometer wiring cable in position Remove the two BHCS M3 x 0 5 x 10 mm and flat washer Figure 1 36 Items 5 and 4 securing the potentiometer body in position and slide out the potentiometer from the body o
124. t 3 Ethernet Tx went Event 10 Event Arm Status RS 232 Level V Armed 12 Power ON short to GND ON 13 Status Output 14 Start Record Vin Record NOTE Belden 9507 cable contains 7 twisted pairs Each pair contains a black wire and a colored wire It is very important that the pairs be kept together as shown above C7 Event black pair Moin Power 12 VDC red Event white pair Main Power 12 VDC back Main GND black pair 6 Arm Status blue pair Main GND brown pai Power On back pair Ethernet Tx 4 black pair Ethernet Tx orange Start Record black pair Ethernet Rx green pair Status Out yellow pair Ethernet Rx black pair Figure 2 Dummy exit to TDAS status box cable 2B 14 pin lemo connector wiring side view sockets Start Record black pair Main Power 12 VDC red Status Out yellow pair Main Power 12 VDC black Power On black Arm Status blue pair Ethernet Tx 1 black pair Event 1 black pair Main GND black pair amp Event white pair Main GND brown pair Ethernet Rx green pair Ethernet Tx orange Figure Dummy exit to TDAS status box cable 2B 19 pin lemo connector wiring side view pins C 19 Sensor cable length When the G5 system is used in the WorldSID sensor cable lengths will be dep
125. t secures the potentiometer shaft To install the y axis potentiometer this section must be assembled on to the X version assembly Insert the potentiometer body into the appropriate mounting hole shown in Figure 1 86 and tighten the SSNT M3 x 0 5 x 3 mm Do not over tighten this set screw or the potentiometer will be damaged Note that the SSNT M3 x 0 5 x 3 mm need only be tightened enough to secure the body and keep it from moving 110 aS Y version L7 assembly a M3 x 0 5 x 3 mm SSNT x0 5 x 4 mm SSCP M3 x 0 5x 3 mm SSNT Y Axis Pot version assembly Figure 1 86 Ankle assembly potentiometers 1 7 4 Adjusting the leg 1 7 4 1 General The WorldSID leg assembly has two joint adjustments that control the 1 to 2 G setting and that one of the joint adjustment points is located at the knee pivot and the other is located at the top of the ankle assembly Note the following The knee pivot screw see Figure 1 87 controls the motion of the lower leg In order to do this there are several components involved clamping compression and friction washers and the pivot shaft assembly For the knee pivot screw to control the friction in the knee joint all of these component must be correctly installed and in good working condition Tighten the knee pivot 111 screw to obtain a1 to 2 G setting This screw will squeeze the compression washer against the friction washer thus increasing the resis
126. t the rear using two BHCS M5 x 6 Figure 1 15 Item 26 Secure the inner band of the abdomen Figure 1 15 Item 13 with two damping clamps Figure 1 15 Item 24 and four BHCS 5 x 10 Figure 1 15 Item 10 To permit easier access to the connector 33 boxes in the spine box install the instrumentation before attaching the ribs to the rib and abdominal couplers Attach the IR TRACC Figure 1 15 Item 2 to the spine box with a BHCS M2 5 x 10 Figure 1 15 Item 32 Connect it to the rib accelerometer bracket Figure 1 15 Item 15 with the IR TRACC mount screw Figure 1 15 Item 21 accessed from the bottom of the rib accelerometer bracket Figure 1 15 Item 15 Connect the rib clamping bracket Figure 1 15 Item 19 and the rib accelerometer mounting bracket Figure 1 15 Item 15 to the inner band and rib with four BHCS M5 x 10 Figure 1 15 Item 10 Secure the triaxial accelerometer Figure 1 15 Item 16 to the rib accelerometer mounting bracket Figure 1 15 Item 15 with a cheese screw M2 x 16 Figure 1 15 Item 38 As each IR TRACC assembly and accelerometer is installed route the cables toward the centre front Figure 1 28 and Figure 1 29 of the dummy and plug them into the G5 module connectors See Section 3 for more detailed wiring information Figure 26 shows the arrangement of the components in the first thoracic WorldSID rib and that all of the ribs have a similar general assembly The inner band of the rib Figure 1 2
