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1. REAR DATUM REFERENCE AT CENTER OF REAR BUMPER TO BOTTOM OF 7 QM 5 COLUMN AX ae X17 TO lt X12 13 X14 15 A POST RIGHT LEFT SIDE X16 TO STEERING COLUMN TO FIREWALL RIGHT LEFT SIDE N41 DATA SHEET NO 12 CONTINUED VEHICLE PROFILE MEASUREMENTS Test Vehicle NHTSA No Test Program Test Date Measurement Description Post Test Total Length of Vehicle at Centerline 2 Rear Surface of Vehicle RSOV to Front of Engine 3 RSOV to Firewall 4 RSOV to Upper Leading Edge of Right Door 5 RSOV to Upper Leading Edge of Left Door RSOV to Lower Leading Edge of Right Door RSOV to Lower Leading Edge of Left Door RSOV to Upper Trailing Edge of Right Door RSOV to Upper Trailing Edge of Left Door 0 RSOV to Lower Trailing Edge of Right Door 1 RSOV to Lower Trailing Edge of Left Door 12 RSOV to Bottom of A Post of Right Side 13 RSOV to Bottom of A Post of Left Side 14 RSOV to Firewall Right Side 15 RSOV to Firewall Left Side 16 RSOV to Steering Column 17 Center of Steering Column to A Post 18 1 7 Center of Steering Column to Headliner RSOV to Right Side of Front Bumper RSOV to Left Side of Front Bumper Length of Engine Block RSOV to Right Side of Dash Panel CD RSOV to Center of Dash Panel LD RSOV to Left Side of Dash Pan
2. TEST 572 134 6 YEAR OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive thorax impact tests are necessary 1 It has been at least 30 minutes since the last thorax impact test 572 127 0 __ N A ONLY one thorax impact test performed 2 The test fixture conforms to the specifications in Figure 11C 3 The complete assembled dummy 127 0000 is used 572 124 b 4 The dummy assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to this test 572 134 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity 5 Remove the chest skin and visually inspect the thorax assembly for cracks cuts abrasions etc Particular attention should be given to the rib damping material chest displacement transducer assembly and the rear rib supports Inspect for rib deformation using the chest depth gage If any damage is noted repair and or replace the damaged components unless the damage resulted from the vehicle crash test in which the dummy was an occupant in which case the damage must be documented and post test calibration verification testing completed before any repairs or replacements are made No damage Damage from crash test no repairs or
3. 3 5 TEST SCHEDULING AND MONITORING 3 6 FACILITY AND EQUIPMENT PRETEST REQUIREMENI S 4 Gl TOW ROAD Gua assqa ter hoped ec iden t aspexi de bn desi Dri nae debe aS 4 6 2 TEST VEHICLE PREPARATION BUILDING STRUCTURE t 4 6 3 TOW AND GUIDANCE SYS Fo rated raid Ext e 4 6 4 FIXED COLLISION BARRIER eto teneo et oem a a ux 6 6 5 TEST VEHICLE VELOCITY MEASUREMENT eerte 6 6 6 TEST BRAKE AB RT SYSTEM hanan haasi drea 7 6 7 STATIC ROLLOVER DEVICE u n ananassa eere ut us 7 7 GOVERNMENT FURNISHED PROPERTY GEP 8 deb TBSIOVBEHIOLES se 8 72 ANTHROPOMORPHIC TESTING DEVICES 8 d MOAI CELE BARRIER usu nanan aa idet ete a a eb abet dede ei 9 8 CALIBRATION AND TEST INSTRUMENTA TIONN 10 9 PHOTOGRAPHIC DOCUMENTATION 13 CAMERA Sang NR NG 13 9 2 COLORING REQUIREMENTS FOR PHOTOGRAPHIC PURPOSES 16 9 3 VEHICLE AND DUMMY PHOTOGRAPHIC COVERAGE REAL TIME 17 IMPACTEVENEMARKERS L Su a n d db beads 18 9 5 PHOTOGRAPHIC TARGETS AND TAPE FOR TEST VEHICLE 18 9 6 TARGET VEHICLE INFORMATION PLACARDS
4. DATA SHEET 1 Seating and Dummy Positioning Procedures for the 50 Male Driver Dummy Part 572 Subpart E all section references refer to FMVSS No 208 Position the seat s adjustable lumbar supports so that the lumbar support is in its lowest retracted or deflated adjustment position S8 1 3 N A No lumbar adjustment 2 Position any adjustable parts of the seat that provide additional support so that they are in the lowest or most open adjustment position 516 2 10 2 _ N A No additional support adjustment 3 Use all the seat controls that have any affect on the fore aft movement of the seat to move the seat cushion to the rearmost position Mark this position 8 31 95 legal interp to Hogan and Hartson 4 Use all the seat controls that have any affect on the fore aft movement of the seat to move the seat cushion to the foremost position Mark this position 8 31 95 legal interp to Hogan and Hartson 5 Mark each fore aft position so that there is a visual indication when the seat is at a particular position For manual seats mark each detent For power seats mark only the rearmost middle and foremost positions Label three of the positions with the following F for foremost M for mid position if there is no mid position label the closest adjustment position to the rear of the mid point and R for rearmost Determine the mid fore aft seat position based on the foremost and rearmost positions determined
5. Manual Seat Track Adjuster Total number of detents Frontal impact test detent 50 percentile male Side impact test detent 50 percentile male Side impact test detent 5 percentile female For manual seat track adjustments test detent is measured from foremost detent which is defined as 0 Power Seat Track Adjuster Complete range of travel as determined for Frontal NCAP mm Frontal impact test distance from the foremost position 50 percentile male Complete range of travel as determined for Side NCAP mm Side impact test distance from the foremost position 50 percentile male Side impact test distance from the foremost position 5 percentile female Seat Cushion Angle If the seat cushion angle is adjustable while maintaining the test fore aft seat track position describe the angle used during certification testing and how to measure it Include any reference points and photographs Dummy Angle Used Additional Description Frontal Impact 50 Male Side Impact 50 Male Side Impact 5 Female Seat Cushion Height If the seat and or seat cushion height is adjustable at the test fore aft seat track position and can be adjusted so that the seat cushion angle can be at the angle used in the N52 certification test describe the height used during certification testing and how to measure it
6. Redundant Head Top NAAH Head Front Indicates Nine Accelerometer Array Head 4 Negative Channels to be Reversed In Data Acquisition Negative Channels to be Reversed In Data Acquisition System Check Data Sheet For Axis Accelerometers limiy Type Serial Channel Orientation of Positive Upright Lean Dam Value Chrientarion f r LU or Positive Polarity Head C Heal CAG Kechirim Head Head Front Indicates Nine Accelerometer Array Head 5 Megalive Channels la he Beversed In lata A vcuuisitin Systens APPENDIX N TEST DELIVERABLES AND REPORT GUIDELINES NEW CAR ASSESSMENT PROGRAM REPORT GUIDELINES TABLE OF CONTENTS 1 TEST DELIVERABLES AND REPORTING REQUIREMENTS 1 1 1 MONTHLY STATUS REPORTS ganer a eR Hu 1 12 CABPARENLTBESDEAXIEURB Z u san asa Sh bus ra cals 1 13 NCAP TEST DELIVERABLES rete rrr tu den ai 1 2 SAMPLE TEST REPORT PAYOUT uuu eo Ebr tha tq Ernie bue Ina decida bui 10 REPORT AREA 1 PURPOSE AND SUMMARY OF eee 11 RE POR AREA T DATASHEETS ieu a nasua ee N 13 REPORT AREA 3 PHOTOGRAPHS u laa a gr eed AEA 14 REPORT AREA 4 DUMMY RESPONSE DATA TRACES eee 19 REPORT AREA 5 DUMMY CALIBRATION AND PERFORMANCE V
7. 12 4 12 5 12 6 NCAP 58 90 PASSENGER RIGHT FOOT Z FRONT 91 PASSENGER SHOULDER BELT 92 PASSENGER LAP BELT VEHICLE DATA TRACES INSCOM LEFT REAR SEAT CROSSMEMBER X RIGHT REAR SEAT CROSSMEMBER X TOP OF ENGINE X BOTTOM OF ENGINE X LEFT REAR SEAT CROSSMEMBER Z RIGHT REAR SEAT CROSSMEMBER Z LEFT REAR SEAT CROSSMEMBER X REDUNDANT RIGHT REAR SEAT CROSSMEMBER X REDUNDANT LOAD CELL BARRIER DATA TRACES CURNO INSCOM VARIES Depends on load cell barrier size See Appendix P PERFORMANCE REQUIREMENTS NOTIFICATION OF TEST RESULTS The performance requirements are found in Section 2 General Requirements of this test procedure If test results indicate that the test vehicle has exceeded any of the injury criteria or has not met a requirement the Contractor shall notify the COTR in accordance with Appendix N Test Deliverables and Report Guidelines NCAP TEST DELIVERABLES Required deliverables for each test are discussed in Appendix N Test Deliverables and Report Guidelines A Schedule of Deliverables is also provided in that location DATA RETENTION BY THE CONTRACTOR The Contractor shall retain reproducible copies of all data tapes high speed and real time digital videos digital photographs and Form No 1 manufacturer information for at least five 5 years at no extra cost to the NHTSA The tested vehicles protected from the elements shall be retained by the test Contract
8. LL Gr 10 141 APPARENT NONCONFORMANCE tette a 10 14 2 CALIBRATION DOCUMENTATION ettet 11 5 DATA SEES LC metet u died auf E cd i DATASHEET E Nasal ta a i tact en ae he A 12 DATA SHBET EE au DEDE 14 HEER NN 21 EE 25 HAL GM EN 27 DATA SHEET BO castus 33 DATLOHEED D de ciu ut dta Le cO ER 38 DATA SUBE BB uet bie musst d RE c Ar RD Su Led 41 DATASHEET BOR S sete s LE SE Mr t 43 DATASHEET akse 46 Bl PURPOSE AND APPLICATION The purpose of this laboratory procedure is to provide dummy users independent testing laboratories under contract with the Office of Crashworthiness Standards with standard test procedures for performing receiving inspection and performance calibration tests on the Part 572 Subpart O dummy so that repetitive and correlative test results can be obtained The following tests have been developed to establish a uniform calibration procedure for all users as the means of verifying the performance of the dummy A EXTERNAL DIMENSIONS drawing 880105 000 XH pg 5 of 6 amp PADI B HEAD DROP TEST 572 132 C NECK FLEXION TEST 572 133 b 1 D NECK EXTENSION TEST 572 133 b 2 E THORAX IMPACT TEST 572 134 F TORSO FLEXION 572 135 G KNEE IMPACT TESTS 572 136 This laboratory procedure fo
9. OK Accelerometer Head mounting secure Mountings Chest mounting secure Knees Skin condition Insert do not remove Casting Limbs Normal movement and adjustment Knee Sliders Wires intact Rubber returned to at rest position Pelvis Broken Other If upon visual examination damage is apparent in any of these areas the appropriate engineer or engineering technician is to be consulted for a decision on repair or replacement of parts Repair or Replacement approved by Signature Describe the repair or replacement of parts Checked by Signature Date Date Dummy Serial Number Test Date 16 DATA SHEET A2 EXTERNAL MEASUREMENTS 50 Male Procedures for Disassembly Inspection and Assembly of the Hybrid III Dummy Appendix A Technician Pretest calibration Post test calibration verification l Remove the dummy s chest jacket and the abdominal insert Seat the dummy on a flat rigid smooth clean dry horizontal surface as shown in Figure 3A The seating surface is at least 406 mm 16 in wide and 406 mm 16 in in depth with a vertical section at least 406 mm 16 in wide and 914 mm 36 in high attached to the rear of the seating fixture The dummy s midsagittal plane is vertical and centered on the test surface Remove the four socket head cap screws that attach the lumbar spine to the thoracic spine Lift the uppe
10. rests against the seat back 510 4 1 1 amp 510 4 1 2 20 Rest the thighs on the seat cushion S10 5 F3 21 Position the H point of the dummy within 0 5 inch of the vertical dimension and 0 5 inch of the horizontal dimension of a point 0 25 inch below the H point determined using the SAE J826 H point machine 510 4 2 1 Then measure the pelvic angle with respect to the horizontal using the pelvic angle gage Adjust the dummy position until these three measurements are within the specifications S10 4 2 1 and 510 4 2 2 horizontal inches from the point 0 25 below the determined H point 0 5 inch max S10 4 2 1 _ vertical inches from the point 0 25 below the determined H point 0 5 inch max S10 4 2 1 pelvic angle 20 to 25 22 Is the head level within 0 5 S10 1 Yes go to 23 No go to 22 1 22 1 Adjust the position of the H point S10 1 22 2 15 the head level within 0 5 S10 1 Yes record the following then go to 23 No go to 22 3 horizontal inches from the point 0 25 below the determined H point 0 5 inch max S10 4 2 1 vertical inches from the point 0 25 below the determined H point 0 5 inch max S10 4 2 1 pelvic angle 20 to 25 S10 4 2 2 223 Adjust the pelvic angle 510 1 22 4 Is the head level within 0 5 S10 1 __ Yes record the following then go to 23 No go to 22 5 horizontal inches from the point 0 25 below the determined H point 0 5 inc
11. seen 20 9 7 DOCUMENTATION VIDEO TITLE AND SEQUENCE eee 21 9 8 DOCUMENTATION VIDEO RECORDING AND EDITING 21 9 9 STILE PHOTOG RAPS vadet ee 22 10 DEFINITIONS qutm 22 11 N 0 410 05 4 LOL BU MEO Jy Pese 24 ILI TESEVBHICLE PREPARATION ae eiie A qe ue beo Pie ashuan qub een 24 112 TEST DUMMY PREPARATION POSITIONING AND PLACEMENT 33 113 LOADCELL BARRIER PREPARATION n aaa 45 II WBHICEBR MEASUREMENTS n e qut nent ha quoe 45 IL5 ELECTROMAGNETICINTERFERENCE ate tiens 49 12 TEST DATA DISPOSITION 50 121 u eee imaqa a e qa agag 50 122 DAA PROCESSING see 52 123 RECOMMENDED DATA TRACE ORDER iere naa 55 124 PERFORMANCE REQUIREMENTS NOTIFICATION OF TEST RESULTS 58 12 5 NCAP TEST DELIV BRA BLES uicti tn aee trt medan stend 58 12 6 DATA RETENTION BY THECONTRAGCTONR net tritt 58 I2 DATA AVAILABILITY TO THE PUBLIG riter nausea tenen enn Deine hen ete teta 59 NCAP LABORATORY TEST PROCEDURE LIST OF FIGURES FIGURE 1 TYPICAL FRONTAL NCAP RIGID BARRIER IMPACT TEST 2 6 FIGURE 2 CAMERA POSITIONS FOR FRONTAL 6
12. to the pendulum longitudinal centerline Note Plane D is the top horizontal surface of 027 neck load cell These measurement devices should designed to minimize their influence upon the performance of the head neck assembly 11 Plane D is perpendicular 1 degree to the centerline of the pendulum _ 12 Set the instrumentation so that the moment and rotation are defined to be zero when the longitudinal centerline of the neck and pendulum are parallel 572 143 b 2 Gii 13 Release the pendulum and allow it to fall freely from a height to achieve an impact speed of 3 55 m s to 3 75 m s as measured at the center of the pendulum accelerometer 572 143 c 4 _ 14 Complete the following table Neck Extension Test Results 572 143 b 2 amp 572 143 c 4 11 Parameter Specification Result Pendulum impact speed 3 55 m s speed lt 3 75 m s Pendulum 6 ms 1 0 m s AV lt 1 4 m s AV with respect g l0ms 1 9 m s lt AV 2 5 m s to impact speed 14 ms 2 8 m s lt AV 3 5 m s Plane D Rotation Peak moment Nm 53 3 Nm lt moment lt 43 7 Nm during the degrees following rotation range 83 lt angle lt 93 Negative Moment Decay Time to decay to 10 Nm Extension 60ms lt time lt 80ms 1 215 moment is direct reading from load cell Time zero is defined as the time of initial contact between the pendulum striker plate and th
13. 0 5 degrees If head cannot be leveled using the seat back adjustment or the seat back is not adjustable use the lower neck bracket adjustment to level the head If a level position cannot be achieved adjust the head as closely as possible to 0 5 degree range 516 3 3 1 9 and 516 3 3 1 10 Check That Apply Seat back not adjustable Seat back not independent of driver side seat back Head Level Achieved Check all that apply Head leveled using the adjustable seat back Head leveled using the neck bracket Head Angle degrees Head Level NOT Achieved Check all that apply __ Head adjusted using the adjustable seat back Head adjusted using the neck bracket Head Angle degrees 2 15 Verify the pelvis is not interfering with the seat bight S16 3 3 1 9 No interference Pelvis moved forward the minimum amount so that it is not caught in the seat bight 16 Verify the dummy abdomen is properly installed 516 3 3 1 9 Abdomen still seated properly into dummy Abdomen was adjusted because it was not seated properly into dummy 17 Head Angle N A neither the pelvis nor the abdomen were adjusted 17 1 Head still level Go to 16 17 2 Head level adjusted Head Level Achieved Check all that apply Head leveled using the adjustable seat back A Head leveled using the neck bracket Head Angle degrees 10 _ Head Level NOT Achieved Check all that apply Head adjusted u
14. 5 572 523 TE3200 140 REF NOTE MOUNT NECK AT LEADING EDGE OF PENDULUM TO AVOID INTERFERENCE FIGURE SE E32 NECK EXTENSION TEST SET UP SPECIFICATIONS DIRECTION OF PENDULUM J FLIGHT PENDULUM REF FIG 22 SUBPART E NECK ASSEMBLY 921022 041 REF PLANE D hw ADAPTER ASSEMBLY TE3200 160 REF LOADCELL SA572 823 HEADFORM TE320 140 REF NOTE MOUNT NECK AT LEADING EDGE OF PENDULUM TO AVOID INTERFERENCE FIGURE 9E E33 DATA SHEET E7 THORAX IMPACT TEST 572 154 12 MONTH OLD Dummy Serial Number Test Date Technician __ Pretest calibration Post test calibration verification Test attempt no when successive thorax impact tests are necessary 10 TE It has been at least 30 minutes since the last thorax Impact test 572 155 m __ N A ONLY one thorax impact test performed The test fixture conforms to the specifications in Figure 10 The complete assembled dummy 921022 000 15 used 572 154 b and 15 dressed in cotton polyester based tight fitting long sleeved sweat shirt and ankle length pants The weight of the shirt and pants shall not exceed 0 25 kg 572 154 c 2 The dummy assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to this test 572 154 c 1 Record the maximum temperature Record the minimum temperat
15. DIAMETER HOLES IN SKULL DISTANCE A DISTANCE 0 0 mm NOTE TOLERANCE ON TEST SETUP DIMENSIONS 1 mm 0 04 in FIGURE 6A 26 HEAD TEST SETUP FIGURE 7A 27 DATA SHEET A4 NECK FLEXION TEST 572 33 50 Male Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive flexion tests are necessary l 2 It has been at least 30 minutes since the last flexion test 572 36 m __ N A ONLY one neck test performed The components required for the neck tests include the head assembly 78051 61X neck assembly 78051 90 bib simulator 78051 84 upper neck adjusting bracket 78051 307 lower neck adjusting bracket 78051 303 six axis neck transducer C 1709 and either three accelerometers or their mass equivalent installed in the head assembly Data from the accelerometers are not required 572 33 b The assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to a test 572 33 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Visually inspect neck assembly for cracks cuts and separation of the rubber from the metal segments Note If the damage resulted from the vehicle crash test in which the dummy was an occupant
16. Door Opening Inside Window Jam Left Knee Bolster to X Right Knee Bolster to X Brake Pedal to X Foot Rest to X Center of Steering Column Wheel Hub to X X Front of Seat Track Stationary DRIVER COMPARTMENT N45 DATA SHEET NO 15 SUMMARY OF FMVSS 212 219 PARTIAL AND 301 DATA Test Vehicle NHTSA No Test Program Test Date Please provide windshield mounting details The standard requires that the post test retention measurement be a minimum of 7590 of the pre test total periphery measurement for vehicles not equipped with occupant passive restraints and 50 for each side of the windshield for vehicles which are equipped with occupant passive restraints Temperature of windshield molding during test WINDSHIELD PERIPHERY MEASUREMENTS Measurement Pre Test mm Post Test mm Retention m Left Side Right Side Item Units AREAS OF PROTECTED ZONE FAILURES A Provide coordinates of the area that the protected zone was penetrated more than 25 inches by a vehicle component other than one that is normally in contact with the windshield B Provide coordinates of the area beneath the protected zone that the inner surface of the windshield was penetrated by a vehicle component N46 DATA SHEET NO 15 CONTINUED SUMMARY OF FMVSS 212 219 PARTIAL AND 301 DATA Test Vehicle NHTSA Test
17. Dummy Inspect for Comments Damaged OK Accelerometer Head mounting secure Mountings Chest mounting secure Knees Skin condition Insert do not remove Casting Limbs Normal movement and adjustment Knee Sliders Wires intact Rubber returned to at rest position Pelvis Broken Other If upon visual examination damage is apparent in any of these areas the appropriate engineer or engineering technician is to be consulted for a decision on repair or replacement of parts Repair or Replacement approved by Signature Describe the repair or replacement of parts Checked by Signature Date Dummy Serial Number Test Date 15 DATA SHEET 2 EXTERNAL MEASUREMENTS 12 MONTH OLD See the PADI pages 52 55 Technician Pretest calibration Post test calibration verification l Seat the dummy on a flat rigid smooth clean dry horizontal surface The seating surface is at least 406 mm 16 in wide and 221 mm 8 11 16 in in depth with a vertical section at least 406 mm 16 in wide and 610 mm 24 in high attached to the rear of the seating fixture The dummy s midsagittal plane is vertical and centered on the test surface Secure the dummy to the test fixture so that the upper torso and buttocks are tangent to the rear vertical surface of the fixture as tangent as possible Push the dummy s forehead rearward and secure the head at the for
18. Gashes rips cracks Head Ballast secure General appearance Neck Broken or cracked rubber Upper neck bracket firmly attached to the lower neck bracket Looseness at the condyle joint Nodding blocks cracked or out of position Spine Broken or cracks in rubber Ribs Broken or bent ribs Broken or bent rib supports Damping material separated or cracked Rubber bumpers in place Chest Displacement Assembly Bent shaft Slider arm riding in track Transducer leads Torn cables B13 Dummy Inspect for Comments Damaged OK Accelerometer Head mounting secure Mountings Chest mounting secure Knees Skin condition Insert do not remove Casting Limbs Normal movement and adjustment Knee Sliders Wires intact Rubber returned to at rest position Pelvis Broken Other If upon visual examination damage is apparent in any of these areas the appropriate engineer or engineering technician is to be consulted for a decision on repair or replacement of parts Repair or Replacement approved by Signature Describe the repair or replacement of parts Checked by Signature Date Dummy Serial Number Test Date 14 DATA SHEET 2 EXTERNAL MEASUREMENTS 59 Female See the PADI Technician Pretest calibration Post test cali