127. t the wires for the accelerometer and tilt sensor exit the slot in the top of the instrumentation bracket Route the accelerometer wire over the non struck sacroiliac load cell interface towards the front of the dummy 88 Attach the left and right sacroiliac load cell interfaces Figure 1 51 Item 22 and Item 8 with eight SHCS M6 x 10 Figure 1 51 Item 45 that hold each in place Connect the lumbar mounting bracket weldment Figure 1 51 Item 17 to the lumbar load cell or its structural replacement Figure 1 51 Item 25 with four FHCS M6 x 16 Figure 1 51 Item 16 Place the lumbar mounting wedge Figure 1 51 Item 28 on top of the lumbar spine lining up the threaded holes on the bottom with those in the lumbar spine Place the upper lumbar clamping plate Figure 1 51 Item 12 over the holes in the lumbar spine and secure it with four BHCS M5 x 25 Figure 1 51 Item 15 Place the assembled lumbar spine Figure 1 51 Item 13 over the lumbar mounting bracket Position a lower lumbar clamping plate Figure 1 51 Item 11 over the holes in the side of the lumbar spine so the curve of the plate matches the curve in the rubber with the radius edge facing down Secure the lumbar spine and clamping plate to the mounting bracket with three BHCS M6 x 20 Figure 1 51 Item 47 and three lumbar bushings Figure 1 51 Item 10 Repeat the procedure for the other side of the lumbar spine Connect the pubic buffers to the pubic load cell or its str
128. ta Neck bracket mounting plate wso ato20 1 Side plate left Worldsid wso atozo 2 Side plate left Worldsid wso atoso 1 Side plate right Worldsid wso a1030 2 Side plate right Worldsid z x x x x x x x x lws0 21041 Spacer WorldSID x wso a1042 Mounting bracket 1 x wso a1043 Mounting bracket 2 x wso a104s Cover plate spine box x lws0 21050 Ball joint assembly IRTRACC x lws0 21051 Ballshaft assembly x wso a1053 Ball shaft IRTRACC x wso a1054 Ball socket IRTRACC x lws0 a1086 Ball retainer IRTRACC x lws0 21060 IR TRACC mass replacement x wso a2000 Rib shoulder x lws0 22001 Rib assembly shoulder x lws0 22010 Rib doubler shoulder x wso a2110 Thorax rib 1 WorldSID x wso azu Thorax rib assembly 1 WorldSID x wso a2130 Thorax rib 2 and 3 abdominal ribs WorldSID x lws0 a2131 Thorax rib assembly 2 and 3 WorldSID x lws0 22150 Thorax rib assembly inner band WerldSID x lws0 22151 Rib damping x wso a2182 Thorax rib bent WorldSID x wso a2158 Abdomen rib assembly inner band WorldSID x wso a2156 Rib damping x lws0 22160 Shoulder rib assembly inner band WorldSID x F2 Drawing number Description Electronic file format Por sre lws0 32161 Rib damping x wso aztez Shoulder rib bent WorldSID x
129. tach the shoulder rib mounting bracket Figure 1 15 Item 14 to the shoulder rib and shoulder load cell assembly Table 1 3 Item 23 with four FHCS 5 x 16 Figure 1 15 Item 20 After the instrumentation is plugged into the connectors position a threaded rib mounting strip Table 1 3 Item 18 behind the front holes each rib and place the abdominal rib coupler Figure 1 15 Item 6 over Put the rib mounting strip Figure 1 15 Item 8 over the rib coupler and secure the rib at the front with two BHCS M5 x 10 Figure 1 15 Item 10 The installed rib couplers are shown in Figure 1 29 Attach the lower neck bracket to the spine box with four SHCS M6 x 16 Table 1 3 Item 37 Attach the thorax pad Figure 1 15 Item 36 with Velcro Place the shoulder pads Figure 1 15 Items 27 and 28 in position To install the thorax pads check fit the pad against the dummy to make sure the pad covers the ribs and press into place engaging the Velcro with light pressure 37 and abdominal couplers are attached to the ribs after instrumentation is plugged Figure 1 29 The ri 1 3 3 2 Assembling spine box Begin assembly of the spine box by mounting the ball joints for the IR TRACC assemblies to the side plate so they face the struck side of the dummy Secure each ball joint Figure 1 17 14 with four FHCS M2 5 x 6 Figure 1 17 Item 13 Attach the seven spacers Figure 1 17 Item 6 to the struck side plate Fi