19. SIDE Q A C D R M FIGURE 2C C19 EXTERNAL DIMENSIONS TEST SETUP 9999 90900 900609 yw FIGURE C20 EXTERNAL DIMENSIONS TEST SETUP FIGURE 4C 21 DATA SHEET HEAD DROP TEST 572 122 6 YEAR OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive head drops are necessary l 2 It has been at least 2 hours since the last head drop 572 122 c 5 N A ONLY one head drop performed The head assembly consists of the complete head 127 1000 a six axis neck transducer SA572 S11 or its structural replacement 78051 383X a head to neck pivot pin 78051 339 and three 3 accelerometers SA572 S4 572 122 a Torque the skull cap screws 10 32 x 1 2 SHCS to 10 2 Nm Accelerometers and their respective mounts are smooth and clean The head accelerometer mounting plate screws 10 24 x 3 8 SHCS are torqued to 9 0 Nm The data acquisition system including transducers conforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 126 m The head assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 1096 to 7096 for a period of at least four 4 hours prior to a test 572 122 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Vis
20. Vaud NET Date of Odometer T Vehicle Odometer Complete Shipment No Make and Delivery Reading Reading N71 FORM 5 SAMPLE QUICKLOOK REPORT QUICKLOOK REPORT 56 km h 35 mph Frontal Impact NCAP Rigid Barrier Test Laboratory Name and Logo Model Year Make Model Trimline Body Style NHTSA No MXXXXXXXX Test Date Month Day Year Driver 50th Percentile Male Passenger 5th Percentile Female 70 F po j C 200 2520 2 35 wp j C 52 60 o 6800 Femur Force Rig 6 00 ish Uni 11 _ Windshield Periphery Retention Units 219 partial Windshield Zone Intrusion 7 25 6 5 68 Value Vehicle Impact Velociy imn Vehicle Curb Weight w Vehicle Test Weight e Y As Delivered Vehicle Width mm Delivered Vehicle Wheelbase mm Delivered Vehicle Length mm Driver Pl Front Passenger PI Deployment Mount Deployment Driver 1 1 Header Yes No ABS Yes No APPENDIX O RESERVED APPENDIX P LOAD CELL BARRIER CONFIGURATIONS APPENDIX P LOAD CELL BARRIERS PURPOSE In conjunction with NHTSA s compatibility research activities frontal NCAP tests may be used as a means of collecting data through load cells mounted to the rigid barrier wall In these cases an array of load cells will be provided to the contractor The type and amount of load cells furnished will dictat
21. general planer degrees Note this is not an SI unit vehicle frontal area square meters ENERGY heat kilojoules mass flow rate kilometers per second volume flow rate for liquids volume flow rate for gases K3 WHEN MEASURING THE PREFERRED UNITS ARE IMPULSE general newton seconds LENGTH engineering drawings millimeters motor vehicle dimension millimeters or meters vehicle crash deformations centimeters short land distance meters long land distance kilometers MASS small masses grams large masses kilogram very large masses metric ton MOMENTS second moment of area millimeters or centimeters of force torque or bending newton meters of inertia gram or kilogram meter square MOMENTUM general kilograms meters per second POWER general watts or kilowatts PRESSURE general kilopascals STRAIN general micrometers per meter STRESS general megapascals 4 WHEN MEASURING THE PREFERRED UNITS ARE mum I angular degrees per second preferred radians per second acceptable APPENDIX L UPPER NECK LOAD CELL POLARITY CHECK L1 APPENDIX L PROCEDURE FOR CHECKING DUMMY UPPER AND LOWER NECK LOAD CELL POLARITY FOR THE HYBRID III 5019 AND 5 PERCENTILE Purpose The purpose of this procedure is to provide a practical methodology for checking and documenting the recorded polarity of the data channel for each dummy mounted load cell relative to the NHTSA sign convention Documenting the
22. telephone 301 419 5070 SECURITY NHTSA Part 572 Subpart P test dummies delivered to the contract laboratory as Government Furnished Property GFP will be stored in a safe and secure area such as a dummy calibration laboratory The contractor is financially responsible for any acts of theft and or vandalism that occur during the storage of GFP Any security problems shall be reported by telephone to the Industrial Property Manager IPM Office of Contracts and Procurement within two working days after the incident A letter containing specific details of the security problem will be sent to the IPM with copy to the COTR within 48 hours 02 The contractor 15 responsible maintaining test dummies in good working order and shall protect and segregate data that evolves from conducting Part 572 Subpart P dummy calibration tests before and after each vehicle crash test No Information concerning the Part 572 Subpart P dummy calibration data shall be released to anyone except the COTR unless specifically authorized by the COTR or the COTR s Branch or Division Chief NOTE No individuals other than contractor personnel directly involved in the dummy calibration test program shall be allowed to witness dummy calibration tests unless specifically authorized by the COTR GOOD HOUSEKEEPING Contractors shall maintain the entire dummy calibration laboratory test fixtures and instrumentation in a neat c
23. time dependent test parameters THORAX IMPACTOR PROBE 572 137 a A B The test probe for thoracic impacts shall be of rigid metallic construction concentric about its longitudinal axis It shall have a mass of 13 97 0 023 kg 30 8 0 05 Ibs 1 3 of the weight of the suspension cables and any attachments to the impact probe must be included in the calculation of mass and such components may not exceed 5 percent of the total weight of the test probe It shall have a minimum mass moment of inertia of 3646 kg cm 3 22 Ibs in sec in yaw and pitch about the center of gravity 11 4 F G B7 The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It must have a flat continuous and non deformable face with diameter of 152 4 0 25 mm 6 00 0 01 in and a maximum edge radius of 7 6 12 7 mm 0 3 0 5 m The impactor is a cylinder with a diameter of 152 4 152 6 mm 6 0 6 1 in and it is at least 25 mm 1 0 in long The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe The impact probe shall have a free air resonant frequency of not less than 1000 Hz KNEE IMPACTOR PROBE 572 137 b A B The test probe for knee impacts shall be of rigid metallic construction concentric about its longitudinal axis It shall have a mass of 2 99 0 01 kg 6 6 0 022
24. 101 6 mm t ini STRUCTURAL STEEL TUBE boo mm 4 8 mm 10 1875 in p 31 8 mm PIVOT 50 8 mm 2 in DIA 11 25 in INERTIAL PROPERTIES OF PENDULUM MOUNTING PLATE AND MOUNTING HARDWARE WITHOUT TEST SPECIMEN T PENDULUM X 7 ACCELEROMETER CENTERLINE WEIGHT 29 57 165 21 156 198 1 mm MOMENT OF INERTIA 33 2 kg m roy 8 294 in Ib sec ABOUT PIVOT AXIS P 7 4 8 mm GE 188 in mm 38 1 mm 8 28 mm f 7 F 11 5 in 132 6m3 A i f i ON 886 2 mm 188 6 mm CG OF PENDULUM SES 9225 in 7 75 in APPARATUS WITHOUT 7 Eu 463 6 NE RADIOS HEXCEL 28 8 kg m zw 1 8 1b ft REF ACCELEROMETER BEFORE TESTING RECRUSH THE HONEYCOMB w MATFRIAL WITH THE PENDULUM TO ASSURE THAT 90 TO 100 OF THE HONEYCOMB SURFACE 15 CONTACTING THE PENDULUM STRIKER PLATE 4 ft 38 1 mm REF 1 5 in MOUNTING PLATE PENDULUM STRIKER PLATE SHARP EDGES 76 2 x 152 4 x 9 5 mm 3 x 6 x 3 8 in FIGURE 7B B30 NECK FLEXION TEST SETUP SPECIFICATIONS y PENDULUM CENTERLINE PENDULUM REF FIG 22 CFR 49 572 33 ACCELEROMETER P N 880105 207 BIB SIMULATOR P N 880105 210 NECK ASS Y P N 880105 250 BRACKET NECK ADJUSTING LOWER P N 880105 208 MOUNTING SCREW CENTERLINE 6 AXIS UPPER NECK LOAD CELL SA572 511 D PLANE OCCIPITAL CONDYLES PER
25. 3 Attach the loading adapter bracket to the spine of the dummy as shown in Figure 11C 572 125 c 6 Flex the dummy forward and back 3 times such that the angle reference plane moves between 0 and 30 with respect to the vertical transverse plane 572 125 c 4 Support the dummy such that the angle reference plane is at or near 0 vertical with respect to the vertical transverse plane Wait at least 30 minutes before continuing 572 125 c 4 Remove all external support that was implemented in 9 above 572 125 c 5 Measure the initial orientation angle of the torso reference plane of the seated unsupported dummy 572 135 c 5 Record reference plane angle max allowed 22 Attach the pull cable and the load cell 572 125 c 6 Apply a tension force in the midsagittal plane to the pull cable at any upper torso deflection rate between 0 5 and 1 5 per second until the angle reference plane is at 45 0 5 of flexion relative to the vertical transverse plane 572 125 c 7 Maintain angle reference plane at 45 0 5 of flexion for 10 seconds 572 125 c 8 As quickly as possible release the force applied to the attachment bracket 572 125 c 9 C37 _ 16 3 minutes after the release of the force measure the reference plane angle 572 125 c 9 __17 Complete the following table Torso Flexion Results 572 125 b 572 125 c 7 572 125 c 8 Parameter Specification Re
26. 572 127 k 2 11 5 Thorax and thorax pendulum Class 180 572 127 3 1 acceleration 6 Sternum deflection Class 600 572 127 K 3 Gii 7 Knee pendulum acceleration Class 600 8 Femur force Class 600 572 127 k 6 9 Torso flexion Class 60 filter classes should be of the phaseless type to be compatible with the time dependent test parameters 11 3 THORAX IMPACTOR PROBE 572 127 a A B The test probe for thoracic impacts shall be of rigid metallic construction concentric about its longitudinal axis It shall have a mass of 2 86 0 02 kg 6 3 0 05 Ibs 1 3 of the weight of the suspension cables and any attachments to the impact probe must be included in the calculation of mass and such components may not exceed 5 percent of the total weight of the test probe It shall have a minimum mass moment of inertia of 160 kg cm 0 141 165 in yaw and pitch about the center of gravity The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It must have a flat continuous and non deformable face with 11 4 C7 diameter of 101 6 0 25 mm 4 00 0 01 in and an edge radius of 7 6 12 7 mm 0 3 0 5 in The impactor is a cylinder with a diameter of 101 103 mm 4 0 4 1 in and it is at least 12 5 mm 0 5 in long The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear wit
27. BUTTOCK TO KNEE PIVOT LENGTH Knee pivot bolt to the fixture s rear vertical surface 178 5 188 7 HEAD BREADTH Distance across the head at its widest point 124 4 134 6 Distance from the forward most surface of the head to the HEADET rearmost surface of the head in line with the midsgittal plane Hone HIP BREADTH E across the width of the hip at the widest point of the 1585 1737 SHOULDER BREADTH Distance between the outside edges of the shoulder flesh in line 200 7 215 9 with the shoulder pivot bolts FOOT BREADTH The widest part of the foot 39 1 49 3 CHEST CIRCUMFERENCE Distance around chest at reference location AA with Jacket on 4524 4778 WITH Measured 261 6 5 1 mm above seat surface WAIST CIRCUMFERENCE Distance around waist at reference location BB with jacket on 447 472 4 Measured 111 8 5 1 mm above the seat surface REFERENCE LOCATION 4 FOR DIMENSIONS GO Reference 261 6 5 1 mm above the seat surface 256 5 266 7 E18 HYBRID III SUBPART R EXTERNAL DIMENSIONS continued ASSEMBLY ACTUAL DIMENSION DESCRIPTION DETAILS Guy o MEASUREMENT REFERENCE LOCATION FOR DIMENSION Z Reference 111 8 5 1 mm above seat surface 106 7 116 9 SHOULDER HEIGHT Top of arm to seat surface 299 7 314 9 CHIN HEIGHT Bottom of chin to seat surface 289 6 304 8 2 AXIS SIDE VIEW FIGURE 4E FRONT VIEW E19 20 DATA SHEET FRONTAL HEAD DROP TEST 572 15
28. Contract Number Date From To The vehicle was inspected upon arrival at the laboratory for the test and found to contain all the equipment listed below variances have been reported within 2 working days of the vehicle arrival by letter to the NHTSA Industrial Property Manager with a copy to the COTR The vehicle is again inspected after the above test has been conducted and all changes are noted below The final condition of the vehicle is also noted in detail PLEASE LIST OTHER PERTINENT OPTIONAL EQUIPMENT ON THE NEXT PAGE IN THE REMARKS SECTION NHTSA No Model Year Anti Lock Brakes Make Tilt Steering Model Power Steering Body Style Driver Front Airbag VIN Driver Side Seat or Door Airbag Body Color Driver Side Curtain Airbag Delivery Date Driver Knee Airbag Odometer Reading km mi Driver Other Airbag Dealer Passenger Front Airbag Transmission Passenger Side Seat or Door Airbag Drivetrain Passenger Side Curtain Airbag Type No Engine Cylinders Passenger Knee Airbag Engine Displacement L Passenger Other Airbag Engine Placement Second Row Seat or Door Airbag Roof Rack Second Row Side Curtain Airbag Sunroof T Top First Row Pretensioners Traction Control First Row Load Limiters Power Brakes Second Row Pretensioners F
29. IMPACT POINT OF LONGITUDINAL CENTERLINE OF PROBE COINCIDES WITH MIDSAGITTAL PLANE OF DUMMY 4 ALIGN PROBE TO CENTER OF MIDDLE RIB 2 5mm 0 118 WITHIN 0 OF HORIZONTAL PLANE UPPER BACK PLATE OF SPINE BOX AT 90 1 ORIZONT IMPACT PROBE WEIGHT INCLUDING INSTRUMENTATION AND 13 WEIGHT OF SUPPORT CABLES 1 70 40 02 kg 3 75 34 05 Ibs P 1 3 WEIGHT OF PROBE SUPPORT CABLES AND THEIR ATTACHMENTS TO THE IMPACT PROBE NOT TO EXCEED 5 OF THE TOTAL IMPACT PROBE WEIGHT Probe specifications l 2 Rigid metallic construction concentric its longitudinal axis A mass of 1 7 0 02 kg 3 75 0 05 Ibs 1 3 of the weight of the suspension cables and their attachments to the impact probe are included in the calculation of mass and such components may not exceed 5 percent of the total weight of the test probe Minimum mass moment of inertia of 164 kg cm 0 145 Ibs in sec in yaw and pitch about the center of gravity The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It has a flat continuous and non deformable face with diameter of 50 8 0 2 mm 2 00 0 01 in and a maximum edge radius of 7 6 12 7 mm 0 3 0 5 in The impactor is a cylinder with a diameter of 53 3 mm 2 1 1n and it is at least 25 4 mm 1 0 in long The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear wit
30. The driver position 1 ATD Serial No PISNo and the right front passenger position 2 ATD Serial No P2SNo were calibrated previous to this test Certification details along with instrumentation calibration data are found in Appendix C of this report The DataCh channels of data were recorded on an on board data acquisition system Appendix B contains the vehicle load cell barrier and dummy response data traces There was 100 percent windshield retention and no intrusion into the protected zone of the windshield during the event There was no Stoddard solvent leakage after the event or during any phase of the static rollover The maximum static crush of the vehicle was MaxCrush mm and both the driver and passenger side doors remained closed during the impact event and were operable after the impact The driver s visible contact points were as follows XXXXXX The passenger s visible contact points were as follows XXXXXX The occupant data is summarized below ATD Position HIC 15 Neck Neck 3ms Chest Left Right Chest Disp Femur Femur mm N N N Gs Ni Tension Compression Driver 50 Male Passenger 59 Female N13 REPORT AREA 2 DATA SHEETS Data sheets can be found in Section 3 of this Appendix For purposes of consistency it is highly suggested that exact replicas of these sheets are Inserted into the Fina
31. The list of test equipment shall include instrument accuracy and calibration dates All equipment shall be calibrated in accordance with the manufacturer s instructions There shall be no contradictions between the Laboratory Test Procedure and the Contractor s in house test procedure Written approval of the in house test procedures shall be obtained from the COTR before initiating the NCAP test program The OCWS Laboratory Test Procedures are not intended to limit or restrain a Contractor from developing or utilizing any testing techniques or equipment which will assist in procuring the required data These Laboratory Test Procedures do not constitute an endorsement or recommendation for use of any product or method However the application of any such testing technique or equipment is subject to prior approval of the COTR NOTE The NCAP Laboratory Test Procedures prepared for the limited purpose of use by independent laboratories under contract to conduct NCAP tests for the OCWS are not rules regulations or NHTSA interpretations regarding the meaning of an FMVSS or this procedure The Laboratory Test Procedures may not include all of the various FMVSS minimum performance requirements Recognizing applicable test tolerances the Laboratory Test Procedures may specify test conditions that are more or less severe than the minimum requirements of the standard GENERAL REQUIREMENTS This laboratory test procedure is derived from the FMVSS No 20
32. nor other attachments to the probe including the velocity vane make contact with the dummy 572 126 c 6 40 11 Complete following table Knee Impact Results 572 126 b 1 and 572 126 c 5 Parameter Specification Result Probe speed 2 07 m s lt speed lt 2 13 m s Peak resistance force 2000 N lt force lt 3000 N Force impactor mass x deceleration 572 126 b 2 Plots of acceleration versus time and force versus time follow this sheet Signature Date C41 DATA SHEET C9 RIGHT KNEE IMPACT TEST 572 126 6 YEAR OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive knee impact tests are necessary 1 It has been least 30 minutes since last impact test 572 127 0 __ N A ONLY one knee impact test performed 2 test fixture conforms to the specifications in Figure 12C 3 knee assembly consisting of the knee machined 127 4013 knee flesh 127 4011 lower leg 127 4014 foot assembly 127 4030 2 and femur load transducer SA572 510 may use the load cell structural replacement 127 4007 were used 572 126 b __4 knee assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 1096 to 7096 for a period of at least four 4 hours prior to this test 572 126 c 1 Record the ma
33. plane angle Angle lt 20 Torso rotation rate 0 5 s rate lt 1 5 s Force at 45 0 5 320 N force lt 390 N Final ref plane angle Initial ref plane angle 8 Signature Date TORSO FLEXION TEST SET UP SPECIFICATIONS S VERTICAL TRANSVERSE PLANE LOADING ADAPTER BRACKET ATTACH TO SPINE BOX WITH FOUR 10 32 SCREWS PELVIS LUMBAR JOINING SURFACE HORIZONTAL 1 ATTACH PELVIS BONE 880105 431 TO FIXTURE WITH FOUR 1 4 20 x 1 2 BOLTS gt ADAPTER DUMMY ASSEMBLY N CABLE AND ATTACHMENT 890105 000 FIGURE 13B 40 B41 DATA SHEET B8 LEFT KNEE IMPACT TEST 572 136 58 Female Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive knee impact tests are necessary 1 It has been at least 30 minutes since the last knee impact test 572 137 q __ N A ONLY one knee impact test performed 2 test fixture conforms to the specifications in Figure 14B 3 knee assembly 880105 528L lower leg structural replacement 880105 603 lower leg flesh 880105 601 ankle assembly 880105 660 foot assembly 880105 650 and femur load transducer SA572 S14 may use the load cell structural replacement 78051 319 were used 572 136 b 1 __4 knee assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from
34. with copy to the COTR within 48 hours Vehicle equipment thefts or acts of vandalism must be reported to NHTSA authorities immediately Under no circumstances shall any vehicle components be removed during a visitor inspection unless authorized by OCWS engineers data developed from the crash test program shall be protected NO INDIVIDUALS OTHER THAN THE CONTRACTOR S PERSONNEL DIRECTLY INVOLVED IN THE CRASH TEST PROGRAM SHALL BE ALLOWED TO WITNESS A FRONTAL NCAP TEST OR INSPECT PHOTOGRAPH OR VIDEOTAPE ANY TEST VEHICLE UNLESS AUTHORIZATION IS GRANTED BY A REPRESENTATIVE FROM THE OCWS IT IS THE CONTRACTOR S RESPONSIBILITY TO SECURE THE TEST SITE AREA DURING A TEST AND TO SHIELD THE BARRIER IMPACT AREA FROM THE PUBLIC VIEW BY THE USE OF CANVAS OR OTHER BLOCKING DEVICES RULES FOR CONTRACTORS No vehicle manufacturer s representative s or anyone other than the Contractor s personnel working on NCAP contracts and NHTSA personnel shall be allowed to inspect NHTSA vehicles or witness vehicle preparations and or crash testing without prior permission of the OCWS Such permission can never be assumed All communications with vehicle manufacturers shall be referred to the OCWS and at no time shall the Contractor release crash test data videos or photos without the permission of the OCWS NCAP 3 Unless otherwise specified the vehicle manufacturer s representatives shall only be authorized to visit the Contractor s test facility o
35. 1 The dummy assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 7096 for a period of at least four 4 hours prior to this test 572 144 c 2 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Remove the arms Unzip the 3 zippers and fold down the chest jacket Visually inspect the thorax assembly for cracks cuts abrasions etc Particular attention should be given to the rib damping material chest displacement transducer assembly and the rear rib supports Inspect for rib deformation using the chest depth gage If any damage is noted repair and or replace the damaged components unless the damage resulted from the vehicle crash test in which the dummy was an occupant in which case the damage must be documented and post test calibration verification testing completed before any repairs or replacements are made No damage Damage from crash test no repairs or replacement because this is a post test calibration verification Record damage The following repairs or replacement was performed Record Seat the dummy without back and arm supports on the test fixture surface as shown in Figure 11D The surface must be long enough to support the pelvis and outstretched legs 572 144 c 3 Level the middle rib both longitudinally and laterally 0 5 572 144 c 3 The midsagittal plane o
36. 1 CHEST CIRCUMFERENCE 16 3 17 2 REFERENCE LOCATION FOR MEASUREMENT OF Reference 8 9 9 1 WAIST CIRCUMFERENCE NOTE THE H POINT IS LOCATED 1 83 INCHES FORWARD AND 2 57 INCHES DOWN FROM THE CENTER OF THE PELVIS ANGLE REFERENCE HOLE 20 EXTERNAL DIMENSIONS SPECIFICATIONS Z AXIS 1 7 04 REF l Z AXIS i FRONT VIEW NOTE Figure is referenced to the erect seated position The curved lumbar does not allow the Hybrid Ill to be positioned in a perfect erect attitude REF 8572 31 A 6 SIDE VIEW FIGURE 3A 21 EXTERNAL DIMENSIONS TEST SETUP FIGURE 4A 22 EXTERNAL DIMENSIONS TEST SETUP FIGURE 5A 23 DATA SHEET A3 HEAD DROP TEST 572 32 50 Male Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive head drops are necessary l It has been at least 3 hours since the last head drop 572 32 c 5 __ N A ONLY one head drop performed The head assembly consists of the complete head 78051 61X the neck transducer structural replacement 78051 383X and three 3 accelerometers 572 32 b Torque the skull cap screws to 160 Ibf in Accelerometers and their respective mounts are smooth and clean The data acquisition system including transducers conforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 35 1 The head assembly soaked at a temp
37. 127 k 8 test fixture pendulum conforms to the specifications in Figure 6C 572 123 c 3 9 The head neck assembly is mounted on the pendulum so the midsagittal plane of the head is vertical and coincides with the plane of motion of the pendulum longitudinal centerline as shown in Figure 8C for the extension test 572 123 c 3 10 With the pendulum resting against the honeycomb material the neck bracket was adjusted until the longitudinal centerline of the pendulum was perpendicular 1 degree to plane D on the dummy s head 11 Release the pendulum and allow it to fall freely from a height to achieve an impact speed of 4 18 m s to 4 42 m s as measured at the center of the pendulum accelerometer 572 123 c 4 12 Complete the following table Neck Extension Test Results 572 123 b 2 amp 572 123 c 4 1 amp 11 Parameter Specification Result Pendulum impact speed 4 18 m s lt speed lt 4 42 m s Pendulum 10ms 1 0 m s lt AV lt 1 4 m s AV with 20 ms 2 2 m s lt lt 3 0 m s respect to 30ms 3 2 m s lt AV lt 4 2 m s impact speed Plane D Rotation Peak moment 24 Nm lt moment lt 19 Nm during _ degrees following rotation range 85 lt angle lt 103 Negative Moment Decay Extension Time to decay to 5 Nm 123 ms lt time 147 ms Moment about the occipital condyle M 0 01778 m x Fx 572 123 6 2 M
38. 135 5 Female Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive torso flexion tests are necessary 10 It has been least 30 minutes since last torso flexion test 572 137 q __ N A ONLY one torso flexion test performed The test fixture conforms to the specifications in Figure 13B The complete assembled dummy 880105 000 is used 572 135 c 2 with legs below the femurs _ without legs below the femurs The dummy assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to this test 572 135 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Secure the pelvis to the fixture at the pelvis instrument cavity rear face by threading four Ya cap screws into the available threaded attachment holes Tighten the mountings so that the test material is rigidly affixed to the test fixture and the pelvic lumbar joining surface is horizontal 572 135 c 3 Attach the loading adapter bracket to the spine of the dummy as shown in Figure 13B 572 135 c 4 Inspect and adjust if necessary the seating of the abdominal insert within the pelvis cavity and with respect to the torso flesh assuring that the torso flesh provides uniform fit and overl
39. 2 A mass of 2 86 0 02 kg 6 3 0 05 Ibs 1 3 of weight of suspension cables and their attachments to the impact probe are included in the calculation of mass and such components may not exceed 5 percent of the total weight of the test probe 3 Minimum mass moment of inertia of 164 kg cm 0 145 Ibs in sec in yaw and pitch about the center of gravity 4 The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It has a flat continuous and non deformable face with diameter of 101 6 0 25 mm 4 00 0 01 in and a edge radius of 7 6 to 12 7 mm 0 3 to 0 5 5 A 101 103 mm 4 0 4 1 in diameter cylinder surface extends at least 12 5 mm to the rear of the impact face 6 The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe y The impact probe shall have a free air resonant frequency of not less than 1000 Hz in line with the longitudinal axis of the impactor FIGURE 10E E36 DATA SHEET ES PART 572 INSTRUMENTATION CALIBRATION INFORMATION DATE OF LAST DATE OF NEXT MANUFACTURER MODEL NO SERIAL NO CALIBRATION CALIBRATION DUMMY INSTRUMENTATION HEAD ACCELEROMETERS NECK ROTATION TRANSDUCER 1 OPTIONAL NECK ROTATION TRANSDUCER 2 OPTIONAL LABORATORY TECHNICIAN APPENDIX DRIVER AND PASSENGER DUMMY SEATING amp POSITIONING PROCEDURES
40. 33 c 3 10 Install the transducers or other devices for measuring the D plane rotation with respect to the pendulum longitudinal centerline Note Plane D is the bottom horizontal surface of the skull These measurement devices should be designed to minimize their influence upon the performance of the head neck assembly An example of a measurement device is shown in Figure 11A 11 With the pendulum resting against the honeycomb material the neck bracket was adjusted until the longitudinal centerline of the pendulum was perpendicular 1 degree to plane D on the dummy s head 12 Release the pendulum and allow it to fall freely from a height to achieve an impact speed of 19 5 ft s to 20 3 ft s as measured at the center of the pendulum accelerometer 572 33 c 4 13 Complete the following table Neck Extension Test Results 572 33 b 2 amp 572 33 c 4 Parameter Specification Result Pendulum impact speed 19 5 ft sec lt speed lt 20 3 ft sec Pendulum 10ms 17 2 lt 5 212 Deceleration 20 ms 14 lt lt 19 versus time 30ms 11 0 lt g lt 16 0 pulse Above 30 22 g maximum ms First Pendulum Decay to 5g 38 ms lt time lt 46 ms Plane D Rotation 81 lt max rotation lt 106 72 ms lt time of max rotation lt 82 ms Time for Plane D Rotation to Cross 0 During First Rebound 147 ms lt time lt 174 ms Maximum Moment 59 Ibf ft lt moment lt 3
41. 4 00 0 01 in a maximum edge radius of 7 6 to 12 7 mm 0 3 to 0 5 in and is flat continuous and non deformable A 101 103 mm diameter cylinder surface extends at least 12 5 mm to the rear of the impact face The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe The impact probe shall have a free air resonant frequency of not less than 1000 Hz measured in line with the longitudinal axis of the impactor 9 SIGN CONVENTION FOR PART 572 TEST DUMMIES C G POSSIBLE TARGET Ay Ay 3 UNIAXIAL ACCELEROMETERS LOCATED AT THEC G OF THE HEAD ASSEMBLY A Y A A A2 Gs 3 UNIAXIAL ACCELEROMETERS LOCATED AT THE C G OF THE CHEST ASSEMBLY RIGHT FEMUR LOAD CELL Fa LEFT FEMUR LOAD CELL F FIGURE 3E 10 TABLE 1E SIGN CONVENTION FOR HYBRID III TRANSDUCER OUTPUTS BODY SEGMENT MEASURED FORCE POSITIVE OUTPUT DIRECTION NECK FX SHEAR HEAD REARWARD OR CHEST FORWARD FY SHEAR HEAD LEFTWARD CHEST RIGHTWARD FZ AXIAL HEAD UPWARD CHEST DOWNWARD MX MOMENT ROLL LEFT EAR TOWARD LEFT SHOULDER MY MOMENT PITCH CHIN TOWARD STERNUM MZ MOMENT YAW CHIN TOWARD LEFT SHOULDER LEFT SHOULDER LEFT ARM SHOULDER FORWARD CHEST REARWARD FZ LEFT ARM SHOULDER DOWNWARD CHEST UPWARD RIGHT SHOULDER FX RIGHT ARM SHOULDER FOR
42. Block No 4 TITLE AND SUBTITLE Final Report of NEW CAR ASSESSMENT PROGRAM Testing of a 20XX World XYZ Deluxe 4 door sedan NHTSA No CX0401 Block No 5 REPORT DATE March 1 20XX Block No 6 PERFORMING ORGANIZATION CODE ABC Block No 7 AUTHOR S John Smith Project Manager Bill Doe Project Engineer Block No 8 PERFORMING ORGANIZATION REPORT NUMBER ABC DOT XXX 001 Block No 9 PERFORMING ORGANIZATION NAME AND ADDRESS ABC Laboratories 405 Main Street Detroit 48070 N8 Block No 10 WORK UNIT NUMBER Leave blank Block No 11 CONTRACTOR GRANT NUMBER DTNH22 0X D 1 2345 Block No 12 SPONSORING AGENCY NAME AND ADDRESS US Department of Transportation National Highway Traffic Safety Administration Office of Crashworthiness Standards 1200 New Jersey Ave SE Room W43 410 Washington DC 20590 Block No 13 TYPE OF REPORT AND PERIOD COVERED Final Test Report Feb 15 to Mar 15 20XX Block No 14 SPONSORING AGENCY CODE NVS 111 Block No 15 SUPPLEMENTARY NOTES Leave blank Block No 16 ABSTRACT A 56 3 km h NCAP Frontal Impact Test was conducted a 200 XYZ Deluxe 4 door sedan in accordance with the specifications of the Office of Crashworthiness Standards Frontal NCAP Laboratory Test Procedure This test was conducted to obtain data indicant of FMVSS 208 212 219 partial 301 and foot well intrusion performance The test was conducted at the ABC Laboratories
43. C of the final test report A copy of Appendix C should also be uploaded to the FTP site along with the Quicklook Package REPORT AREA 6 TEST EQUIPMENT AND INSTRUMENTATION CALIBRATION A list of test equipment and instrumentation used during the event along with calibration data is not needed for the test report However the contractor should be prepared to provide this information should the COTR request it N23 3 DATA SHEETS Data sheets are provided as tools to document test data in the final test report format outlined in the previous section The Contractor 15 not restricted from using other tools or expanding the data sheets provided in this section Nevertheless for consistency and uniformity in reporting data the Contractor must present the data in the order outlined in this Section N24 DATA SHEET NO 1 GENERAL TEST AND VEHICLE PARAMETER DATA Test Vehicle NHTSA No Test Program Test Date NHTSA No Model Year Make Model Body Style VIN Body Color Odometer Reading km mi Engine Displacement L Type No Cylinders Engine Placement Transmission Type Transmission Speeds Overdrive Final Drive Roof Rack Sunroof T Top Running Boards Tilt Steering Wheel Power Seats Anti Lock Brakes ABS Automatic Door Locks ADLs Does owner s manual provide instructions to turn off automatic door locks TEST VEHICLE INFORMATION Traction Control 2 2 7 TCS Power Power
44. CHEST X PRIMARY 1 2 3 4 5 6 7 8 9 10 11 NCAP 56 DRIVER CHEST Y PRIMARY DRIVER CHEST Z PRIMARY DRIVER CHEST X REDUNDANT DRIVER CHEST Y REDUNDANT DRIVER CHEST Z REDUNDANT DRIVER CHEST DISPLACEMENT DRIVER PELVIS X DRIVER PELVIS Y DRIVER PELVIS Z DRIVER LEFT FEMUR DRIVER RIGHT FEMUR DRIVER LEFT FEMUR REDUNDANT DRIVER RIGHT FEMUR REDUNDANT DRIVER LEFT UPPER TIBIA X MOMENT DRIVER LEFT UPPER TIBIA Y MOMENT DRIVER LEFT UPPER TIBIA Z FORCE DRIVER LEFT LOWER TIBIA X MOMENT DRIVER LEFT LOWER TIBIA Y MOMENT DRIVER LEFT LOWER TIBIA Z FORCE DRIVER RIGHT UPPER TIBIA X MOMENT DRIVER RIGHT UPPER TIBIA Y MOMENT DRIVER RIGHT UPPER TIBIA Z FORCE DRIVER RIGHT LOWER TIBIA X MOMENT DRIVER RIGHT LOWER TIBIA Y MOMENT DRIVER RIGHT LOWER TIBIA Z FORCE DRIVER LEFT ANKLE X DRIVER LEFT ANKLE Z DRIVER LEFT FOOT Z FRONT DRIVER RIGHT ANKLE X DRIVER RIGHT ANKLE Z DRIVER RIGHT FOOT Z FRONT DRIVER SHOULDER BELT DRIVER LAP BELT PASSENGER DATA TRACES INSCOM PASSENGER HEAD X PRIMARY PASSENGER HEAD Y PRIMARY PASSENGER HEAD Z PRIMARY 50 PASSEN NCAP 57 GER HEAD X REDUNDANT 51 PASSEN GER HEAD Y REDUNDANT 52 PASSEN GER HEAD Z REDUNDANT 53 PASSEN GER NECK X FORCE 54 P
45. Corridor 12 5 38 mm 200 0 LOAD DISPLACEMENT mm Point A Maximum Force in Deflection Corridor Point B Max Force between 12 5 mm 38 0 mm shall not exceed 1500 N FIGURE 10C C36 DATA SHEET C7 TORSO FLEXION TEST 572 125 6 YEAR OLD Dummy Serial Number Test Date Technician __ Pretest calibration Post test calibration verification Test attempt no when successive torso flexion tests are necessary 210 12 14 15 It has been at least 30 minutes since the last torso flexion test 572 127 0 __ N A ONLY one torso flexion test performed The test fixture conforms to the specifications in Figure 11C The complete assembled dummy 127 0000 is used 572 125 c 2 with legs below the femurs _ without legs below the femurs The dummy assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to this test 572 135 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Secure the pelvis to the fixture at the pelvis instrument cavity rear face by threading four VAx20x inch cap screws into the available threaded attachment holes Tighten the mountings so that the test material is rigidly affixed to the test fixture and the pelvic lumbar joining surface is horizontal 572 125 c
46. DUMMY PERFORMANCE CALIBRATION IN SUPPORT OF NEW CAR ASSESSMENT PROGRAM NCAP TESTING B Contractor s Name and Address such as ABC TESTING LABORATORIES INC 405 Main Street Detroit Michigan 48070 NOTE DOT SYMBOL WILL BE PLACED BETWEEN ITEMS B AND C C Date of Final Performance Calibration Report completion D The sponsoring agency s name and address as follows DOT NHTSA Office of Crashworthiness Standards 1200 New Jersey Ave SE W43 404 NVS 110 Washington DC 20590 14 15 DATA SHEETS DATA SHEET A1 DUMMY DAMAGE CHECKLIST 50 Male Dummy Serial Number Test Date Technician This check sheet is completed as part of the post test calibration verification Perform general cleaning Dummy Item Inspect for Comments Damaged OK Outer skin Gashes rips cracks Head Ballast secure General appearance Neck Broken or cracked rubber Upper neck bracket firmly attached to the lower neck bracket Looseness at the condyle joint Nodding blocks cracked or out of position Spine Broken or cracks in rubber Ribs Broken or bent ribs Broken or bent rib supports Damping material separated or cracked Rubber bumpers in place Chest Displacement Assembly Bent shaft Slider arm riding in track Transducer leads Torn cables Dummy Item Inspect for Comments 15 Damaged
47. DUMMY SEATING AND POSITIONING PROCEDURES Document the final positions of the dummy after it is seated in the test vehicle by taking the following measurements accurate 10 3 mm Record measurements on applicable data sheet NCAP 34 DUMMY MEASUREMENT FOR FRONT SEAT PASSENGERS AD Arm to Door HD H Point to Door HR Head to Side Header HS Headto Side Window KK Knee to Knee SHY Striker to H Point Y Direction CD Chest to Dash CS Steering Wheel to Chest HH Head to Header HW Head to Windshield HZ Head to Roof KDA Knee to Dash Angle KDL Left Knee to Dash KDR Right Knee to Dash NA Nose to Rim Angle NR Nose to Rim PA Pelvic Angle RA Rim to Abdomen SA Seat Back Angle VERTICAL SCA Steering Column Angle TRANSVERSE SH Striker to H Point SK Striker to Knee ST Striker to Head SWA Steering Wheel Angle TA Tibial Angle WA Windshield Angle VERTICAL LONGITUDINAL PLANES Figure 6 Dummy Measurements for Front Seat Passengers NCAP 35 C DUMMY LONGITUDINAL CLEARANCE DIMENSIONS see Figure 6 and any additional diagrams that may be included The following measurements are to be made within a vertical longitudinal plane l 2 HH Head to Header Taken from the point where the dummy s nose meets his forehead between his eyes to the furthest point forward on the header HW Head to Windshield Taken from the po
48. HEAD ASSEMBLY 921022 001 REF 90 376 mm 14 8 SURFACE FIGURE 6E 26 DATA SHEET ES NECK FLEXION TEST 572 153 12 MONTH OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive flexion tests are necessary 1 It has been at least 30 minutes since the last neck test 572 155 m __ N A this is the first neck test performed __2 components required for the neck tests include the neck assembly 921022 041 and headform TE 3200 160 572 153 a __3 The assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to a test 572 153 1 Record maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity __4 Visually inspect neck assembly for cracks cuts and separation of the rubber from the metal segments Note If the damage resulted from the vehicle crash test the damaged area Is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions __6 Torque the jam nut 9001336 on the neck cable ATD 6206 between 0 2 Nm and 0 3 Nm 572 153 c 2 7 data acquisition system including transducers conf
49. NOTE The standard does NOT apply to forward control vehicles walk in van type vehicles or to open body type vehicles with fold down or removable windshields PROTECTED ZONE LOWER EDGE MARKING PROCEDURE The lower edge of protected zone is determined as follows 1 Place a 6 5 inch diameter rigid sphere weighing 15 pounds in a position such that it simultaneously contacts the inner surface of the windshield glazing and the surface of the instrument panel including padding 2 Draw the locus of points on the inner surface of the windshield contacted by the sphere across the width of the instrument panel From the outer most contactable points extend the locus line horizontally to the edges of the glazing material NOTE Do not scratch glazing as a method of marking the contact between sphere and windshield 14 3 Draw a line surface of windshield below and 0 5 Inch distant from the locus line 4 The lower edge of the protected zone is the longitudinal projection onto the outer surface of the windshield on the line determined in item C The protected zone is the space enclosed by the following surfaces 1 The outer surface of windshield in the pre crash configuration 2 The focus of points 3 inches outward along perpendiculars drawn to each point on the outer surface of the windshield 3 The locus of lines forming a 45 angle with the outer surface of the windshield at each point along the top and
50. OF MZ MOMENT YAW DUNAY KNEE CLEVIS FZ AXIAL TIBIA DOWNWARD TENSION FEMUR UPWARD UPPER TIBIA MX MOMENT MY MOMENT MX MOMENT ROLL ANKLE LEFTWARD HOLD KNEE IN PLACE ANKLE FORWARD BOTTOM OF KNEE CLEVIS REARWARD LOWER TIBIA FX SHEAR FY SHEAR FZ AXIAL ANKLE FORWARD KNEE REARWARD ANKLE RIGHTWARD KNEE LEFTWARD ANKLE DOWNWARD TENSION KNEE UPWARD ANKLE LEFTWARD HOLD KNEE IN PLACE ee 1 ANKLE FORWARD BOTTOM OF KNEE CLEVIS REARWARD CHEST DISPLACEMENT CHEST COMPRESSED NEGATIVE KNEE SHEAR DISPLACEMENT PUSH ON FRONT OF TIBIA NEGATIVE NOTE DIRECTIONS ARE DEFINED IN RELATION TO A SEATED DUMMY 11 5 12 13 14 14 1 All GENERAL TEST CONDITIONS A Surfaces of dummy components are not painted unless otherwise specified 572 36 n B Dummy performance tests of the same component segment assembly or fully assembled dummy are separated in time by a period of not less than 30 minutes unless otherwise specified 572 36 m Dummy performance tests conducted any temperature from 69 F to 72 F unless otherwise specified and at any relative humidity from 10 to 70 after exposure of the dummy to these conditions for a pertod of not less than 4 hours D Dummy limb joints are set at 1 g barely restraining the weight of the limb when it is extended horizontally The force required to move a limb segment does not exceed 2 Gs throughout the range of limb motion 5
51. Pole 2 Row Seat 5 percentile female in side impact only With the seat in the test seat track position what is the angle of the seat back when it is in the forward most locked position Dummy Angle Side Impact 5 Female With the seat in the test seat track position what is the angle of the seat back when it is set to the test position Note The seat back angle will be determined by the related dummy seating procedure for the side impact barrier test Dummy Angle Side Impact 5 Female Describe any references used for measuring the seat back angle e g door sill Include photograph s 3rd Row Seat side impact only The seat should be set to accommodate a 5 percentile female dummy however this dummy will not be part of the test s With the seat in the test seat track position what is the angle of the seat back when it is in the forward most locked position Dury Angle Side Impact 5 Female With the seat in the test seat track position what is the angle of the seat back when it is set to the test position Note The seat back angle will be determined by the related dummy seating procedure for the side impact barrier test Dummy Angle Side Impact 5 Female N57 Describe any references used for measuring the seat back angle e g door sill Include photograph s ADJUSTABLE D RING SE
52. Pretest calibration Post test calibration verification Test attempt no when successive thorax impact tests are necessary 1 It has been at least 30 minutes since the last thorax impact test 572 137 q __ N A ONLY one thorax impact test performed 2 test fixture conforms to the specifications in Figure 12A 3 The complete assembled dummy 78051 218 is used 572 34 b and is dressed in a form fitting cotton stretch above the elbow sleeved shirt and above the knee pants No shoes are worn 572 34 b 4 The dummy assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to this test 572 34 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity 5 Remove the chest skin and visually inspect the thorax assembly for cracks cuts abrasions etc Particular attention should be given to the rib damping material 78051 17 thru 78051 22 chest displacement transducer assembly 78051 317 and the rear rib supports 78051 304 Inspect for rib deformation using the chest depth gage 83 5006 007 If any damage is noted repair and or replace the damaged components unless the damage resulted from the vehicle crash test in which the dummy was an occupant in which case the damage must be documented and post test calibration verification testing completed before
53. Program Test Date FMVSS 301 FUEL SYSTEM INTEGRITY POST IMPACT DATA Temperature at Time of Impact Test Time Stoddard Solvent Spillage Measurements A From impact until vehicle motion ceases OZ maximum allowable 1 oz B For the 5 minute period after motion ceases OZ maximum allowable 5 oz C For the following 25 minutes 07 maximum allowable 1 oz minute D Spillage N47 DATA SHEET NO 16 FMVSS 301 STATIC ROLLOVER RESULTS Test Vehicle NHTSA No Test Date Test Program 1 The specified fixture rollover rate for each 90 of rotation 15 60 to 180 seconds 2 The position hold time at each position is 300 seconds minimum 3 Details of Stoddard Solvent spillage 270 TO 3602 SOLVENT COLLECTION TIME TABLE IN SECONDS Test Phase Rotation Time Hold Time Total Time 0 to 90 90 to 180 180 to 270 FMVSS 301 SPILLAGE TABLE Test Phase 0 to 90 90 to 180 1802 to 270 270 to 360 0 to 90 90 to 180 180 to 270 270 to 360 N48 DATA SHEET NO 17 DUMMY VEHICLE TEMPERATURE STABILIZATION Test Vehicle NHTSA No Test Program Test Date Please place the temperature stabilization chart data in this space FORMS N49 Forms like Data Sheets are provided as tools to use in the exchange of data between the COTR and the Contractor Forms unlike Data Sh