130. tance to movement of the knee bone in the knee clevis The friction washer must be installed with the friction material toward the knee clevis or the washer will provide very little resistance to movement The compression washer a neoprene material should be inspected to ensure that it is not permanently compressed or damaged The SSHDP that locks the pivot shaft assembly in place in the knee bone must be correctly installed The SSHDP M6 shown in Figure 1 88 must be installed so that the tip is in the locking hole at the middle of the pivot shaft Knee Pivot Screw Ankle Friction 27 Adjustment Screw M x 6 mm NTSS Figure 1 87 Knee assembly 112 M6 x 12mm SSHOP nes Frinton Washer EX Clamping Washer qo emes gt Figure 1 88 Leg joint adjustments Compression Washer 1 7 4 3 Adjusting ankle rotat Note the following The ankle adjustments are not easily done due to the lack of mass of the components This joint is adjusted to approximate a 1 to 2 G setting The ankle rotation friction is controlled by a M6 set screw and M14 lock nut z axis nut see Figure 1 89 Loosen the M6 set screw and check the z axis movement of the lower leg load cell in the ankle assembly The z axis is on a line extending perpendicular to the sole of the foot and through longitudinal centerline of the lower leg load cell Tighten the z axis nut sufficiently to eliminat
131. tatus Box The user must supply a 100 240 VAC source 14 TDAS power supply The TDAS power supply non impact resistant device accepts 100 240 VAC input and provides 13 5 VDC output to the TDAS Status Box The user must supply a 100 240 VAC source 15 TDAS software The provided TDAS software is used for sensor database management test setup test execution data download post test viewing and data export See the manufacturer supplied software user s manual for additional information C 16 Status box to PC cable The status box to PC cable connects a PC to the TDAS Status Box This cable carries Ethernet communications signals C 17 Notebook PC If an optional notebook PC was acquired with the WorldSID G5 DAS it may be pre loaded with TDAS software sensor database and example test setups Since WorldSIDs will move from place to place it is strongly recommended that a PC be dedicated to the dummy This will make setup at the new operating location much easier 6 C 18 Dummy exit to status box cable pinout Table C 2 and Figure C 2 and Figure C 3 give the cable pinout scheme for the dummy exit to status box cable Table C 2 Dummy exit to status box cable pinout Lemo Pin Numb 20 Feet 9507 Color Code Function 1 Main Power 12 VDC 2 Main Power 12 VDC 8 Em Main GND 4 Main GND 5 Ethernet Rx Ethernet Rx 7 p Etherne
132. ter installation 106 Attach the knee contact load cell Figure 1 75 Item 3 using four SHCS 4 x 0 7 x 10 mm for each load cell Figure 1 75 Item 1 Install the load cell directly on to the knee clevis and install the M4 screws in the counter bored holes Tighten these M4 screws to 5 Nm using the M4 star pattern see Figure 1 83 so as to distribute the load equally across the load cell Figure 1 83 Torquing the knee contact load cell Attach the knee covers Figure 1 75 Item 2 and pad Figure 1 75 Item 14 Attach the knee covers directly to the knee contact load cells with four SHCS M4 x 0 7 x 10 Re attach the knee covers using the same star pattern as the knee contact load cell see Figure 1 83 Attach the knee pad using six BHCS M4 x 0 7 x 12 mm Figure 1 75 Item 15 1 7 3 4 Assembling the lower leg The lower leg load cells Figure 1 76 Item 1 are attached to the lower leg tube using four modified BHCS M6 Figure 1 76 Item 2 for each load cell Torque these modified BHCS to 10 Nm Both the upper and lower leg load cells are W50 71010 and can be positioned interchangeably but must be annotated so that the correct sensitivities are used The load cells shall be installed with the connectors positioned toward the knee end of the assembly 107 The ankle Z pivot pin Figure 1 76 Item 6 is installed in the lower load cell The Z pivot pin is secured in position using three SSCP M6 x 1 8 mm Figu