54. SAE Recommended Practice J211 1 MAR95 572 146 1 7 The head assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 1090 to 7096 for a period of at least four 4 hours prior to a test 572 142 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity 8 Visually inspect the head skin for cracks cuts abrasions etc Repair or replace the head skin if the damaged area is more than superficial Note If the damage resulted from the vehicle test in which the dummy was an occupant the damaged area 15 to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions 9 Clean the impact surface of the skin and the impact surface of the fixture with isopropyl alcohol trichloroethane or equivalent prior to the test 572 142 c 2 210 Ns 212 14 215 16 249 022 Suspend and orient head assembly as shown in Figure 70 The lowest point forehead is 376 0 1 0 mm 14 8 0 04 inch from the impact surface 572 142 c 3 Record the actual distance NOTE The masses of the suspension device and the accelerometer cables are to be kept as lightweight as possible to minimize their effect on the test results The 3 3 mm 0 13 inch diameter holes located on either side of the
55. SETUP FIGURE 6B 25 DATA SHEET 4 NECK FLEXION TEST 572 133 5 Female Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive flexion tests are necessary l 2 It has been at least 30 minutes since the last flexion test 572 137 q __ N A ONLY one neck test performed The components required for the neck tests include the head assembly 880105 100X neck 880105 250 bib simulator 880105 371 upper neck adjusting bracket 880105 207 lower neck adjusting bracket 880105 208 six axis neck transducer SA572 S11 and either three accelerometers SA572 S4 or their mass equivalent installed in the head assembly as specified in drawing 880105 100X Data from the accelerometers are not required 572 133 b The assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to a test 572 133 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Visually inspect neck assembly for cracks cuts and separation of the rubber from the metal segments Note If the damage resulted from the vehicle crash test in which the dummy was an occupant the damaged area is to be documented with photography and the post test calibration verification testing completed befor
56. SHEET 5 NECK EXTENSION TEST 572 133 5 Female Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive extension tests are necessary l 2 It has been at least 30 minutes since the last extension test 572 137 q __ N A ONLY one neck test performed The components required for the neck tests include the head assembly 880105 100X neck 880105 250 bib simulator 880105 371 upper neck adjusting bracket 880105 207 lower neck adjusting bracket 880105 208 six axis neck transducer SA572 S11 and either three accelerometers SA572 S4 or their mass equivalent installed in the head assembly as specified in drawing 880105 100X Data from the accelerometers are not required 572 133 b The assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to a test 572 133 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Visually inspect neck assembly for cracks cuts and separation of the rubber from the metal segments NOTE If the damage resulted from the vehicle crash test in which the dummy was an occupant the damaged area is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are ma
57. SINCAP PINCA P gt Quicklook pdf zip with filename format lt NHTSANO gt lt Model Year gt lt Make amp Model gt lt Body gt lt NCAP SINCAP PINCA P gt Datatape zip zip with filename format lt NHTSANO gt lt Model Year gt lt Make amp Model gt lt Body gt lt NCAP SINCAP PINCA P gt QCPackage zip pdf with filename format lt NHTSANO gt lt ModelYear gt lt Make amp Model gt lt gt lt NCAP SINCAP PINCA P gt DraftReport pdf zip with filename format lt NHTSANO gt lt Model Year gt Make amp Model gt lt Body gt lt NCAP SINCAP PINCA P gt FinalDeliverables zip Time Requirement One 1 day from test Three 3 business days from test Five 5 business days from test Two 2 weeks from test date Two 2 weeks after receiving corrections to preliminary test report Submit Via Email F TP dependi ng on size N4 Submit To OCWS FT N5 TEST REPORT REQUIREMENTS The final test report and associated documentation including photographs and videos 15 relied upon as the chronicle of the NCAP test The final documentation and data will be released to the public domain after review and acceptance by the COTR For these reasons each final report must be a complete document capable of standing by itself The contractor should use detailed descriptions of all NCAP test events Any events that are not directly associated with the NCAP but
58. TRANSDUCER CONDITIONS e nnne 7 11 3 THORAX IMPACTOR PROBE 572 36 a es 8 KNBRIMPACTOR PROBE L eset Deos 8 11 5 GENERAL TEST CONDITIONS enne 11 CALIBRATION TEST 1 141100 11 POST TEST REQUIREMENTS tee pacem n casto Roscoe ae 11 141 APPARENT NONCONFORMANGCE ertet 11 142 FINAL PERFORMANCE CALIBRATION REPORTS 12 NERE ire LAM LL 14 DATASHEET A cuoco te asnu aaa sa asta a au I 14 DADA AD Tuala du s ere tL er Hd 16 PE GR e eh ce 23 PASTE D LM E DADASHEET AB Me Gene 30 DNT cu ies a I E CA IE 36 DATA GHBET ATE ossa esse karene 41 DELE GN MA M UE 43 DATA SHEET GJE EE AEQ ELE 46 DATA FAT ua Genesee 52 Al PURPOSE AND APPLICATION The purpose of this laboratory procedure is to provide dummy users independent testing laboratories under contract with the Office of Crashworthiness Standards with standard test procedures for performing receiving inspection and performance calibration tests on the Part 572 Subpart E dummy so that repetitive and correlative test results can be obtained The following tests have been developed to establish a uniform calibration procedure for all users as the means of verifying the perfor
59. The contractor shall keep records of calibrations for all test Instrumentation in a manner that assures the maintenance of established calibration schedules All such records shall be readily available for inspection when requested by the COTR The calibration system will need the written acceptance of the COTR before testing begins Test equipment shall receive a calibration check immediately prior to and after each test This check shall be recorded by the test technician s and submitted with the final report Anthropomorphic test devices shall be calibrated as Indicated in NCAP test procedure These calibrations shall be submitted with the final report PHOTOGRAPHIC DOCUMENTATION Provide still photographs color prints properly focused for clear Images no more than two 2 per 8 57 11 sheet of post test damage resulting from the vehicle crash test DEFINITIONS PADI Procedures for Assembly Disassembly and Inspection PRETEST REQUIREMENTS TRANSDUCER REQUIREMENTS The contractor shall provide and install the following instrumentation to the GFP dummies excluding the chest deflection transducer A HEAD The head accelerometers shall have dimensions response characteristics and sensitive mass locations specified in drawing SA572 S4 and be mounted in the head as shown in drawing 921022 000 572 155 b Three accelerometers shall be mounted in the head cavity to measure orthogonal accelerations Ax Ay Az at the cen
60. The reference locations must be accessible after installation of the chest skin It may be necessary to leave the chest skin zipper unfastened until the references are checked and fasten it just prior to the test Install the chest skin and reposition the dummy as described in the preceding paragraph using the reference measurements recorded The dummy is dressed in a tight fitting size 5 short sleeve shirt 572 124 c 2 Place the arm assemblies horizontal 2 and parallel to midsagittal plane The arms are held in place by tightening the adjustment nut which holds the arm yoke to the clavicle assembly The data acquisition system including transducers must conform to the requirements of SAE Recommended Practice J211 1 MAR95 572 127 k Impact the anterior surface of the thorax with the test probe so the longitudinal centerline of the probe is within 2 of a horizontal line in the dummy s midsagittal plane at the moment of impact 572 124 c 4 The velocity of test probe at the time of impact is 6 71 m s 0 12m s 572 124 b The probe is guided so there is no significant lateral vertical or rotational movement during the impact 572 124 c 5 Neither the suspension hardware suspension cables nor other attachments to the probe including the velocity vane make contact with the dummy 572 124 c 6 17 Complete following table C33 Thorax Impact Results 572 124 b and 572 124 b 1 amp 2 Parameter Sp
61. accelerometers shall have the dimensions response characteristics and sensitive mass locations specified in drawing SA572 S4 and be mounted in the torso assembly in triaxial configuration at the T4 location as shown drawing 210 0000 The chest accelerometers are not required for dummy calibration testing but are required for NCAP testing 572 146 e The chest deflection potentiometer shall have the dimensions and response characteristics specified in drawing SA572 S50 and be mounted in the torso assembly as shown in drawing 210 0000 572 146 f TEST FIXTURE The neck pendulum thorax and knee probe accelerometers shall have the dimensions and characteristics of drawing SA572 S4 1 2 OTHER TRANSDUCER CONDITIONS A TRANSDUCER MOUNTS The mountings for sensing devices shall have no resonance frequency less than 3 times the frequency range of the applicable channel class 572 146 n TRANSDUCER SIGN CONVENTION The sign convention for outputs of transducers mounted within the dummy that measure head and chest accelerations chest deflection and neck loads are located in Figure 3D For other transducers see SAE J1733DEC94 572 146 m TRANSDUCER OUTPUT FILTERING The outputs of acceleration and force sensing devices installed in the dummy and in the test apparatus specified by this part are recorded with individual data channels Each data channel will be comprised of a sensor signal conditioner data acquisition device and all i
62. against the rear surface Position the dummy s H point so it is 39 4 5 1 mm 1 55 0 2 in above the horizontal seating surface and 62 0 5 1 mm 2 44 0 2 in forward of the rear vertical surface of the fixture Extend the dummy s neck so that the base of the skull is level both fore and aft and side to side within 0 5 degrees The rearmost surface of the head should be 53 3 5 1 mm 2 1 0 2 in from the vertical surface of the test fixture A strap or bungee cord may placed around the forehead of the dummy to stabilize the head in this position Position the upper and lower legs parallel to the midsagittal plane so the centerline between the knee pivot and the ankle pivot is parallel to the rear vertical surface of the fixture Position the feet parallel to the dummy s midsagittal plane with the bottoms horizontal and parallel to the seating surface Position the upper arms downward vertically so the centerline between the shoulders and elbow pivots is parallel to the rear vertical surface of the fixture Position the lower arms horizontally so the centerline of the lower arm hand is parallel to the seat surface Record the dimensions listed in following table except for dimension Q X Y and Z reference figure 4D Mark the locations AA and BB and record the dimensions Y Z as specified in the following table and figure 4D Measure and record dimensions Q and X Signature Date 016 HYBRID III PART 572
63. and R for rearmost 1 12 Use only the controls that primarily move the seat in fore aft direction to place the seat in the rearmost position 1 13 Use any part of any control other than the parts which primarily move the seat or seat cushion fore aft to find and visually mark the maximum minimum and middle height of the seat cushion reference point with the seat cushion reference line at the mid angle determined in 1 8 520 1 9 4 522 1 2 S22 1 7 4 522 3 1 522 4 3 1 S24 1 2 S24 3 1 524 4 3 1 526 2 3 526 3 1 N A No seat height adjustment Go to 1 18 1 14 Use only the controls that primarily move the seat and or seat cushion in the fore aft direction to place the seat in the mid fore aft position __ 1 15 Use any part of any control other than the parts which primarily move the seat or seat cushion fore aft to find and visually mark the maximum minimum and middle height of the seat cushion reference point with the seat cushion reference line at the mid angle determined in 1 8 S20 1 9 4 S22 1 2 S22 1 7 4 522 3 1 24 1 2 524 3 1 1 16 Use only the controls that change the seat in the fore aft direction to place the seat in foremost position 516 2 10 3 2 1 17 Use any part of any control other than the parts which primarily move the seat or seat cushion fore aft to find and visually mark the maximum minimum and middle height of the seat cushion reference point with the seat cushion reference line at the mid
64. chest deflection transducer assembly 78051 317 revision A for assembly into 78051 218 revision T 572 36 f LEGS The single axis femur force transducer shall have the dimensions response characteristics and sensitive axis locations specified in drawing 78051 265 GSE Model 2430 and be mounted in assemblies 78051 46 and 47 for assembly into 78051 218 revision T The femur transducers are not required for calibration of the dummy but are required for NCAP testing 572 36 h E A7 TEST FIXTURE The neck pendulum thorax and knee probe accelerometers shall have the dimensions and characteristics of Endevco Model 7231C 572 36 g 1 2 OTHER TRANSDUCER CONDITIONS A TRANSDUCER MOUNTS The mountings for sensing devices shall have no resonance frequency within range of 3 times the frequency range of the applicable channel class 572 36 k The sign convention for outputs of transducers mounted within the Hybrid that measure head and chest accelerations chest deflection and femur loads are located in Figure 2A For other transducers see SAE J1733DEC94 Appendix 572 36 amp 572 31 a 5 TRANSDUCER OUTPUT FILTERING The outputs of acceleration and force sensing devices installed in the dummy and in the test apparatus specified by this part are recorded with individual data channels Each data channel will be comprised of a sensor signal conditioner data acquisition device and all interconnecting cables a
65. data channels apply a blow to the left side and top of the head with a rubber mallet never apply the blow directly to an accelerometer mount and record the data channel output as shown for the y axis in Figure 2 Analysis of Figure 2 for the y axis shows that the polarity of the y axis accelerometer data channel in the dummy head in this example is negative Change the polarity to be positive perhaps the simplest way is to change the sign in the software to agree with the sign convention and make a new plot to document the change Following this approach it is possible to document the polarity of each accelerometer data channel in the dummy head M3 WU Figure Response of X Axis Accelerometer Data Channel from blow to rear of head showing desired positive polarity Figure 2 Response of Y Axis Accelerometer Data Channel from blow to left side of head showing incorrect negative polarity Polarity Check Data Sheet For X Axis Accelerometers Dummy Serial No Orientation of Most Positive Value 121 Orientation for FU or FD Positive Polarity Head Redundant Head Top NAAH Head Left NAAH Indicates Nine Accelerometer Array Head Polarity Check Data Sheet For Y Axis Accelerometers Dummy Type Serial Orientation of Most Positive Value Right Shoulder A 1211 Orientation for Down RSD s Positive Polarity Head C G Head
66. dummy s head are equidistant within 2 mm from the impact surface 572 142 c 3 Record the right side distance Record the left side distance The impact surface is clean and dry and has a microfinish in the range of 203 2x10 mm 8 micro inches to 2032 0 10 mm 80 micro inches RMS 572 142 c 4 Record actual microfinish The impact surface is a flat horizontal steel plate 50 8 mm 2 inches thick and 610 mm 24 inches square 572 142 c 4 Record thickness Record width Record length Drop the head assembly from a height of 376 0 1 0 mm 14 8 inches 0 04 inches by a means that ensures a smooth instant release onto the impact surface 572 142 b amp 572 142 c 4 Complete the following table 572 142 b Parameter Specification Result Peak resultant acceleration 250g lt x lt 280g Resultant versus time history curve Unimodal Oscillations after the main pulse Less than 10 of the peak resultant acceleration Lateral acceleration y axis acceleration lt 15 g Plots of the x y z and resultant acceleration data follow this sheet Signature Date 223 TEST SET UP SPECIFICATIONS HEAD SUSPENSION CABLES QUICK RELEASE HEAD ASSEMBLY 210 1000 REF WITH HEAD ACCELEROMETERS 210 0000 SHT 3 OF 7 REF 1 2 NECK TRANSDUCER MASS SIMULATOR TE 107 001 REF D PLANE PERPENDICULAR TO SKULL CAP SKULL INTERFACE DROP HEIGHT 376 mm
67. existing mounting fixtures is desirable because of their light weight B Redundant SAE572 S4 accelerometers can be attached directly to the primary one either head to head or back to back and then attach both to one side of the mounting cube C Use of spacers between the primary and redundant accelerometers is recommended for better stability Spacers shall be made of aluminum due to weight considerations 4 The injury criterion values HIC Chest Clip and Femur Loads generated by using the redundant data sets shall not deviate more than ten 10 percent from their respective primary injury criterion values APPENDIX H FOOT INSTRUMENTATION RECOMMENDED PRACTICE HI APPENDIX H RECOMMEND PRACTICE HYBRID III FOOT INSTRUMENTATION The Hybrid III Driver and Passenger feet are instrumented to measure acceleration in the X Y and Z axis for both the outboard ankle and toe regions as shown in the following diagrams A tri axial cube with SAE572 S4 accelerometers is used The design is easily adapted to the proposed 45 degree ankle H2 Easily Adapted to Proposed 45 degree ankle A HASC ANKLE SHAFT REA Faa VINYL SKIN VINYL FOAM Right shown ATD 7310 1 Left opposite hr OT_STRICTURAL ASSY Foam per Dwg 78051 373 ATD7309 L R Skin Modei 78051 284 L amp 285 R within 0 02 in H3 AWS SY 41005 MOLN Sa Wd ut 0680 eee 26 E EEN ia d s t N P
68. expedite data transfer between the Contractor and NHTSA a File Transfer Protocol FTP website will be made available to Contractors The Quicklook Package see above Section 1 3 C is required to be uploaded via FTP five 5 working days after the test has been completed The agency will then retrieve the data to begin the quality control process 1 ACCESSING THE FTP SITE N3 The Point of Contact at each test facility will receive an e mail with the FTP site address and a unique username and password to access the website A new password will be issued on the 1 of each month Any FTP client can be used to access and upload data 2 LOADING TEST DATA The Quicklook Package must be placed in organized and labeled folders such that each folder s contents are easily recognizable Once the data is organized the Contractor shall provide ONE 1 zip file per test via the FTP website Upload the zip file using an FTP client To ensure successful transfers please contact your network administrator and confirm that FTP transfers are permitted Set your FTP client program to upload in passive PASV mode and set the file exists action to skip For FTP assistance please contact the FTP administrator if one has been identified otherwise contact the COTR DRAFT TEST REPORT Contractors are required to submit to the OCWS via e mail a draft Final Test Report an electronic copy in pdf or doc form within two weeks of the test be
69. facility in Detroit Michigan on November 15 200X The impact velocity of the vehicle was 56 1 km h and the ambient temperature at the barrier face at the time of impact was 28 C The target vehicle post test maximum crush was 351 mm at The test vehicle s performance is as follows N9 Driver ATD Pass ATD Measurement Units Threshold Result Units Threshold Result Description Head Injury Criteria N A 700 N A 700 HIC 5 Maximum Chest 63 in 52 Compression Nij n a 1 n a 1 Neck Tension Newtons 4170 Newtons 2620 Neck Compression Newtons 4000 Newtons 2520 Left Femur Force Newtons 10008 Newtons 6805 Right Femur Force Newtons 10008 Newtons 6805 Block No 17 KEY WORDS 35 mph Frontal Barrier Impact test New Car Assessment Program NCAP Block No 18 DISTRIBUTION STATEMENT Copies of this report are available from the following National Highway Traffic Safety Administration Technical Information Services Division NPO 411 1200 New Jersey Ave SE Washington DC 20590 e mail tis nhtsa dot gov FAX 202 493 2833 Block No 19 SECURITY CLASSIFICATION OF REPORT Unclassified Block No 20 SECURITY CLASSIFICATION OF PAGE Unclassified Block No 21 NO OF PAGES Add appropriate number Block No 22 PRICE Leave blank N10 2 SAMPLE TEST REPORT LAYOUT Draft and final NCAP Test Reports shall have the following layout for standardi
70. fixture conforms to the specifications in Figure 12C 3 knee assembly consisting of the knee machined 127 4013 knee flesh 127 4011 lower leg 127 4014 foot assembly 127 4030 1 and femur load transducer SA572 510 may use the load cell structural replacement 127 4007 were used 572 126 b __4 knee assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 1096 to 7096 for a period of at least four 4 hours prior to this test 572 126 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity __5 Mount the test specimen and secure it to the rigid test fixture 572 126 c 2 6 No parts of the foot or tibia contact any exterior surface 572 126 c 2 7 Align the test probe so that throughout its stroke and at contact with the knee it is within 2 degrees of horizontal and collinear with the longitudinal centerline of the femur 572 126 c 3 8 probe is guided so there is no significant lateral vertical or rotational movement during the impact with the knee 572 136 c 4 9 data acquisition system including transducers must conform to the requirements of SAE Recommended Practice J211 1 MAR95 572 136 m Class 600 10 Contact the knee with the test probe at a speed between 2 07 m s and 2 13 m s 572 126 c 5 Neither the suspension hardware suspension cables
71. for Windows and select the latest version of the program QUICKLOOK PACKAGE The Quicklook Package is a zip file that includes all of the information necessary for quality control review It is uploaded to an FTP site for review by the OCWS This data is a summary of the test and includes the data tape all photographs and all videos as well as a copy of the Quicklook Report previously e mailed to the OCWS The filename for the Quicklook Package should be formatted as follows lt NHTSANO gt lt Model Year gt lt Make amp Model gt lt Body gt lt NCAP gt QC zip The contractor will also provide website related material in a folder within this file The contractor will provide a jpg image of the vehicle impact appropriate for use on the website This photo should be a duplicate of photo number 75 in the Frontal NCAP photo list found in Section 3 of this document The photo should be labeled as follows lt Model Year gt lt Make gt lt Model gt Frontal Impact Event for web jpg It should also be 227 pixels wide by 127 pixels tall landscape horizontal orientation and of a high image quality In this same folder the contractor will also use Camera No 1 the Real Time Left Overall Camera as described in Section 9 of the main procedure to provide a web ready video of the impact event in wmv format This film should be labeled as follows lt Model Year gt lt Make gt lt Model gt Frontal Impact Event wmv FTP WEBSITE To
72. honeycomb material the neck bracket was adjusted until the longitudinal centerline of the pendulum was perpendicular 1 degree to plane D on the dummy s head 12 Release the pendulum and allow it to fall freely from a height to achieve an impact speed of 6 89 m s to 7 13 m s as measured at the center of the pendulum accelerometer 572 133 c 4 1 2 13 Complete the following table Neck Flexion Test Results 572 133 b 1 amp 572 133 c 4 I amp ii Parameter Specification Result Pendulum impact speed 6 89 m s lt speed lt 7 13 m s Pendulum 10ms 2 1 m s AV lt 2 5 m s AV with respect 20ms_ 4 0 m s lt AV 5 0 m s to impact speed 30ms 5 8 m s lt AV lt 7 0 m s Plane D Rotation Peak moment Nm 69 Nm lt moment lt 83 Nm during the _ degrees following rotation range 77 lt angle lt 91 Positive Moment Decay Time to decay to 10 Nm Flexion 80 ms lt time lt 100ms Moment about the occipital condyle M 0 01778 m x Fx 572 133 b 1 ii My Moment in Nm measured by the transducer Force in N measured by the transducer Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material 572 133 b 3 14 Plots of acceleration velocity y axis moment and x axis force and y axis moment about the occipital condyle follows this sheet Signature Date 27 DATA
73. in lt compression lt 2 86 in Peak resistance force 1160 Ib lt peak force lt 1325 Ib Internal Hysteresis 69 lt hysteresis lt 85 Time zero is defined as the time of initial contact between the test probe and the chest skin Force impactor mass x acceleration 572 34 b Area under loading curve minus the area under the unloading curve divided by the area under the loading curve 7 Plots of chest compression pendulum acceleration pendulum speed and pendulum force versus chest compression follow this sheet Signature Date A39 TEST SET UP SPECIFICATIONS PENDULUM ACCELEROMETER MODE 7231C OR EQUIVALENT MOUNTED WITH SENSITIVE AXIS PARALLEL 12 7 mm 1 TO PENDULUM LONGITUD NAL CENTERLINE 0 50 in x 0 04 0 INDEX MARKS ALIGNED REF DWG 78051 303 AND DWG 78051 307 CENTERLINE OF ARMS HORIZONTAL 2 eee REF DWG 78051 123 AND DWG 78051 124 NO 3 RIB CENTERLINE HORIZONTAL 0 5 REF DWG 78051 31 PENDULUM CENTERLINE HORIZONTAL 0 5 SEATING SURFACE HORIZONTAL 0 5 NOTE A NO EXTERNAL SUPPORT IS REQUIRED ON THE DUMMY TO MEET SETUP SPECIFICATIONS THE MIDSAGITTAL PLANE OF THE DUMMY IS VERTICAL X 1 AND WITHIN 2 OF THE CENTERLINE OF THE PENDULUM C THE MIDSAGITTAL PLANE OF THE DUMMY IS CENTERED ON THE CENTERLINE OF THE PENDULUM WITHIN 3 mm 0 12 in FIGURE 12A 40
74. in Figure 14A The leg assembly 86 5001 002 with the upper leg assembly 78051 47 removed and the load cell simulator 78051 319 is used 572 35 b 2 The knee assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 1096 to 7090 for a period of at least four 4 hours prior to this test 572 35 b 2 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Mount the test specimen and secure it to the rigid test fixture 572 35 6 2 11 Figure 14A No parts of the foot or tibia contact any exterior surface 572 35 b 2 i11 Align the test probe so that at contact the longitudinal centerline of the probe is collinear within 2 degrees with the longitudinal centerline of the femur load cell simulator except it is within 0 5 degrees horizontally 572 35 b 2 iv amp vi The probe is guided so there is no significant lateral vertical or rotational movement during the impact with the knee 572 35 b 2 v The data acquisition system including transducers must conform to the requirements of SAE Recommended Practice J211 1 MAR95 572 136 m Class 600 Contact the knee with the test probe at a speed between 6 8 ft s and 7 0 ft s 572 35 b Complete the following table Knee Impact Results 572 35 b 1 Parameter Specification Result Probe speed 6 8 ft s lt speed lt 7 0 ft s Peak resistance force 10
75. instrumentation to the GFP dummies excluding the chest deflection transducer A HEAD The head accelerometers shall have dimensions response characteristics and sensitive mass locations specified in drawing SA572 S4 and be mounted in the head as shown in drawing 127 0000 sheet 3 572 127 c Three accelerometers shall be mounted in the head cavity to measure orthogonal accelerations Ax Ay Az at the center of gravity CG of the head assembly NECK The upper neck force transducer shall have the dimensions response characteristics and sensitive axis locations specified in drawing SA572 S11 and shall be mounted in the head neck assembly as shown in drawing 127 0000 sheet 3 572 127 d CHEST The chest accelerometers shall have the dimensions response characteristics and sensitive mass locations specified in drawing SA572 S4 and be mounted in the torso assembly in triaxial configuration at T4 as shown in drawing 127 0000 sheet 3 The chest accelerometers are not required for dummy calibration testing but are required for NCAP testing 572 126 e The chest deflection transducer shall have the dimensions and response characteristics specified in drawing SA572 S50 and be mounted to the upper torso assembly as shown in drawing 127 0000 sheet 3 572 137 f LEGS The single axis femur force transducer shall have the dimensions response characteristics and sensitive axis locations specified in drawing SA572 S10 and be mou
76. measured by the transducer Force in lbf measured by the transducer Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material 572 133 b 3 4 Plots of pendulum acceleration y axis moment x axis force y axis moment about the occipital condyle and D plane rotation follows this sheet Signature Date A30 DATA SHEET 5 NECK EXTENSION TEST 572 33 50 Male Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive extension tests are necessary l 2 It has been at least 30 minutes since the last extension test 572 36 m __ N A ONLY one neck test performed The components required for the neck tests include the head assembly 880105 100X neck 880105 250 bib simulator 880105 371 upper neck adjusting bracket 880105 207 lower neck adjusting bracket 880105 208 six axis neck transducer SA572 S11 and either three accelerometers SA572 S4 or their mass equivalent installed in the head assembly as specified in drawing 880105 100X Data from the accelerometers are not required 572 33 b The assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to a test 572 33 c 1 Record the maximum temperature Record the minimum temperature Re
77. minimize their influence upon the performance of the head neck assembly An example ofa measurement device is shown in Figure 11A With the pendulum resting against the honeycomb material the neck bracket was adjusted until the longitudinal centerline of the pendulum was perpendicular 1 degree to plane D on the dummy s head Release the pendulum and allow it to fall freely from a height to achieve an impact speed of 22 6 to 23 4 ft sec as measured at the center of the pendulum accelerometer 572 33 c 4 13 Complete following table Neck Flexion Test Results 572 33 1 amp 572 33 c 4 A29 Parameter Specification Result Pendulum impact speed 22 6 ft sec speed lt 23 4 ft sec Pendulum 10ms 22 5 lt g lt 27 5 Deceleration 20 ms 17 6 lt g lt 22 6 Versus Time 30ms 12 5 lt g lt 18 5 Pulse Above 30 29 g maximum First Pendulum Decay to 5g 34 ms lt time lt 42 ms Plane D Rotation 64 lt max rotation lt 78 57 ms lt tlme of max rotation lt 64 ms Time for Plane D Rotation to 113 ms lt time lt 128 ms Cross 0 During First Rebound Maximum Moment 65 Ibf ft lt moment lt 80 Ibf ft 47 ms lt time of max moment lt 58 ms Time of first decay to 0 Ibf ft 97 ms x time lt 107ms Positive Moment Decay Flexion Moment about the occipital condyle M 0 058 ft x Fx 572 33 6 1 1 My Moment in lbf ft
78. mm 14 76 in 04 in IMPACT SURFACE FIGURE 7D 024 04 NECK FLEXION TEST 572 143 3 YEAR OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive flexion tests are necessary 1 It has been at least 30 minutes since the last neck test 572 146 p __ N A this is the first neck test performed _ 2 components required for the neck tests include the neck molding assembly 210 2015 neck cable 210 2040 nylon shoulder bushing 9001373 upper mount plate insert 910420 048 bib simulator TE 208 050 urethane washer 210 2050 neck mounting plate TE 250 021 two jam nuts 9001336 load moment transducer SA572 19 and headform TE 208 000 572 143 a __3 The assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to a test 572 143 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity __4 Visually inspect neck assembly for cracks cuts and separation of the rubber from metal segments Note If the damage resulted from the vehicle crash test the damaged area is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are ma
79. of Crashworthiness Standards OCWS NCAP TEST DELIVERABLES Required deliverables for each test are discussed in this section Schedule of Deliverables is also provided at the end of this section A QUICKLOOK REPORT The Quicklook Report is a preliminary summary of the test that should be e mailed to the OCWS within 24 hours of the impact event The Quicklook Report should detail all relevant injury criteria vehicle information airbag deployment and evidence of FMVSS 208 FMVSS 212 FMVSS 219 FMVSS 301 and FMVSS 305 if applicable compliance and should include relevant data traces Also anything interesting or out of the ordinary should be included in the Quicklook Report in a comments section A sample Quicklook Report is included as Form 5 in this document B DATA TAPE Within three 3 working days of the test the Contractor shall email the NHTSA the test data formatted as specified in the Office of Crashworthiness Research Data Reference Guide Volume I Vehicle Tests Visit http www nrd nhtsa dot gov and click on R amp D Software Under NVS Software Applications click ENTREE for Windows and select the latest version of the program Data entry software ENTR E may also be downloaded from the website and used to generate the specification data files as defined in the guides Visit N2 http www nrd nhtsa dot gov and click on R amp D Software Under NVS Software Applications click ENTREE
80. passenger dummies from the previous test will become the auxiliary set If more than two of each type of dummy is furnished to the Contractor they should be rotated in an analogous manner Document the final positions of the dummy after it is seated in the test vehicle by taking the following measurements accurate to 3mm Record measurements on applicable data sheet 11 3 11 4 NCAP 45 LOAD CELL BARRIER PREPARATION The fixed barrier shall be instrumented with load cells as seen in Appendix P as per any barrier configuration provided to the Contractor by NHTSA VEHICLE MEASUREMENTS 2 EXTERIOR VEHICLE MEASUREMENTS l Establish a fixed reference plane that is perpendicular to the vehicle s longitudinal centerline as shown in Figure 9 Prior to the test with the vehicle in the As Tested configuration measure and record the dimensions from the fixed reference plane as specified in the applicable data sheet Post test place the vehicle on a flat level surface Inflate the test vehicle s tires to maximum cold pressure found on tire placard Take the same measurements as in step 2 Record on the applicable data sheet Compute the difference between the measurements taken in steps 2 and 4 and record on the applicable data sheet NCAP 46 REAR DATUM REFERENCE LENGTH OF ENGINE BLOCK TO EDGE OF DOOR L EVEN NUMBER FOR RIGHT SIDE AND ODD NUMBER FOR LEFT SIDE TO TRAILING EDGE BEHIN
81. replacement because this is a post test calibration verification Record damage The following repairs or replacement was performed Record 6 The dummy is dressed in a size 4 pair of long pants having a weight of less than 0 090 kg 0 2 Ib with the legs cut off sufficiently above the knee to allow the knee target to be visible 572 124 c 2 7 Seat the dummy chest skin still removed without back support on the test fixture surface as shown in Figure 9C The surface must be long enough to support the pelvis and outstretched legs 572 124 c 2 8 Level the ribs both longitudinally and laterally 0 5 and adjust the pelvis angle to 8 2 The angle may be measured at the pelvis lumbar joining surface 3 35 210 13 14 15 16 C32 The midsagittal plane of dummy is vertical within 1 572 124 c 3 The longitudinal centerline of the test probe is centered within 2 5 mm of the midsagittal plane of the dummy and is 12 7 mm Imm below the horizontal peripheral centerline of the No 3 rib and is within 0 5 of a horizontal line in the dummy s midsagittal plane 572 124 c 3 Record locations such as the rear surfaces of the thoracic spine and the lower neck bracket reference with respect to locations such as the rear surfaces of the thoracic spine and the lower neck bracket These reference measurements are necessary to ensure the dummy is in the same position after the chest skin is installed
82. required Additional clearance available Seat moved Forward from the previous position Seat moved Forward _ detent positions from the previous position Seat moved Forward Full Forward position reached 22 Passenger foot positioning Indicate final position achieved S16 3 3 2 22 1 Place feet flat on the toe board OR S16 3 3 2 1 22 2 If the feet cannot be placed flat on the toe board set the feet perpendicular to the lower leg and rest the heel as far forward on the floor pan as possible OR S16 3 3 2 2 22 3 If the heels do not touch the floor pan set the legs as perpendicular to the thighs as possible and set the feet parallel to the floor pan 516 3 3 2 2 F11 23 Passenger arm hand positioning S16 3 3 3 23 1 Place the dummy s upper arms adjacent to the torso with the arm centerlines as close to a vertical longitudinal plane as possible 516 3 3 3 1 23 2 Place the palms of the dummy in contact with the outer part of the thighs S16 3 3 3 2 23 3 Place the little fingers in contact with the seat cushion S16 3 3 3 3 24 Adjustable head restraints S16 3 4 N A there is no head restraint adjustment 24 1 If the head restraint has an automatic adjustment leave it where the system positions the restraint after the dummy 15 placed in the seat 516 3 4 1 Go to 25 242 Adjust each head restraint vertically so that the horizontal plane determined in item 2 is aligned wit
83. s midsagittal plane should be vertical Position the dummy s H point so it is 68 6 5 1 mm 2 7 0 2 in above the horizontal seating surface and 94 0 5 1 mm 3 7 0 2 in forward of the rear vertical surface of the fixture The H point is located 34 5 mm 1 36 in forward and 48 7 mm 1 92 in downward from the center pelvic angle reference hole Extend the dummy s neck so that the plane perpendicular to the skull to skullcap interface 1s level both fore and aft and side to side within 0 5 degrees The vertical mating surface between the skull and skull cap will be vertical The rear surface of the skullcap should be 20 3 2 5 mm 0 8 0 1 in from the vertical surface of the test fixture A strap or bungee cord may be placed around the forehead of the dummy to stabilize the head in this position Position the upper and lower legs parallel to the midsagittal plane so the knee and ankle pivots centerlines are parallel forming a 90 angle between the tibia and femur Position the feet parallel to the dummy s midsagittal plane with the bottoms horizontal and parallel to the seating surface Position the upper arms downward vertically so the centerlines of the shoulder yoke and elbow pivots are parallel 2315 13 14 C15 Position the lower arms horizontally so the centerline of the elbow and wrist pivot are parallel Record the dimensions listed in following table except for dimension Y and Z reference figure 20 I
84. signing an acceptance of test vehicles The Contractor must check to verify the following options listed on the window sticker are present on the test vehicle Tires and wheel rims are the same as listed There are no dents or other interior or exterior flaws The vehicle has been properly prepared and is in running condition The glove box contains an owner s manual warranty document consumer information and extra set of keys Proper fuel filler cap is supplied on the test vehicle 7 Verify that spare tire jack lug wrench and tool kit if applicable is located in the vehicle cargo area 8 The Contractor shall check for damage that may have occurred during transit The COTR is to be notified of any damage prior to preparation of the vehicle for testing RS e ANTHROPOMORPHIC TESTING DEVICES An adequate number of Part 572 Subpart E 508 Percentile Male test dummies and Part 572 Subpart O 5 Percentile Female test dummies will be furnished to the contract laboratory by the NCAP In addition Part 572 Subpart N 6 year old Subpart P 3 year old and Subpart R 12 month old test dummies will be provided if needed The dummies will be instrumented with 6 axis neck load cells and instrumented lower legs all other dummy instrumentation shall be provided by the Contractor The Subpart E 50th male O Sth female and N 6 year old dummies shall be stored in an upright sitting position with the wei
85. the method used of determining seat fore aft positions Total Fore Aft Travel Placed in Position Driver Seat Passenger Seat SEAT BELT UPPER ANCHORAGE Describe the method of positioning seat belt upper anchorages Total of Positions Placed in Position Driver Seat Passenger Seat N29 DATA SHEET NO 2 CONTINUED SEAT ADJUSTMENT FUEL SYSTEM AND STEERING WHEEL DATA Test Vehicle NHTSA Test Program Test Date FUEL TANK CAPACITY Usable Capacity of Standard Tank Usable Capacity of Optional Tank 92 94 of Usable Capacity Actual Amount of Solvent Used 1 3 of Usable Capacity Describe the fuel system what type of fuel pump details about how it operates etc STEERING COLUMN ADJUSTMENT Steering wheel and column adjustments are made so that the steering wheel hub is at the geometric center of the locus it describes when moved through its full range of motion Describe how this measurement was taken LEFT SIDE VIEW STEERING COLUMN ASSEMBLY STEERING COLUMN POSITIONS Degrees Fore AftPosition mm Lowermost position No 1 Geometric center position No 2 Uppermost position No 3 Telescoping Steering Wheel Travel Test Position N30 DATA SHEET NO 3 DUMMY LONGITUDINAL CLEARANCE DIMENSIONS Test Vehicle NHTSA Test Program Test Date
86. the photos should be labeled in Appendix A of the final test report and on the final CD provided to NCAP A list of photographs with their labeling convention can be found in Section 3 of Appendix N 10 DEFINITIONS The Contractor shall check the Code of Federal Regulations for the most recent definitions A citation is provided after each definition not specified in Standard 208 A Automatic locking retractor A retractor incorporating adjustment hardware by means of a positive self locking mechanism which is capable when locked of withstanding restraint forces 571 209 S3 B Designated seating capacity The number of designated seating positions provided 571 3 C Designated seating positions Any plan view location capable of accommodating a person at least as large as a 5th percentile adult female if the overall seat configuration and design and vehicle design is such that the position is likely to be used as a seating position while the vehicle is in motion except for auxiliary seating accommodations such as temporary or folding jump seats Any bench or split bench seat in a passenger car truck or multipurpose passenger vehicle with a GVWR less than 4 586 kilograms 10 000 pounds having greater than 127 centimeters 50 inches of hip room measured in accordance with SAE Standard J1100 shall nave not less than three seat designated seating positions unless the set design or vehicle design is such that the NCAP 23 center
87. the temperature range is 20 6 C 69 F to 22 2 C 72 F D Dummy limb joints are set at 1 G barely restraining the weight of the limb when it is extended horizontally The force required to move a limb segment does not exceed 2 Gs throughout the range of limb motion 572 146 0 E Dummies will be clothed for the thorax calibration tests with a form fitting cotton polyester based tight fitting long sleeved shirt and ankle length pants The total weight of the shirt and pants shall not exceed 0 25 kg 0 55 1b 572 144 1 CALIBRATION TEST EXECUTION Complete the Data Sheets in section 15 POST TEST REQUIREMENTS The contractor shall verify all instrumentation and check data sheets and photographs Make sure data is recorded in all data blocks on every performance calibration test data sheet REPORTS APPARENT NONCONFORMANCE During calibration verification any indication of apparent nonconformance to the requirements of Regulation P572 shall be communicated by telephone to the COTR within 24 hours with written notification mailed within 48 hours Saturdays and Sundays excluded Written notification shall be submitted with a copy of the particular test data sheet s and preliminary data plot s In the event of an apparent nonconformance a calibration check of some critically sensitive test equipment and instrumentation may be required for verification of accuracy 14 2 14 2 1 012 The necessity for calibration