133. tilt sensors are given in Table 7 8 Position the dummy according to the criteria given in Table 7 9 166 Table 7 8 Relationship between mechanical measurement indicators and the tilt sensors Location Mechanical reference Tit sensor angular displacement about the noted axis Head zero Landmark on head is horizontal Xio v o Thorax zero Top of the lower neck bracket is horizontal Xio v o Pelvis zero X angle zero degree Hpoint tool oriented at X 0 Y 144 45 below horizontal Y Table 7 9 Dummy set up criteria Variable Criteria Sensor readings Thorax angle vim Pelvic orientation Sei This pelvic orientation is coincident with point tool at 40 2 below horizontal and pelvic tit sensor at 19 5 2 Distance between knee centres 279 mm 50 mm Due to the low friction of the Teflon pieces the Five degrees is an achievable angle on the test bench dummy is not able to sit at zero pelvis angi 167 jure 7 6 Side view of setup for full dummy certification tests 168 Figure 7 7 Using an inclinometer with the H point tool to check pelvis angle 7 3 3 Shoulder When assembled according to Section 1 and tested using the procedure specified in 7 3 2 and 7 3 3 1 the shoulder assembly shall meet the specifications given in Table 7 10 Table 7 10 WorldSID shoulder certification specification
134. ttery and temperature sensor cable The G5 DB to battery and temperature sensor cable connects these three components C 9 G5 DB to dummy exit cable The G5 DB to dummy exit cable is a separate replaceable cable used for connecting the G5 DB system to the outside of the dummy This cable carries external power Ethernet communications t event signal and status signals See the manufacturer supplied G5 DB hardware user s manual for additional information C 10 Dummy exit to TDAS status box cable The dummy exit to TDAS status box cable is a separate replaceable cable used for connecting the WorldSID to the TDAS Status Box This cable carries external power Ethernet communications t 0 event signal and status signals See C 5 for additional information C 11 TDAS status box The impact resistant TDAS status box is connected to the WorldSID and displays the status of the system via large red yellow and green lights In place of the internal Li lon batteries DTS has provided two options for external power see C 2 10 and C 2 11 below The TDAS Status Box is described in a later clause of this annex C5 C 12 DC DC converter This impact resistant device accepts 10 18 VDC input and provides 18 5 VDC output to the TDAS Status Box The user must supply a 10 18 VDC source with a minimum of 5A current capability C 13 AC DC converter This impact resistant device accepts 100 240 VAC input and provides 13 5 VDC output to the TDAS S
135. uctural replacement Figure 1 51 Item 6 with four SHCS M4 x 8 Figure 1 51 Item 37 on each side Attach the moulded pubic buffers Figure 1 51 Item 5 to the moulded pelvis with three M4 x 16 Figure 1 51 Item 44 and M4 flat washers Figure 1 51 Item 43 on each side Position the central assembled portion of the pelvis within the moulded pelvis pubic assembly Attach each sacroiliac load cell backing plates Figure 1 51 Item 26 with four FHCS 6 x 30 Figure 1 51 Item 34 and three FHCS 6 x 20 Figure 1 51 Item 33 Use the shorter screws on the inboard holes If the pelvis DAS module is being used plug in the connectors for the lumbar pubic and sacroiliac load cells and the pelvis triaxial accelerometer see Figure 1 72 Make sure the connectors for the tilt sensor are free so they can be connected to the off board readout later If a pelvis DAS is not 89 used route the wires toward the front along the non struck side so they be plugged into the lower G5 module on the spine box Figure 1 72 Routing of wires for pelvis instrumentation Place the pelvis into the pelvis flesh placing the pubic assembly in first then adjusting the flesh over the pelvic bones Make sure the flesh is correctly positioned over the pelvis by checking that access holes in the pelvis flesh line up with screw the pelvis When assembling the hip joint as shown in Figure 1 51 apply grease to joint inner ring Figure 1 51 Item