88. thoracic spine and the lower neck bracket These reference measurements are necessary to ensure the dummy is in the same position after the chest skin is installed The reference locations must be accessible after installation of the chest skin It may be necessary to leave the chest skin zipper unfastened until the references are checked and fasten it just prior to the test Install the chest skin and reposition the dummy as described in the preceding paragraph using the reference measurements recorded Place the arm assemblies horizontal 2 and parallel to midsagittal plane The arms are held in place by tightening the adjustment nut that holds the arm yoke to the clavicle assembly The data acquisition system including transducers must conform to the requirements of SAE Recommended Practice J211 1 MAR95 Class 180 Impact the anterior surface of the thorax with the test probe so the longitudinal centerline of the probe is within 2 of a horizontal line in the dummy s midsagittal plane at the moment of impact 572 34 c 5 The velocity of the test probe at the time of impact is 22 f s 0 4 f s 572 34 b The probe 15 guided so there is no significant lateral vertical or rotational movement during the impact 572 34 c 6 A38 16 Complete the following table Thorax Impact Results 572 34 b Parameter Specification Result Test Probe Speed 21 6 f s lt speed x 22 4 f s Chest Compression 2 5
89. to 25 3 25 3 Check the ONLY one of the following that applies The left foot did not contact the brake or clutch pedal To the extent practicable keep the left thigh and the leg in a vertical longitudinal plane S10 5 Set the foot perpendicular to the leg and place it as far forward as possible with the heel resting on the floor pan S10 6 1 2 The left foot did contact the brake or clutch pedal and the foot was rotated to avoid contact To the extent practicable keep the left thigh and the leg in a vertical longitudinal plane S10 5 Set the foot perpendicular to the leg and place it as far forward as possible with the heel resting on the floor pan and rotate the foot the minimum amount to avoid pedal contact 510 6 1 2 The left foot did contact the brake or clutch pedal and the foot was rotated about the leg and the leg was rotated outboard about the hip the minimum distance necessary to F5 avoid pedal contact Set the foot perpendicular to the leg and place it as far forward as possible with the heel resting on the floor pan and rotate the foot about the leg and the thigh and leg outboard about the hip the minimum distance necessary to avoid pedal contact S10 6 1 2 26 Place the right upper arm adjacent to the torso with the centerline as close to a vertical plane as possible S10 2 1 27 Fasten the seat belt around the dummy 27 1 Remove all slack from the lap belt portion 510 9 27 2 Pull the upper torso webbin
90. tow cable attachment device and the test vehicle front frame assembly shall be provided by the Contractor NO HARD POINT CONNECTIONS BETWEEN THE TOW CABLE AND THE TEST VEHICLE SHALL BE ALLOWED The tow cable attachment shall release from the cable so that the vehicle will roll into the barrier at a constant velocity no acceleration D The tow system must be capable of ensuring that the test vehicle shall impact the barrier face at a speed of 56 30 km h 0 80 km h or range of 55 50 km h to 57 10 km h Any photographs or video footage of the test speed readout must show the impact speed in km h to two decimal places ONLY Test data submitted without a photograph and or video footage of the test speed readout or displaying a primary test speed that does not conform to this range may ultimately be considered nonconforming FOR THE VEHICLE TOWING AND LATERAL GUIDANCE SYSTEMS THE PERFORMANCE REQUIREMENT OF SOFT CONNECTIONS IS CONSTRUED TO BE SYSTEMS WHICH DO NOT OBSTRUCT OR RESTRAIN THE VEHICLE STRUCTURAL DEFORMATION DURING IMPACT SYSTEMS THAT FAIL TO COMPLY WITH THIS REQUIREMENT ARE INTERPRETED AS SYSTEMS WITH HARD POINT CONNECTIONS AND ARE GROUNDS FOR RETEST IN ADDITION ENGAGEMENT OF THE VEHICLE TOWING AND GUIDANCE SYSTEMS SHALL NOT ALTER THE NATURAL ATTITUDE OF THE VEHICLE MODIFICATION OF ANY KIND TO THE TEST VEHICLE FOR TOWING PURPOSES SUCH AS WELDING DRILLING ETC IS PROHIBITED NCAP 6 TEST CONTROL CENTER TOW CA
91. was adjusted until the longitudinal centerline of the pendulum was perpendicular 1 degree to plane D on the dummy s head 2 Release the pendulum and allow it to fall freely from a height to achieve an impact speed of 5 95 m s to 6 19 m s as measured at the center of the pendulum accelerometer 572 133 c 4 1 2 13 Complete the following table Neck Extension Test Results 572 133 b 2 amp 572 133 c 4 I amp ii Parameter Specification Result Pendulum impact speed 5 95 m s speed x 6 19 m s Pendulum AV with respect to impact speed 10ms 1 5 m s lt AV lt 1 9 m s 20 ms 3 1 m s AV 3 9 m s 30ms 4 6 m s lt AV lt 5 6 m s Plane D Rotation Peak moment Nm 65 Nm lt moment lt 53 Nm during the degrees following rotation range 99 lt angle 114 Negative Moment Decay Extension Time to decay to 10 Nm 94 ms time lt 114 ms Moment about the occipital condyle M 0 01778 m x Fx 572 133 b 1 11 My Moment in Nm measured by the transducer Fx Force in N measured by the transducer Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material 572 133 b 3 2214 Plots of acceleration velocity y axis moment and x axis force and y axis moment about the occipital condyle follow this sheet Signature Date 29 PENDULUM SPECIFICATIONS
92. when and how they are activated If YES above designate ONE ride mode to be used for all three crash tests frontal side MDB and side pole tests and provide instructions for adjusting the test vehicle to that designated ride mode 13 14 15 N62 HEAD RESTRAINTS Do any of the head restraints in this vehicle have a non use position Please note that use positions are defined in FMVSS No 202a YES If YES please indicate seating positions that apply and how to properly put the applicable head restraint s in the lowest use position EVENT DATA RECORDER EDR LOCATION Please specify where the EDR is located and provide brief instructions for its removal If available please include a diagram LIST OF REMOVABLE PARTS NCAP will remove the following parts if the target test weight cannot be achieved Frontal NCAP test spare tire rear door windows rear radio speakers interior door trim on the rear doors rear seat cushions outboard mirrors taillights rear bumper Side NCAP tests spare tire rear radio speakers interior door trim and windows on non struck side outboard mirrors on non struck side taillights rear bumper Please prioritize the items in this list in order of removal preference for each NCAP test Please make a note of any parts that should not be removed because they serve as load bearing or structural components and therefore wi
93. 0 4 04 6060000 14 FIGURE 3 REFERENCE PHOTO 6 0 00 000000000000 00088 19 FIGURE 4 REFERENCE PHOTO TARGETS CONT D vrrrrrvrvnrnrnrnrernrnrererererevnrevevevernrerevererererereveveveverer 19 FIGURE 5 VEHICLE ACCELEROMETER LOCATIONS eene eene enee tener 26 FIGURE 6 DUMMY MEASUREMENTS FOR FRONT SEAT PASSENGERS 34 FIGURE 7 EXTERIOR VEHICLE MEASUREMENTS nennen nnns 46 FIGURE 8 DOOR OPENING WIDTH AND WHEELBASE MEASUREMENTS 47 FIGURE 9 DRIVER COMPARTMENT MEASUREMENTS 48 FIGURE 10 VEHICLE CRUSH PROFILE 5 5 0000 49 APPENDIX A APPENDIX B APPENDIX C APPENDIX D APPENDIX E APPENDIX F APPENDIX G APPENDIX H APPENDIX I APPENDIX J APPENDIX K APPENDIX L APPENDIX M APPENDIX N APPENDIX O APPENDIX P NCAP LABORATORY TEST PROCEDURE APPENDICES PART 572E 50 PERCENTILE MALE DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE PART 5720 STH PERCENTILE FEMALE DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE PART 572N 6 YEAR OLD DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE PART 572P 3 YEAR OLD DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE PART 572R 12 MONTH OLD DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE DRIVER AND PASSENGER DUMMY SEATING AND POSITIONING PROC
94. 050 051 052 053 054 055 056 N16 should be shown and labeled if applicable Post Test View of Belt Anchorage for Driver Dummy This photograph should show the position of the upper belt anchorage Detent or millimeter markings should be shown and labeled if applicable Pre test Driver Dummy Feet taken with the door open Post test Driver Dummy Feet taken with the door open Pre test Driver s Side Knee Bolster without dummy present Post test Driver s Side Knee Bolster without dummy present show driver knee contact if it occurred Pre test Driver s Side Floorpan Post test Driver s Side Floorpan Post Test Driver Dummy Face Post test Driver Dummy Contact with Airbag Post test Driver Dummy Contact with Headrest Pre test View of the Steering Wheel do NOT disassemble any parts to take this photograph take perpendicular to the longitudinal centerline of the vehicle Post test View of the Steering Wheel do NOT disassemble any parts to take this photograph take perpendicular to the longitudinal centerline of the vehicle Pre test Passenger Dummy Front View taken through the windshield directly in front of the passenger with the camera parallel to the longitudinal centerline of the vehicle Post test Passenger Dummy Front View taken through the windshield directly in front of the passenger with the camera parallel to the longitudinal centerline of the vehicle Pre test Passenger Dummy Wind
95. 1096 to 7096 for a period of at least four 4 hours prior to this test 572 136 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity __5 Mount the test specimen and secure it to the rigid test fixture 572 136 c 2 6 No parts of the foot or tibia contact any exterior surface 572 136 c 2 7 Align the test probe so that throughout its stroke and at contact with the knee it is within 2 degrees of horizontal and collinear with the longitudinal centerline of the femur 572 136 c 3 8 probe is guided so there is no significant lateral vertical or rotational movement during the impact with the knee 572 136 c 4 9 data acquisition system including transducers must conform to the requirements of SAE Recommended Practice J211 1 MAR95 572 136 m Class 600 10 Contact the knee with the test probe at a speed between 2 07 m s and 2 13 m s 572 136 5 Neither the suspension hardware suspension cables nor other attachments to the probe including the velocity vane make contact with the dummy 572 136 c 6 42 11 Complete following table Knee Impact Results 572 136 b 1 and 572 136 c 5 Parameter Specification Result Probe speed 2 07 m s lt speed lt 2 13 m s Peak resistance force 3450 N lt force lt 4060 N Force impactor mass x deceleration 572 136 b 2 12 Plots of acc
96. 19A 572 35 c 2 1v 210 _12 13 A47 Complete the following table Left Hip Joint Femur Flexion Results 572 35 c 1 amp c 2 iv Parameter Specification Result Rotation Rate 5 lt rotation rate lt 10 Femur Torque at 30 torque lt 70 ft lbf Rotation at 150 Ibf ft 40 rotation lt 50 Secure the lever arm into the right femur shaft opening of the upper leg structure assembly 78051 44 and firmly secure it using the 3 8 16 socket head cap screws Figure 19A 572 35 2 11 Lift the lever arm parallel to the midsagittal plane at a rotation rate between 5 and 10 degrees per second while maintaining in shoulder bolt longitudinal centerline horizontal throughout the range of motion until the 150 ft Ibf torque level is reached Figures 18A and 19 572 35 c 2 iv Complete the following table Right Hip Joint Femur Flexion Results 572 35 c 1 amp c 2 iv Parameter Specification Result Rotation Rate 5 rotation rate 10 Femur Torque at 30 torque lt 70 ft lbf Rotation at 15 Ibf ft 40 lt rotation 50 Signature Date 48 PELVIC BONE STABLIZER INSERT TAP FOR SUITABLE ATTACHMENT BOLTS PER FIGURE 25 INSERT INTO PELVIS INSTRUMENT CAVITY 60 OF PART 78051 59 e gt 1 87 N 4 25 1 75 CA J 2 15 NOTE HOLE LOCATIONS n MATCHING INSTRUMENT 0 1
97. 2 12 MONTH OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive head drops are necessary 1 It has been at least 2 hours since the last frontal head drop and at least 30 minutes since the last rear head drop 572 152 c 5 __ N A ONLY one head drop performed 2 The head assembly consists of the head 921022 001 triaxial accelerometer mounting block SA572 S80 and three 3 accelerometers SA572 S4 572 152 a 3 Accelerometers and their respective mounts are smooth and clean 4 The data acquisition system including transducers conforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 155 1 5 The head assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 1096 to 7096 for a period of at least four 4 hours prior to a test 572 152 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity 6 Visually inspect the head skin for cracks cuts abrasions etc Repair or replace the head if the damaged area is more than superficial Note If the damage resulted from the vehicle crash test in which the dummy was an occupant the damaged area is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and a
98. 2 OTHER TRANSDUCER CONDITIONS cnet dons 6 11 3 THORAX IMPACTOR PROBE 572 127 a e 6 114 KNEE IMPACTOR PROBE 572 127 b orici tetris decetero 7 i5 GENERAL TEST CONDITIONS U SL SSS nce umu e 10 12 CALIBRATION TEST EXECUTION a tus ettet be e seuls te tenes 10 13 POST TEST REQUIREMENT Sixties tds edge 10 SREP OR RSS ee E 10 141 APPARENT NONCONFORMANGCE certet nN 10 142 CALIBRATION DOCUMENTATION teret 11 15 DATA ah Ata e nasal ea 12 12 DATAS eee ed 14 DATO NE 21 Ho as Ru ri ena e uA ML EN 24 DAA GHEE Th OS ous maaa nasa E a D E I i LAU 26 DATA GSHBET CR ne voccs eate uL A AT DE 31 DATA ETO e cesset Ra LS E 36 DATASHEET Buone Ost see 39 DATA SEET COSS te EN 41 DATA SHEET C10 PURPOSE AND APPLICATION The purpose of this laboratory procedure is to provide dummy users independent testing laboratories under contract with the Office of Crashworthiness Standards with standard test procedures for performing receiving inspection and performance calibration tests on the Part 572 Subpart N dummy so that repetitive and correlative test results can be obtained The foll
99. 3 Load Cell Locations on a 176 Load Cell High Resolution Barrier P3
100. 4 9 4 10 4 11 4 12 14 13 1125 mm 6 8 6 9 6 10 6 11 6 12 6 13 sf ea esos D Figure 2 Load Cell Locations on a 144 Load Cell High Resolution Barrier HIGH RESOLUTION MULTI AXIS 176 LOAD CELL BARRIER NHTSA may also furnish a 176 high resolution multi axis load cell wall for use in frontal NCAP testing as shown in Figure 3 Each load cell will be 125mm x 125mm nominal in size arranged in 11 rows of 16 load cells each The gap between the load cell wall and the floor should be no more than 3 15 80 mm These load cells record force in the x direction as well as moments about the y axis and z axis Each load cell shall have a mount surface and a struck surface The mount surface will be attached to a rigid plate using threaded fasteners Test vehicles will impact struck surface of the barrier The struck surface shall be flat and square 120 000 3048 00mml 58 150 1477 01mm1 o ra 5 T a m m a i e ole o gt AP ode ole ole olo ol ode olb ole 4 olo olo sie sje elo olo ole ele 42 22 22 ole oo 4 b ol olo 45 ol slo e co amp oo ol clo olb oo ole ole olb oo olb 2 mun 2 Centerline Figure
101. 43 4 11 Parameter Specification Result Pendulum impact speed 5 4 m s speed lt 5 6 m s Pendulum 10ms 2 0 m s AV lt 2 7 m s AV with respect 15ms 3 0 m s 4 0 m s to impact speed 20ms 4 0 m s X AV 5 1 m s 215 Plane D Rotation Peak moment _ Nm 2 42 Nm lt moment lt 53 Nm during the _ degrees following rotation range 70 lt angle lt 82 Positive Moment Decay Time to decay to 10 Nm Flexion 60 ms time lt 80ms moment is a direct reading from the load cell Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material 572 143 c 4 iii Plots of pendulum acceleration pendulum velocity neck y axis moment and neck rotation about the y axis follow this sheet Signature Date 026 DATA SHEET 05 NECK EXTENSION TEST 572 133 3 YEAR OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive extension tests are necessary l It has been at least 30 minutes since the last neck test 572 146 p __ N A this is the first neck test performed _ 2 components required for the neck tests include the neck molding assembly 210 2015 neck cable 210 2040 nylon shoulder bushing 9001373 upper mount plate insert 910420 048 bib simulator TE 208 050 urethane w
102. 52 CAVITY COVER 78051 13 MATERIAL Aluminum or Steel 0 20 DIA HOLES THROUGH 4 PLACES FIGURE 15A PELVIS UPPER SUPPORT DEVICE 1 2 HOLES SUITABLE SPACED TO MATCH WITH HOLES IN REAR PLANE OF FIGURE 25 NOTCH TO CLEAR 7 75 p HYBRID CHEST ASSY Y 5 Ss K 8 93 N X 3 8 16 Le dk X 1 DEEP 2 2 0 125 Fy S NN N x HOLE TO 4 125 ES i X x gt CLEAR 1 2 d m LA SHAFT N MM E hc 1 45527 vw STANDOFF mi MIDSAGITTAL 2 Reqd CENTERLINE E A 2 2 50 Vant HOLE SPACING ABOUT THE MIDSAGITTAL CENTERLINE TO MATCH MOUNTING HOLES OF MOUNT PELVIC ADAPTOR 78051 MATERIAL CRS Steel ig FIGURE 16A REAR PLATE RIGID SUITABLE ATTACHMENT BOLTS E A49 HIP JOINT TEST FIXTURE ASSEMBLY USE 1 2 THREADED ROD TO ADJUST PELVIS LEVEL RIGID SUPT DEVICE USE 1 2 THREADED ROD TO ADJUST PELVIS LEVEL 4 FEMUR ROTATION ABOUT TRANSVERSE AXIS RIGID PELVIC BONE STABILIZER INSERT OPTIONAL FIGURE I7A 50 HIP JOINT TEST FIXT
103. 6 UNIT TONS nee ome sa aaa 6 JPRETESTREOUIBEMENJTS see meom entm eet 6 11 1 TRANSDUCER 2412 11 2111066 6 11 2 OTHER TRANSDUCER CONDITIONS ettet 7 11 3 THORAX IMPACTOR PROBE 572 146 8 SIGN CONVENTION FOR PART 572 TEST DUMMIES 9 114 GENERAL FEST CONDITIONS a 11 2 CALIBRATION TEST EXECUTION te ri e 11 13 POST TEST REQUIREMENTS se ll 141 APPARENT NONCONFORMANCE tereti 11 142 FINAL PERFORMANCE CALIBRATION REPORTS nnn 12 ee mi ct eL k Sanapa wa 13 DATASHEET D 1 LLL I A EE 13 DAS LL an Deen sue ios feck 15 ur noc ed inr emp ELT sun rel 21 DATA SIERD DW no eser c alee ML pe ia a ge ARE ME 24 DATA SHBBTS aoaaa a um ueteres o c ed 26 JAGERE JE EN amu a QE as 31 DAT CSBBET D SR a ea a 36 DATA SHEET DS OL na a S aec e e A eee id 39 DI PURPOSE AND APPLICATION The purpose of this laboratory procedure is to provide dummy users independent testing laboratories under contract with the Office of Crashworthiness Standards w
104. 60 Ib lt force x 1300 Ib Force impactor mass x deceleration 572 35 b 1 44 12 Plots of pendulum acceleration pendulum speed and force follow this sheet Time zero is defined as the time of contact between the test probe and the knee 572 3 b 2 vii Signature Date 45 TEST SET UP SPECIFICATIONS PENDULUM ACCELEHOME ER iENDEVCO MODEL 7231C OR EQUIVALENT TORQUE TWO FEMUR LOAD CELL SIMULATOR MOUNTED WITH SENSITIVE AXIS MOUNTING BOLTS P N 78051 99 PARALI TO PENDULUM PN 78051 100 TO 41 NEWTON METRES LONGITUDINAL CENTERLINE 30 FT LBSi CENTERLINE OF FEMUR LOAD CELL SIMULATOR 78051 319 HORIZONTAL 0 5 KNET PIVOT PENDULUM CENTERLINE ADJUST KNFE JOINT HORIZONTAL 0 5 TORQUE TO 1 2 RANGE EACH TEST PENDULUM IMPACTOR ANKLE FIGUREI4A 46 DATA SHEET A9 HIP JOINT FEMUR FLEXION 572 35 c 508 Male Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive hip joint femur flexion tests are necessary 1 It has been at least 30 minutes since the last hip joint femur flexion test 572 36 m N A ONLY one hip joint femur flexion test performed 2 The test fixture conforms to the specifications in Figure 17A 3 Use the assembled dummy 78051 218 except 572 35 c 2 3 1 remove the leg assemblies 86 5001 001 am
105. 7 DATA SHEET NO 17 DUMMY VEHICLE TEMPERATURE STABILIZATION 48 4 FORMS 49 FORM NO 1 TEST VEHICLE INFORMATION S uu s tie resta RE eon a terat oa a 50 FORM NO 2 REPORT OF VEHICLE CONDITION eee nennen 67 FORM NO 3 LABORATORY NOTICE OF TEST FAILURE eee 69 FORM NO 4 MONTHLY VEHICLE STATUS REPORT eterne 70 FORM NO 5 SAMPLE QUICKLOOK REPORT ttn nett tne 71 1 1 1 2 1 3 NI TEST DELIVERABLES AND REPORTING REQUIREMENTS MONTHLY STATUS REPORTS The contractor shall submit Monthly Vehicle Status Report to the COTR The form can be found in Section 3 Forms in this document The report shall be submitted until all vehicles or items of equipment are disposed of APPARENT TEST FAILURE An apparent test failure shall be communicated by telephone to the COTR within 24 hours with written notification mailed within 48 hours Saturday and Sundays excluded Laboratory Notice of Test Failure located in Section 3 of this document with copy of the particular NCAP test data sheet s and preliminary data plot s shall be included In the event of a test failure a post test calibration check of some of the critically sensitive test equipment and instrumentation may be required for verification of accuracy The necessity for the calibration shall be at the COTR s discretion and shall be performed without additional costs to the Office
106. 72 36 1 E Dummies will be clothed for the thorax calibration tests with the exception of the shoes being removed CALIBRATION TEST EXECUTION Complete the Data Sheets in section 15 POST TEST REQUIREMENTS The contractor shall verify all instrumentation and check data sheets and photographs Make sure data is recorded in all data blocks on every performance calibration test data sheet REPORTS APPARENT NONCONFORMANCE During the post test calibration any indication of apparent nonconformance to the requirements of Regulation P572 shall be communicated by telephone to the COTR within 24 hours with written notification mailed within 48 hours Saturdays and Sundays excluded Written notification shall be submitted with a copy of the particular test data sheet s and preliminary data plot s In the event of an apparent nonconformance a post test calibration check of some critically sensitive test equipment and instrumentation may be required for verification of accuracy The necessity for the calibration shall be at the COTR s discretion and shall be performed without additional costs to the OC WS 14 2 14 2 1 14 2 2 14 2 3 A12 FINAL PERFORMANCE CALIBRATION REPORTS COPIES A report containing the pre test calibration and post test calibration verification data for each Part 572 Subpart E dummy used in the NCAP test shall be submitted with the final test report for the vehicle tested Contractors are required to PROOF R