136. ure x and z axis angular acceleration plus a dual axis tilt sensor is mounted near the bottom of the spine box and in addition the ball joint portions of six IR TRACC assemblies are mounted to the spine box plate on the struck side of the dummy 44 14 Full arm 1 4 1 Parts list 1 4 1 1 Parts list for full arm The parts and assemblies required for assembling the WorldSID full arm W50 61000 left W50 61001 right are the upper arm assembly lower arm assembly see Figure 1 36 Items 1 and 9 respectively moulded hand Figure 1 36 Item 10 shoulder assembly Item 22 not included with assembly shown for reference only and moulded shoulder bumper Figure 1 36 Item 19 potentiometer pivot adjustment hardware and strain relief hardware Table 1 6 lists the parts required for assembling the WorldSID full arm which is illustrated in Figure 1 36 Table 1 6 Parts list for full arm Item number Description Part number 1 Upper arm assembly left 1 wso erooz not shown Upper arm assembly right 1 wso eroos 2 Elbow shaft assembly 1 wso 61028 Elbow potentiometer mass replacement wso 6r123 4 M3 flat washer 2 5000181 5 BHCS M3 x 0 5 x 10 mm 2 5000178 BHCS M4 x 0 7 x 6 mm 1 5000179 7 M4 fiat washer 1 5000155 Cable clamp 1 5000191 Lower arm assembly 1 wso eto4 10 Moulded hand assembly left Wso 61037 not shown Moulded hand assembly rig
137. vided to assist the user to more efficiently assemble the WorldSID leg 103 1 7 3 1 Assembling the femoral neck Thread the femoral neck ball on to the femoral neck base until tight see Figure 1 73 Tighten the ball on to the base using a modified 25 mm to 28 mm spanner wrench W50 51001 to turn the ball and a spanner wrench 40 mm to 42 mm W50 51002 to hold the femoral neck base Figure 1 73 Item 4 Be careful not to damage the surface of the ball during disassembly and re assembly Secure the ball by tightening the SSCP Figure 1 73 Item 1 to 2 Nm torque 1 7 3 2 Assembling the upper leg Attach the femoral neck load cell assembly Figure 1 74 Item 3 to the trochanter assembly Figure 1 74 Item 9 Ensure that the base of the load cell is aligned with the dowel pin in the trochanter before tightening the four BHCS M6 x 1 x 16 mm Figure 1 74 Item 5 Torque the BHCS M6 to 10 Nm Attach the trochanter assembly and the leg tube assembly Figure 1 74 Item 7 to the upper leg load cell Figure 74 Item 8 using eight modified BHCS M6 Figure 1 74 Item 5 four at each side of the load cell Torque the modified BHCS M6 to 10 Nm The knee assembly Figure 1 74 Item 6 is attached to the leg tube assembly using four modified BHCS M6 The left and right knee assemblies are different 104 1 7 3 3 Assembling the knee Figure 1 80 Knee assembling To assemble the knee start by placing the knee bone Figure 1 75
138. x 1x 20 5000438 48 _ Cheese screw M2 x 16 5000254 49 MSSFP M4 x6 5000464 Not shown Dual axis tilt sensor mass replacement 1 ws0 10011 72 Item Description Part number number Not shown Linear triaxial accelerometer mass replacement 1 W50 61063 Not shown Pubic symphisis load cell 1 ws0 71051 Not shown Lumbar spine load cell assembly wso 71120 Not shown Sacroiliac load cell assembly wsoz1130 73 Figure 1 51 WorldSID pelvis components 74 Figure 1 52 Rear view of pelvis assembly Figure 1 53 Front view of pelvis assembly 75 Figure 1 55 Close up view of lumbar assembly 76 1 6 2 Disassembling As shown in Figure 1 56 remove the spine box from the pelvis assembly by removing four SHCS 8 x 18 Figure 1 56 Item 14 that connect it to the lumbar mounting wedge Figure 1 56 Item 28 Spine box Figure 1 56 Removing spine box from the pelvis T Detach the femur assemblies by removing the hex head screws 8 x 10 Figure 1 57 Item 46 that attach each to the pelvis assembly see Figure 1 57 They are accessible from the interior of the pelvis bone and can be removed with a box end wrench Washer Hes Head crew Figure 1 57 Detaching the femur assemblies 78 away from Remove the pelvis flesh Figure 1 51 Item 1 by peelin the pelvis see Figure 1 58

USER`S MANUAL FOR THE WORLDSID 50TH PERCENTILE MALE

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