107. 8 test procedure Each vehicle shall be tested by impacting it into an instrumented fixed rigid concrete barrier that conforms to the definition in Part 571 3 Definitions 49 CFR Part 571 3 The contract laboratories are directed by this test procedure to use an impact velocity of 56 30 3 1 2 0 80 km h Any changes to or deviations from this test procedure must be approved by the Contracting Officer s Technical Representative COTR NOTE Vehicles are tested with a 50 percentile male Hybrid in the driver position and a 5 percentile female Hybrid III placed in the front right outboard seating position When tested according to the conditions outlined in this test procedure each 50 percentile occupant shall comply with the injury criteria listed in section S6 of 49CFR571 208 and each 5 percentile occupant shall comply with injury criteria listed in section S15 of 49CFR571 208 SECURITY The Contractor shall provide appropriate security measures to protect NCAP test vehicles dummies load cell barrier and any GFP during the entire crash test program and shall be responsible for all equipment removed from test vehicles before and after the crash test Any security problems which arise shall be reported by telephone to the Industrial Property Manager IPM Office of Acquisition Management within two 2 working days after the incident letter containing specific details of the security problem shall be sent to the IPM
108. 9 65 ms lt time lt 79 ms Time of first decay to 0 Negative Moment Decay Extension 120 ms lt time lt 148 ms Moment about the occipital condyle M 0 01778 m x Fx 572 133 b 1 i 14 My Moment in Nm measured by the transducer Force in N measured by the transducer Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material 572 133 b 3 Plots of pendulum acceleration y axis moment x axis force y axis moment about the occipital condyle and D plane rotation follows this sheet Signature Date A32 PENDULUM SPECIFICATIONS 101 6 mm t ini STRUCTURAL STEEL TUBE boo mm 4 8 mm 10 1875 in p 31 8 mm PIVOT 50 8 mm 2 in DIA 11 25 in INERTIAL PROPERTIES OF PENDULUM MOUNTING PLATE AND MOUNTING HARDWARE WITHOUT TEST SPECIMEN T PENDULUM X 7 ACCELEROMETER CENTERLINE WEIGHT 29 57 165 21 156 198 1 mm MOMENT OF INERTIA 33 2 kg m roy 8 294 in Ib sec ABOUT PIVOT AXIS P 7 4 8 mm GE 188 in mm 38 1 mm 8 28 mm f 7 F 11 5 in 132 6m3 A i f i ON 886 2 mm 188 6 mm CG OF PENDULUM SES 9225 in 7 75 in APPARATUS WITHOUT 7 Eu 463 6 NE RADIOS HEXCEL 28 8 kg m zw 1 8 1b ft REF ACCELEROMETER BEFORE TESTING RECRUSH
109. A FILTERING REQUIREMENTS Filter Class Cut off Frequency Head Acceleration 1000 1650 Neck Forces 1000 1650 Pelvic Acceleration 1000 1650 Foot Acceleration 1000 1650 Chest Acceleration 180 300 Chest Compression 600 1000 Femur Forces 600 1000 Neck Moments 600 1000 Tibia Forces 600 1000 Tibia Moment 600 1000 Nij 600 1000 Vehicle Acceleration 60 100 Load Cell Barrier Loads 60 100 NCAP 54 Seat Loads 60 100 K The Contractor must meet all the requirements in the NHTSA Test Reference Guide It 15 recommended that the Contractor regularly visit NHTSA s website for the most updated version of the guide Visit http www nhtsa gov Research Databasest and Software NHTSA Test Reference Gui des and select the latest version of Volume I Vehicle Tests The latest Test Reference Guide is also available from the following organization U S Department of Transportation National Highway Traffic Safety Administration Office of Crashworthiness Standards 1200 New Jersey Ave SE Washington DC 20590 L When reporting injury measures that have redundant channel capability the following process is used when a primary channel contains questionable data or fails completely All channels should be labeled and submitted as they are recorded in the crash according to the channel list in Section 12 3 Primary channels should never be switched with or labeled as redundant channels f
110. A and be mounted in the head as shown in drawing 78051 61X March 28 1997 and in the assembly shown in drawing 78051 218 revision T 572 36 c Three Endevco 7231C 750 accelerometers with 196 Transverse Sensitivity shall be mounted in the head cavity to measure orthogonal accelerations Ax Ay AZ at the center of gravity CG of the head assembly NECK The neck transducer shall have the dimensions response characteristics and sensitive axis locations specified in drawing 83 5001 008 or C 1709 and be mounted for testing as shown in drawing 79051 63 revision W and in the assembly shown in drawing 78051 218 revision T 572 36 d CHEST The chest accelerometers shall have the dimensions response characteristics and sensitive mass locations specified in drawing 78051 136 revision A and be mounted as shown with adaptor assembly 78051 116 revision D for assembly into 78051 218 revision T The chest accelerometers are not required for dummy calibration testing but are required for NCAP testing Three Endevco 7231C 750 accelerometers with 196 Transverse Sensitivity shall be mounted in the chest cavity to measure orthogonal accelerations Ax Ay Az at the CG of the chest assembly 572 36 e The chest deflection transducer shall have the dimensions and response characteristics specified in drawing 78051 342 revision A Bourns Potentiometer Model 6638S 432 102 or alternate Vernitech Potentiometer Model 81422A and be mounted in the
111. ABLE CAPACITY Suggested methods for draining Is the vehicle equipped with an electric fuel pump YES NO If YES does the pump normally operate when the vehicle s electrical system is activated YES JNO If YES explain the vehicle operating conditions under which the fuel pump will pump fuel Provide a drawing or description that shows the undercarriage view and or location of the fuel tank 10 N60 DEACTIVATION OF SIDE AIRBAGS If this vehicle has side airbags will they deploy in a Frontal NCAP test YES IF YES please be prepared to disable side airbags on test day in event that NCAP requests they be deactivated for the Frontal test If a representative will not be present be sure to provide the laboratory with detailed instructions prior to test day If this vehicle has side airbags will the side airbags on the non struck side deploy in a Side MDB test YES IF YES please be prepared to disable non struck side airbags test day If a representative will not be present be sure to provide the laboratory with detailed instructions prior to test day If this vehicle has side airbags will the side airbags on the non struck side deploy in a Side Pole test YES YES please prepared to disable side airbags non struck side test day If a representative will not be pre
112. ASSEN GER NECK Y FORCE 55 PASSEN GER NECK Z FORCE 56 PASSEN PASSEN GER NECK X MOMENT GER NECK Y MOMENT PASSEN GER NECK Z MOMENT PASSEN GER CHEST X PRIMARY PASSEN GER CHEST Y PRIMARY PASSEN GER CHEST Z PRIMARY PASSEN GER CHEST X REDUNDANT PASSEN GER CHEST Y REDUNDANT PASSEN GER CHEST Z REDUNDANT PASSEN GER CHEST DISPLACEMENT PASSEN GER PELVIS X PASSEN GER PELVIS Y PASSEN GER PELVIS Z PASSEN GER LEFT FEMUR PASSEN GER RIGHT FEMUR PASSEN GER LEFT FEMUR REDUNDANT PASSEN GER RIGHT FEMUR REDUNDANT PASSEN PASSEN GER LEFT UPPER TIBIA X MOMENT GER LEFT UPPER TIBIA Y MOMENT 76 PASSEN PASSEN GER LEFT UPPER TIBIA Z FORCE GER LEFT LOWER TIBIA X MOMENT 77 PASSEN GER LEFT LOWER TIBIA Y MOMENT 78 PASSEN GER LEFT LOWER TIBIA Z FORCE 79 PASSEN GER RIGHT UPPER TIBIA X MOMENT 80 PASSEN GER RIGHT UPPER TIBIA Y MOMENT 81 PASSEN GER RIGHT UPPER TIBIA Z FORCE 82 PASSEN GER RIGHT LOWER TIBIA X MOMENT 83 PASSEN GER RIGHT LOWER TIBIA Y MOMENT 84 PASSEN GER RIGHT LOWER TIBIA Z FORCE 85 PASSEN GER LEFT ANKLE X 86 PASSEN GER LEFT ANKLE Z 87 PASSEN GER LEFT FOOT Z FRONT 88 PASSEN GER RIGHT ANKLE X 89 PASSEN GER RIGHT ANKLE Z
113. AT BELT ANCHORAGE POSITION Nominal Design Position NDP Please complete the following table for adjustable seat belt anchorages Total Dist from Total No ie Range Rete s Gif Travel Position to aplicable NDP mm NDP mm Driver Front Passenger 50 Male Driver Front Passenger 5 Female Rear Passenger 5 Female The detent number of the Nominal Design Position is counted with respect to the upper most detent which is defined as 0 SEAT BELT GUIDES Is this vehicle equipped with a seat belt guide for any of the following seating positions Driver YES NO Right Front Passenger YES NO Left Rear Passenger YES NO If YES for any position please provide instructions for use STEERING COLUMN ASSEMBLY STEERING COLUMN AND WHEEL ADJUSTMENTS If the steering wheel and or steering column adjustments are available provide any specific procedures used to determine the geometric center of the LEFT SIDE VIEW N58 locus the steering wheel hub describes when it 15 moved through its full range of driving positions Angle of the steering wheel with respect to vertical when the steering wheel hub is positioned at the geometric center of the locus it describes when it is moved through its full range of positions Total number of detents Test detent when the wheel hub is positioned at the geome
114. AV with respect 20ms 2 4 m s lt AV 34 m s toimpactspeed 30ms 3 8 m s AV lt 5 0 m s Plane D Rotation Peak moment Nm 2 27 Nm lt moment lt 33 Nm during the _ degrees following rotation range 74 lt angle lt 92 Positive Moment Decay Time to decay to 5 Nm Flexion 103 ms lt time lt 123 ms Moment about the occipital condyle M 0 01778 m x Fx 572 123 b 1 1ii My Moment in Nm measured by the transducer Force in N measured by the transducer Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material 572 123 b 3 4 Plots of acceleration velocity y axis moment and x axis force and y axis moment about the occipital condyle follow this sheet Signature Date 26 DATA SHEET C5 NECK EXTENSION TEST 572 123 6 YEAR OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive extension tests are necessary l 2 It has been at least 30 minutes since last neck test 572 127 __ N A ONLY one neck test performed The components required for the neck tests include the head assembly 127 1000 neck 127 1015 pivot pin 78051 339 bib simulator TE127 1025 neck bracket assembly 127 8221 six axis neck transducer SA572 S11 neck mounting adaptor TE 2208 001 and three accele
115. Assembly Bent shaft Slider arm riding in track Transducer leads Torn cables 014 Dummy Inspect for Comments Damaged OK Accelerometer Head mounting secure Mountings Chest mounting secure Knees Skin condition Insert do not remove Casting Limbs Normal movement and adjustment Knee Sliders Wires intact Rubber returned to at rest position Pelvis Broken Other If upon visual examination damage is apparent in any of these areas the appropriate engineer or engineering technician is to be consulted for a decision on repair or replacement of parts Repair or Replacement approved by Signature Date Describe the repair or replacement of parts Checked by Signature Date 015 DATA SHEET 02 EXTERNAL MEASUREMENTS 3 YEAR OLD See the PADI Dummy Serial Number Test Date Technician __ Pretest calibration Post test calibration verification 1 Seat dummy on a flat rigid smooth clean dry horizontal surface as shown in Figure 5D and 6D The seating surface is at least 406 mm 16 in wide and 221 mm 8 11 16 in in depth with a vertical section at least 406 mm 16 in wide and 610 mm 24 in high attached to the rear of the seating fixture The dummy s midsagittal plane is vertical and centered on the test surface Secure the dummy to the test fixture so that the upper torso and buttocks are
116. BIB SIMULATOR NECK MOLDED ASS Y TE 208 050 210 2015 REF LOAD CELL SA572 S19 D PLANE PERPENDICULAR TO CENTER LINE OF PENDULUM HEADFORM TE 208 000 NOTE MOUNT NECK AT LEADING EDGE OF PENDULUM TO AVOID INTERFERENCE WITH HEADFORM MOTION PENDULUM SHOWN IN VERTICAL ORIENTATION FIGURE 9D 030 NECK EXTENSION TEST SET UP SPECIFICATIONS DIRECTION OF PENDULUM FLIGHT PENDULUM REF FIGURE 22 SUBPART E NECK MOUNTING PLATE TE 250 021 BIB SIMULATOR NECK MOLDED ASS Y TE 208 050 210 2015 REF LOAD CELL 5 572 819 D PLANE PERPENDICULAR TO CENTER LINE OF PENDULUM HEADFORM TE 208 000 NOTE MOUNT NECK AT LEADING EDGE OF PENDULUM TO AVOID INTERFERENCE WITH HEADFORM MOTION PENDULUM SHOWN IN VERTICAL ORIENTATION FIGURE 10D D31 DATA SHEET D6 THORAX IMPACT TEST 572 144 3 YEAR OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive thorax impact tests are necessary It has been least 30 minutes since last Impact test 572 146 __ N A ONLY one thorax impact test performed The test fixture conforms to the specifications in Figure 11D The complete assembled dummy 210 0000 is used 572 144 b and 15 dressed in cotton polyester based tight fitting long sleeved shirt and ankle length pants The weight of the shirt and pants shall not exceed 0 25 kg 572 144 c
117. BLE ORIVE CONCRETE TEST PAD TEST VEHICLE PREPARATION AREA MONORAIL CONCRETE BARRIER PHOTO PIT COVERED WITH CLEAR PLASTIC MINIMUM OF 500 FEET OF PAVED SMOOTH LEVEL ROADWAY 1ST 100 FEET TO BRING VEHICLE UP TO SPEED WITH ACCELERATION LESS THAN 0 5 G AND 2ND 100 FEET FOR TEST DUMMY STABILIZATION Figure 1 Typical Frontal NCAP Rigid Barrier Impact Test Facility 6 4 FIXED COLLISION BARRIER The basic fixed collision barrier must conform to the definition in Part 571 3 Definitions 49 CFR Part 571 3 and at a minimum should consist of a reinforced concrete structure 6 feet high 6 feet thick and 12 feet wide weighing approximately 100 000 pounds The Government furnished property GFP load cell barrier shall be firmly attached to the reinforced concrete structure prior to every test unless otherwise directed by OCWS 6 5 TEST VEHICLE VELOCITY MEASUREMENT A The speed of the test vehicle must be controlled to obtain and maintain the vehicle speed in the range of 56 30 km h 0 80 km h or range of 55 50 km h to 57 10 km h B Primary test vehicle impact speed measurement may be achieved by the use of break wires photocells or laser beams located within 5 feet of the barrier Usually 2 sets of break wires or 2 photocell transmitters and receivers are used in the final speed trap 6 6 6 7 NCAP 7 which records the time on an electronic counter for the test vehicle to travel the last 5 fee
118. CLE PARAMETER DATA Test Vehicle NHTSA Test Program Test Date TARGET VEHICLE STRUCTURAL MEASUREMENT Elements pet mm Total Length Total Width Bumper Top Height Bumper Bottom Height Longitudinal Member Top Height Distance Between Longitudinal Members Longitudinal Member Width Engine Top Height Engine Bottom Height Engine and Gearbox Width Front Bumper Engine Distance Front Shock Absorber Fixing Height Bonnet Leading Edge Height Front Shock Absorber Fixing Front Bumper Front Axle Distance Front Axle A Pillar Distance A Pillar B Pillar Distance B Pillar Rear Axle Distance B Pillar C Pillar Distance Roof Sill Bottom Height Roof Sill Top Height Floor Sill Bottom Height Floor Sill Top Height N28 DATA SHEET NO 2 SEAT ADJUSTMENT FUEL SYSTEM AND STEERING WHEEL Test Vehicle NHTSA No Test Program Test Date 1 DEGREES NOMINAL DESIGN RIDING POSITION For adjustable driver and passenger seat backs Please BBIGHEROSITION a describe how to position the inclinometer to measure the seat back angle Include description of the location of the adjustment latch detent if applicable SEAT BACK INCLINOMETER ADJUSTER p a LEFT SIDE VIEW i Driver seat back angle FRONT SEAT ASSEMBLY Passenger seat back angle SEAT FORE AFT POSITIONS Describe
119. COTR shall be provided as follows This publication is distributed by the U S Department of Transportation National Highway Traffic Safety Administration in the interest of information exchange The opinions findings and conclusions expressed in this publication are those of the author s and not necessarily those of the Department of Transportation or the National Highway Traffic Safety Administration The United States Government assumes no liability for its contents or use thereof If trade or manufacturers names or products are mentioned it is only because they are considered essential to the object of the publication and should not be construed as an endorsement The United States Government does not endorse products or manufacturers Prepared By Approved By Approval Date FINAL REPORT ACCEPTANCE BY OCWS Division Chief New Car Assessment Program NHTSA Office of Crashworthiness Standards Date COTR New Car Assessment Program NHTSA Office of Crashworthiness Standards Date N7 3 Second Page After Front Cover A completed Technical Report Documentation Page Form DOT F1700 7 shall be completed for those items that are applicable with the other spaces left blank Sample data for the applicable block numbers of the title page follows Block No 1 REPORT NO NCAP ABC XX 001 Block No 2 GOVERNMENT ACCESSION NUMBER Leave blank Block No 3 RECIPIENT S CATALOG NUMBER Leave blank
120. D DOOR RIGHT LEFT SIDE TO LEADING EDGE IN FRONT OF DOOR RIGHT LEFT SIDE TO HEADLINER ME CENTER OF 8 STEERING COLUMN T ul C X17 TO A POST REAR DATUM REFERENCE AT CENTER OF REAR BUMPER X12 13 X14 15 TO BOTTOM OF A POST RIGHT LEFT SIDE TO FIREWALL RIGHT LEFT SIDE X16 TO STEERING COLUMN Figure 7 Exterior Vehicle Measurements B VEHICLE INTRUSION MEASUREMENTS 1 Prior to the test record the Door Opening Width Wheelbase and Driver Compartment measurements as shown in Figures 8 and 9 and on the applicable data sheets 2 Post test repeat the measurements taken in step 1 and record on the data sheets 3 Compute the difference between the measurements taken in steps 1 and 2 Record NCAP 47 these values on the applicable data sheets Figure 8 Door Opening Width and Wheelbase Measurements NCAP 48 DX Figure 9 Driver Compartment Measurements C VEHICLE CRUSH MEASUREMENTS 1 Prior to the test record L and C1 through C6 as shown in Figure 10 on the applicable data sheet L is the damage width which is found by taking the measurement from bumper corner to bumper corner Points C1 through C6 can be found by dividing L
121. D FORCE POSITIVE OUTPUT DIRECTION NECK FX SHEAR HEAD REARWARD OR CHEST FORWARD FY SHEAR HEAD LEFTWARD CHEST RIGHTWARD FZ AXIAL HEAD UPWARD CHEST DOWNWARD MX MOMENT ROLL LEFT EAR TOWARD LEFT SHOULDER MY MOMENT PITCH CHIN TOWARD STERNUM MZ MOMENT YAW CHIN TOWARD LEFT SHOULDER FEMUR FX SHEAR FY SHEAR FZ AXIAL KNEE UPWARD UPPER FEMUR DOWNWARD KNEE RIGHTWARD UPPER FEMUR LEFTWARD KNEE FORWARD TENSION PELVIS REARWARD KNEE LEFTWARD HOLD UPPER FEMUR IN PLACE KNEE UPWARD HOLD UPPER FEMUR IN PLACE KNEE ROTATED CCW WHEN FACING FRONT OF DUMMY MX MOMENT ROLL MY MOMENT PITCH MZ MOMENT YAW KNEE CLEVIS FZ AXIAL TIBIA DOWNWARD TENSION FEMUR UPWARD UPPER TIBIA MX MOMENT MY MOMENT ANKLE LEFTWARD HOLD KNEE IN PLACE ANKLE FORWARD BOTTOM OF KNEE CLEVIS REARWARD LOWER TIBIA FX SHEAR FY SHEAR FZ AXIAL ANKLE FORWARD KNEE REARWARD ANKLE RIGHTWARD KNEE LEFTWARD ANKLE DOWNWARD TENSION KNEE UPWARD ANKLE LEFTWARD HOLD KNEE IN PLACE yee MOT ANKLE FORWARD BOTTOM OF KNEE CLEVIS REARWARD CHEST DISPLACEMENT CHEST COMPRESSED NEGATIVE KNEE SHEAR DISPLACEMENT PUSH ON FRONT OF TIBIA NEGATIVE NOTE DIRECTIONS ARE DEFINED IN RELATION TO A SEATED DUMMY 12 13 14 14 1 B10 GENERAL TEST CONDITIONS A Surfaces of dummy components are not painted unless otherwise specified 572 137 Dummy performance tests of same component segment assembly or fully
122. Date Negative Channels to be Reversed in Data Channel Output Acquisition System Upper Neck Upper Neck Y N Y Head Rearward Chest Forward Load Cell Head Left Head Upward Left Ear to My Chin to Sternum In to APPENDIX M HEAD NINE ACCELEROMETER ARRAY POLARITY CHECK MI APPENDIX M PROCEDURE FOR CHECKING AND RECORDING DUMMY ACCELEROMETER POLARITY FOR THE 5019 AND 5 PERCENTILE NINE ACCELEROMETER ARRAY HEAD WITH REDUNDANT C G ACCELEROMETERS Purpose The purpose of this procedure is to provide a practical methodology for checking and documenting the recorded polarity of the data channel for each dummy mounted accelerometer relative to the NHTSA sign convention Documenting the polarity of channels will serve to increase the confidence that polarities have been correctly determined The polarities in this document are the same as those of the SAE J211 and SAE J1733 Background Standardized coordinate systems and recorded polarities for various transducer outputs defined relative to positive directions of those coordinate systems are defined for crash test dummies vehicle structures and laboratory fixtures in the SAE J211 standard The standardized coordinate system and polarities for data permits comparison of data from different crash test facilities There are many ways to influence the polarity of a data channel NHTSA has required the polarity of any given manufacturer s instrumentation be compa
123. Driver Passenger Measurement Description Length Angle ya Angle mm ww NIE N31 DATA SHEET NO 4 DUMMY LATERAL CLEARANCE DIMENSIONS Test Vehicle NHTSA No Test Program Test Date Description Arm to Door H Point to Door Head to Side Header Head to Side Window Knee to Knee Striker to H Point Y Direction Ankle to Ankle N32 DATA SHEET NO 5 SEAT BELT POSITIONING DATA Test Vehicle NHTSA No Test Program Test Date SEAT BELT POSITIONING DATA DUMMY S CENTERLINE SHOULDER BELT PORTION MALE BLADE BUCKLE ASSEMBLY 1 8 THICK ALUMINUM PLATE INBOARD ANCHORAGE FLOORPAN FRONT VIEW OF DUMMY SEAT BELT POSITIONING MEASUREMENTS Measurement Description PBU Top surface of reference to belt upper edge mn PBL Top surface of reference to belt lower edge m J BELT LENGTH DATA Measurement Description Units Shoulder belt length as measured on ATD Lap Belt Length as measured on ATD Remainder of belt on reel Total belt length for continuous webbing systems N33 DATA SHEET NO 6 HIGH SPEED CAMERA LOCATIONS AND DATA Test Vehicle NHTSA No Test Program Test Date CAMERA POSITIONS FOR FRONTAL IMPACTS 14 Pit Camera Engine Compartment View Real Time C
124. E IN PLACE yee MOT ANKLE FORWARD BOTTOM OF KNEE CLEVIS REARWARD CHEST DISPLACEMENT CHEST COMPRESSED NEGATIVE KNEE SHEAR DISPLACEMENT PUSH ON FRONT OF TIBIA NEGATIVE NOTE DIRECTIONS ARE DEFINED IN RELATION TO A SEATED DUMMY 12 13 14 14 1 C10 GENERAL TEST CONDITIONS A Surfaces of dummy components are not painted unless otherwise specified 572 127 p B Dummy performance tests of the same component segment assembly or fully assembled dummy are separated in time by a period of not less than 30 minutes unless otherwise specified 572 127 o C Except for neck assembly and thorax assembly testing the dummy performance tests are conducted at any temperature from 18 9 C 66 F to 25 6 C 78 F and at any relative humidity from 10 to 70 after exposure of the dummy to these conditions for a period of not less than 4 hours For the neck assembly and thorax assembly the temperature range is 20 6 C 69 F to 22 2 C 72 F D Dummy limb joints are set at 1 G barely restraining the weight of the limb when it is extended horizontally The force required to move a limb segment does not exceed 2 Gs throughout the range of limb motion 572 127 n E Dummies will be clothed for the thorax calibration tests with a cotton stretch above the elbow sleeved shirt and above the knee pants 572 124 2 CALIBRATION TEST EXECUTION Complete the Data Sheets in section 15 POST TEST REQUIREMENTS The c
125. EAD all Final Test Reports before submittal to the COTR The OCWS will not act as a report quality control office for contractors Reports containing a significant number of errors will be returned to the contractor for correction and a hold will be placed on invoice payment for the particular test REQUIREMENTS Performance calibration report Table of Contents shall include the following A Section 1 Purpose of Calibration Test B Section2 Calibration Data Summary C Section3 Test Data D Section 4 Test Equipment List and Calibration Information B Section 5 Photographs if applicable The test data for each dummy will be presented in separate sections Each section shall contain a title page test results summary and the test data The title page shall include the dummy s serial number and the manufacturer s name It will also indicate whether the calibration data is pre or post test The test results sheets will provide a summary of each test and describe any damage failures and or corrective action taken The test data shall include the pass fail data sheets the time histories for each data channel used to determine the pass or fail status and instrumentation calibration data sheets FIRST PAGE FRONT COVER A heavy paperback cover or transparency shall be provided for the protection of the final report The information required on the cover is as follows A Final Report Title and Subtitle such as A13
126. EDURES REDUNDANT ACCELEROMETERS RECOMMENDED PRACTICE FOOT INSTRUMENTATION RECOMMENDED PRACTICE COMPUTER PROGRAMS FMVSS 212 219 PARTIAL 301 AND 305 REQUIREMENTS FOR FRONTAL IMPACT NCAP METRIC CONVERSION UPPER NECK LOAD CELL POLARITY CHECK HEAD NINE ACCELEROMETER ARRAY POLARITY CHECK TEST DELIVERABLES AND REPORT GUIDELINES RESERVED LOAD CELL BARRIER CONFIGURATIONS REVISION CONTROL LOG FOR NCAP LABORATORY TEST PROCEDURES FRONTAL RIGID BARRIER IMPACT TEST TEST NEW CAR ASSESSMENT DESCRIPTION PROCEDURE PROGRAM FRONTAL IMPACT TESTING REV EFFECTIVE No DATE AMENDMENT DATE 09 22 2010 09 22 2010 Minor changes to procedure Photo list update and clarifications Removal of test reporting requirements from main procedure and insertion in Appendix N 01 01 13 2010 01 13 2010 Minor changes to procedure Added information to allow for high resolution barrier Updated Appendix G to allow for redundant femur load cells 05 18 2012 05 18 2012 Minor changes to procedure Changes test speed measurement requirements to km h Moved FMVSS 305 data sheets to a separate procedure Removed information in Appendix O and reserved Moved load cell barrier information to Appendix P 03 09 24 2012 09 24 2012 Minor changes to test procedure Reinstated vehicle Z accelerometers Changed data sheet 1 in Appendix m 08 10 2013 08 10 2012 Minor changes to test procedure Overhaul of data processing sect
127. EIGHT INCLUDING ALL INSTRUMENTATION AND 13 OF SUPPORT CABLE WEIGHT N 2 99 30 023 kg 6 6 005 Ib COMPLETE LEG ASSEMBLY KEDTOS SG0 L LH 330105 5547 2 RH WITH UPPER LEG WELDMENT AND UPPER LEG FLESH REMOVED FEMUR LOAD CELL SA572 514 SINGLE AXIS OR SA 72 829 SIX CHANNEL OR STRUCTURAL REPLACEMENT 78051 319 HORIZONTAL 40 5 ANKLE PIVOT FOOT ASSEMBLY R90105 650 LH 80105 051 U3 CABLE WEIGHT TO EXCEED 5 OF THE TOTAL IMPACT PROBE WEIGHT Probe specifications 1 Rigid metallic construction concentric about is longitudinal axis 2 A mass of 2 99 0 23 kg 6 6 0 05 lbs 1 3 of the weight of the suspension cables and their attachments to the impact probe must be included in the calculation of mass and such components may not exceed 5 percent of the total weight of the test probe 3 Minimum mass moment of inertia of 209 kg cm 0 177 Ibs in sec yaw and pitch about the center of gravity 4 The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It must have a flat continuous and non deformable face with diameter of 76 2 0 2mm 3 0 0 01 in and a maximum edge radius of 7 6 to 12 7 mm 0 3 to 0 5 in 5 The impactor is a cylinder with a diameter of 76 2 76 4 mm 3 0 3 1 in and it is at least 12 5 mm 0 5 in long 6 The probe s end opposite to the impact face must have provisions for mounting of an accelerometer
128. ERIFICATION 22 REPORT AREA 6 TEST EQUIPMENT AND INSTRUMENTATION CALIBRATION 22 3 DATA SHEETS aan ani am 23 DATA SHEET NO 1 GENERAL TEST AND VEHICLE PARAMETER DATA 24 DATA SHEET NO 2 SEAT ADJUSTMENT FUEL SYSTEM AND STEERING WHEEL 28 DATA SHEET 3 DUMMY LONGITUDINAL CLEARANCE DIMENSIONS 30 DATA SHEET NO 4 DUMMY LATERAL CLEARANCE DIMENSIONS 31 DATA SHEET 5 SEAT BELT POSITIONING DATA ee 32 DATA SHEET NO 6 HIGH SPEED CAMERA LOCATIONS AND 33 DATA SHEET NO 7 VEHICLE ACCELEROMETER DATA eene 35 DATA SHEET NO 8 PHOTOGRAPHIC REFERENCE TARGET LOCATIONS 36 DATA SHEET NO 9 LOAD CELL LOCATIONS ON FIXED BARRIER 37 DATA SHEET NO 10 TEST VEHICLE SUMMARY OF 38 DATA SHEET NO 11 POST TEST 6 39 DATA SHEET NO 12 VEHICLE PROFILE eene 40 DATA SHEET NO 13 ACCIDENT INVESTIGATION DIVISION DATA 42 DATA SHEET NO 14 VEHICLE INTRUSION MEASUREMENTS 43 DATA SHEET NO 15 SUMMARY OF FMVSS 212 219 PARTIAL AND 301 DATA 45 DATA SHEET NO 16 FMVSS 301 STATIC ROLLOVER RESULTS 4
129. GURE 3B 20 EXTERNAL DIMENSIONS TEST SETUP FIGURE 4B 21 DATA SHEET B3 HEAD DROP TEST 572 132 5 Female Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive head drops are necessary 1 It has been at least 2 hours since the last head drop 572 132 c 5 __ N A ONLY one head drop performed 2 The head assembly consists of the complete head 880105 100X the six axis neck transducer SA572 S11 or neck transducer structural replacement 78051 383X and three 3 accelerometers 5 572 54 572 132 3 The head accelerometer mounting plate screws 10 24 x 3 8 SHCS are torqued to 9 0 Nm 4 Accelerometers and their respective mounts are smooth and clean 5 Torque the skull cap screws 10 24 x 1 2 SHCS to 9 0 Nm 6 The data acquisition system including transducers conforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 136 m 7 The head assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 1090 to 7096 for a period of at least four 4 hours prior to a test 572 132 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity 8 Visually inspect the head skin for cracks cuts abrasions etc Repair or replace the head skin if the damaged area is more than superficial No
130. HOTO PIT LEFT SIDE VIEW Figure 3 Reference Photo Targets PHOTOGRAPHIC DOCUMENTATION Continued ge CAR TOP TARGETS A1 8 2 11 2 2 STEERING WHEEL Hy ifi p D P STEERING COLUMN TARGETS LEFT SIDE VIEW Figure 4 Reference Photo Targets Cont d 9 6 NCAP 20 Reference photographic targets shall rigidly mounted on the test vehicle and attached to the barrier assembly as shown in Figures 3 and 4 The primary moving reference targets Al and A2 MUST BE mounted 24 inches 609 6mm apart on a flat rectangular panel and be firmly fixed to a structure of the vehicle that remains undisturbed by the crash such as the vehicle roof The panel must be in the same plane as the plane of motion The setup rotation of the panel within the motion plane is unimportant To ensure against unexpected displacements of the car top the backup moving reference targets C1 and C2 should also be attached to undisturbed portions of the vehicle such as the vehicle door or body and must also be 24 inches 609 6mm apart l inch wide checkerboard tape should be applied down the center of the vehicle including top of hood roof and deck lid Also apply tape down both sides of vehicle approximately 4 inches above wheel opening Photographic targets should be placed at 12 intervals along the side of the vehicle along the 1 inch tape Target placement should be documented Stadia poles or similar fixed ground refe
131. Ibs 1 3 of the weight of the suspension cables and any attachments to the impact probe must be included in the calculation of mass and such components may not exceed 5 percent of the total weight of the test probe It shall have a minimum mass moment of inertia of 209 kg cm 0 177 Ibs in sec in yaw and pitch about the center of gravity The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It must have a flat continuous and non deformable face with a diameter of 76 2 0 2mm 3 00 0 01 in and a maximum edge radius of 7 6 12 7 mm 0 3 0 5 m The impactor is a cylinder with a diameter of 76 2 76 4 mm 3 00 3 1 in and it is at least 12 5 mm 1 0 in long The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe The impact probe shall have a free air resonant frequency of not less than 1000 Hz SIGN CONVENTIONS FOR PART 572 SUBPART E TEST DUMMIES C G POSSIBLE TARGET A 3 UNIAXIAL ACCELEROMETERS LOCATED AT THE C G OF THE HEAD ASSEMBLY Ay Ap A A A Gs tA 3 UNIAXIAL ACCELEROMETERS LOCATED AT THE C G OF THE CHEST ASSEMBLY RIGHT FEMUR LOAD CELL Fa LEFT FEMUR LOAD CELL F FIGURE IB B8 B9 TABLE 1B SIGN CONVENTION FOR HYBRID III TRANSDUCER OUTPUTS BODY SEGMENT MEASURE
132. Include any reference points and photographs Dummy Height Used Additional Description Frontal Impact 50 Male Side Impact 50 Male Side Impact 5 Female 1 10 Provide any other instructions for positioning the driver s seat at the required test position s Frontal Side MDB Side Pole 12 Front Outboard Passenger Seat 5 percentile dummy in frontal impact only 1 24 Seat Fore Aft Positioning Depending on the seat track adjuster type complete one of the tables below Manual Seat Track Adjuster Total number of detents Frontal impact test detent 5 percentile female For manual seat track adjustments test detent is measured from foremost detent which is defined as 0 Power Seat Track Adjuster Complete range of travel mm Frontal impact test distance from the foremost position 5 percentile female 1 2B Seat Cushion Angle 1 2C 1 2D 1 3 1 3A N53 If the seat cushion angle is adjustable while maintaining the test fore aft seat track position describe the angle used during certification testing and how to measure it Include any reference points and photographs Dummy Angle Used Additional Description Frontal Impact 57 Female Seat Cushion Height If the seat and or seat cushion height is adjustable at the test fore aft seat track position and can be adj
133. LU M u 4482 AK sy WIS TANIA ejnol eqna p 16 0 popaeu oz 1909 4 jeeje H4 Beaj Jomo SU o aue su pug JOO jo doi uo sie 88 489 dop IP s ou Ul 8 6 Foot cube N 0 4300 0 4300 ALL 0 0469 HOLES ARE TAPPED FOR 0 80 SCREWS ALL DIMENSIONS ARE IN INCHES 5 APPENDIX I COMPUTER PROGRAMS H APPENDIX I COMPUTER PROGRAMS Computer programs related to signal processing may be obtained from the NHTSA website to generate specification data files as defined in the guides Visit http www nrd nhtsa dot gov and click on R amp D Software Under NVS Software Applications select the latest version of the program desired For questions related to this software contact Office of Crashworthiness Standards DOT NHTSA 1200 New Jersey Ave SE W43 404 NVS 110 Washington DC 20590 Telephone No 202 366 1740 APPENDIX J FMVSS 212 219 PARTIAL 301 AND 305 REQUIREMENTS FOR FRONTAL NCAP 12 1 PURPOSE The New Car Assessment Program s Frontal Impact Test Procedure is based upon FMVSS 208 This procedure will allow the Office of Crashworthiness Standards OCWS to gain supplemental information on the test vehicle All test variables are to be evaluated at NCAP s 35mph 56 3km h test vehicl
134. NHTSA testing only Fill the coolant system to capacity Fill the engine with motor oil to the max mark on the dip stick NCAP 28 9 Fill the brake reservoir with brake fluid to its normal level 10 Fill the windshield washer reservoir to capacity 11 Inflate the tires to the cold tire pressure indicated on the tire placard If no tire placard is available inflate the tires to the recommended pressure in the owner s manual Record on the applicable data sheet 12 Record the vehicle weight at each wheel to determine the As Delivered or Unloaded Vehicle Weight UVW condition which is found by totaling the weight recorded at each of the four wheels VEHICLE ATTITUDE MEASUREMENTS AS DELIVERED or UVW 1 With the vehicle in the As Delivered UVW weight condition place it on a flat level surface 2 Mark a point on each vehicle body above the center of each wheel 3 Measure the perpendicular distance from the level surface to the four 4 points marked on the vehicle and record each CALCULATION OF VEHICLE TARGET TEST WEIGHT 1 Calculate the Rated Cargo and Luggage Weight RCLW as follows RCLW VCW 68 04 kg x DSC 2 Record VCW on the data sheet where VCW Vehicle capacity weight from the vehicle placard 3 Record DSC on the data sheet where DSC Designated seating capacity as indicated on the vehicle placard 4 Record RCLW on the applicable data sheet FOR TRUCKS MPVs OR BUSES If the RCLW calcul
135. NVENTION FOR PART 572 TEST DUMMIES C G POSSIBLE TARGET Ay Ay 3 UNIAXIAL ACCELEROMETERS LOCATED AT THEC G OF THE HEAD ASSEMBLY A Y A A A2 Gs 3 UNIAXIAL ACCELEROMETERS LOCATED AT THE C G OF THE CHEST ASSEMBLY RIGHT FEMUR LOAD CELL Fa LEFT FEMUR LOAD CELL F FIGURE IC C8 C9 TABLE 1C SIGN CONVENTION FOR HYBRID III TRANSDUCER OUTPUTS BODY SEGMENT MEASURED FORCE POSITIVE OUTPUT DIRECTION NECK FX SHEAR HEAD REARWARD OR CHEST FORWARD FY SHEAR HEAD LEFTWARD CHEST RIGHTWARD FZ AXIAL HEAD UPWARD CHEST DOWNWARD MX MOMENT ROLL LEFT EAR TOWARD LEFT SHOULDER MY MOMENT PITCH CHIN TOWARD STERNUM MZ MOMENT YAW CHIN TOWARD LEFT SHOULDER FEMUR FX SHEAR FY SHEAR FZ AXIAL KNEE UPWARD UPPER FEMUR DOWNWARD KNEE RIGHTWARD UPPER FEMUR LEFTWARD KNEE FORWARD TENSION PELVIS REARWARD KNEE LEFTWARD HOLD UPPER FEMUR IN PLACE KNEE UPWARD HOLD UPPER FEMUR IN PLACE KNEE ROTATED CCW WHEN FACING FRONT OF DUMMY MX MOMENT ROLL MY MOMENT PITCH MZ MOMENT YAW KNEE CLEVIS FZ AXIAL TIBIA DOWNWARD TENSION FEMUR UPWARD UPPER TIBIA MX MOMENT MY MOMENT ANKLE LEFTWARD HOLD KNEE IN PLACE ANKLE FORWARD BOTTOM OF KNEE CLEVIS REARWARD LOWER TIBIA FX SHEAR FY SHEAR FZ AXIAL ANKLE FORWARD KNEE REARWARD ANKLE RIGHTWARD KNEE LEFTWARD ANKLE DOWNWARD TENSION KNEE UPWARD ANKLE LEFTWARD HOLD KNE
136. ORMATION AND CONTACT LOCATIONS Description Dummy Type Serial No Head Contact Upper Torso Contact Lower Torso Contact Left Knee Contact Right Knee Contact DOOR OPENING AND SEAT TRACK INFORMATION Locked Unlocked Doors Front Door Opening Rear Door Opening Track Shift mm Seat Back Failure POST TEST STRUCTURAL OBSERVATIONS Critical Areas of Performance Observations and Conclusions Windshield Damage Window Damage Other Notable Effects VEHICLE REBOUND FROM BARRIER Left Side Center Right Side Average SUPPLEMENTAL RESTRAINT SYSTEM INFORMATION Driver Occupant 1 Passenger Occupant 2 Installed Deployed Installed Deployed Restraint Type Front Airbag Indicate side airbag type in vehicle ndicate side airbag type in vehicle Knee Airbag Seat Belt Pretensioner Seat Belt Load Limiter Other N40 DATA SHEET NO 12 VEHICLE PROFILE MEASUREMENTS Test Vehicle Test Program NHTSA No Test Date REAR DATUM REFERENCE LENGTH OF Te ENGINE BLOCK xi z 8 mW TO EDGE OF DOOR P TO HEADLINER 7 OG EVEN NUMBER FOR RIGHT SIDE lt AND ODD NUMBER 897 FOR LEFT SIDE RIGHT LEFT SIDE Lx X10 1 L TO LEADING EDGE IN FRONT OF DOOR RIGHT LEFT SIDE RIGHT LEFT SIDE
137. PART 572E HYBRID III THORAX CALIBRATION HYSTERESIS THORAX RESISTIVE FORCE Ibs 2 50 Minimum 2 86 Maximum 2400 1800 1200 600 0 00 0 67 1 33 2 00 2 67 3 33 4 00 CHEST DISPLACEMENT inches FIGURE 13A 41 DATA SHEET A7 LEFT KNEE IMPACT TEST 572 35 50 Male Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive knee impact tests are necessary 210 It has been least 30 minutes since last knee impact test 572 36 m __ N A ONLY one knee impact test performed The test fixture conforms to the specifications in Figure 14A The leg assembly 86 5001 001 with the upper leg assembly 78051 46 removed and the load cell simulator 78051 319 is used 572 35 b 2 The knee assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 1096 to 7096 for a period of at least four 4 hours prior to this test 572 35 b 2 11 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Mount the test specimen and secure it to the rigid test fixture 572 35 6 2 11 Figure 14A No parts of the foot or tibia contact any exterior surface 572 35 b 2 i11 Align the test probe so that at contact the longitudinal centerline of the probe is co
138. PENDICULAR TO PENDULUM CENTERLINE 1 D PLANE IS DEFINED AS AN IMAGINARY PLANE HEAD ASS Y PERPENDICULAR TO THE SKULL CAP SKULL P N 880105 100X INTERFACE FIGURE 8B B31 NECK EXTENSION TEST SETUP SPECIFICATIONS PENDULUM CENTERLINE W PENDULUM REF FIG 22 CFR 49 572 33 PENDULUM STRIKE PLATE ACCELEROMETER BRACKET NECK DIRECTION OF PEND ADJUSTING LOWER E P N E 0105 20 amp 38 1 0 5 mm 1 50 0 02 in NECK ADJUSTER UPPER P N 880105 207 BIB SIMULATOR P N 880205 210 NECK ASS Y P N 880105 250 MOUNTING BOLT CENTERLINE D PLANE 6 AXIS UPPER NECK PERPENDICULAR LOAD CELL TO PENDULUM SA572 S11 CENTERLINE 41 OCCIPITAL CONDYLES HEAD ASS Y D PLANE IS DEFINED AS AN IMAGINARY PLANE P N 880105 100X PERPENDICULAR TO THE SKULL CAP SKULL INTERFACE FIGURE 9B ROTATION TRANSDUCER ASSEMBLY xn 5 F TIL B33 DATA SHEET B6 THORAX IMPACT TEST 572 134 5 Female Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive thorax impact tests are necessary l It has been at least 30 minutes since the last thorax impact test 572 137 q __ N A ONLY one thorax impact test performed The test fixture conforms to the specifications in Figure 11B The complete assembled dummy 880105 000 is used 572 134 b and is
139. PROCEDURE 1 PURPOSE AND POTIN 1 Oe GENERAL REGUIREMENTS zm Sa aol ce sa teo YE teta 1 ERE EE SERRE CPP ROUT EET UNE 1 4 GOODTOUSEKEEPINO atenta te tice eed ute 2 5 TEST SCHEDULING AND MONITORING nana N 2 FT DAWIDISBOSPBIONS 22027252 e ones Du e De ERI E sssi 2 7 GOVERNMENT FURNISHED PROPERTY GFP tenent 2 8 CALIBRATION AND TEST INSTRUMENTATION e tnnt 5 9 PHOTOGRAPHIC DOCUMENTATION ccrte tentent totes 6 DENON 2 T am DL Lr ous LE 6 11 PRETEST REQUIREMENTS 2225220 sa nta 6 111 TRANSDUCER REQUIREMENTS scsscccscssccocsessccssssccossessccsssscesssseseccusscessusesestansessstees 6 112 OTHER TRANSDUCER CONDITIONS ia ictor etti rtt ict hae aei 7 11 3 THORAX IMPACTOR PROBE 572 155 a ett 1 11 4 GENERAL TEST CONDITIONS annassa ll 12 CALIBRATION TEST EXECUTION priest d 11 POST TEST REQUIREMENTS u cin eie eee 11 14 REPOR oid pP MIR NM yp NS 11 141 APPARENT NONCONFORMANGCE cette ttt 11 142 FINAL PERFORMANCE CALIBRATION REPORTS es 12 15 DAT ecce trata ACA x En ES LE eT EE 13 DATA SHEET Sy cs OE M Ei MEC 13 DATASET E eaaa Q On te NE 15 BAS aa asna Lema ana
140. RANCE 5 5 seat surface to highest point upper femur 63 0 73 2 G ELBOW PIVOT TO Elbow pivot to the finger tip in line with the elbow and wrist 176 6 191 8 FINGERTIP centerlines i SHOULDER PIVOT TO ELBOW Shoulder pivot bolt to elbow pivot bolt 99 114 3 ELBOW REST HEIGHT Seat surface to bottom of lower arm 150 1 165 3 BUTTOCK TO KNEE The forward most part of the knee flesh to the fixture s rear 202 7 2179 LENGTH vertical surface POPLITEAL HEIGHT Seat surface to the horizontal plane of the bottom of the feet 138 7 153 9 KNEE PIVOT HEIGHT Centerline of knee pivot bolt to the horizontal plane of the 165 1 180 3 bottom of the feet N BUTTOCK POPLITEAL The rearmost surface of the lower leg to the same point on the LENGTH rear surface of buttocks used for dimension K 144 8 160 E17 HYBRID III SUBPART R EXTERNAL DIMENSIONS continued ASSEMBLY ACTUAL DIMENSION DESCRIPTION DETAILS DIMENSION MEASUREMENT mm CHEST DEPTH WITH JACKET Measured 261 6 5 1 mm above seat surface 107 5 122 7 FOOT LENGTH Tip of toe to rear of heal 92 4 102 6 Place the dummy in supine position on the measurement surface Place a block that 15 perpendicular to the table at both the head and feet of the dummy Position the blocks STATURE perpendicular to midsaggital plane of the dummy Position PE the blocks so they are in contact with the head and the heels of the dummy Measure the distance between the blocks
141. RD KNEE LEFTWARD HOLD UPPER FEMUR IN PLACE KNEE UPWARD HOLD UPPER FEMUR IN PLACE MOMENT KNEE ROTATED CCW WHEN FACING FRONT OF MZ MOMENT YAW DUNAY KNEE CLEVIS FZ AXIAL TIBIA DOWNWARD TENSION FEMUR UPWARD UPPER TIBIA MX MOMENT MY MOMENT MX MOMENT ROLL ANKLE LEFTWARD HOLD KNEE IN PLACE ANKLE FORWARD BOTTOM OF KNEE CLEVIS REARWARD LOWER TIBIA FX SHEAR FY SHEAR FZ AXIAL ANKLE FORWARD KNEE REARWARD ANKLE RIGHTWARD KNEE LEFTWARD ANKLE DOWNWARD TENSION KNEE UPWARD ANKLE LEFTWARD HOLD KNEE IN PLACE ee 1 ANKLE FORWARD BOTTOM OF KNEE CLEVIS REARWARD CHEST DISPLACEMENT CHEST COMPRESSED NEGATIVE KNEE SHEAR DISPLACEMENT PUSH ON FRONT OF TIBIA NEGATIVE NOTE DIRECTIONS ARE DEFINED IN RELATION TO A SEATED DUMMY 1 4 12 13 14 14 1 D11 GENERAL TEST CONDITIONS A Surfaces of dummy components are not painted unless otherwise specified 572 146 q B Dummy performance tests of the same component segment assembly or fully assembled dummy are separated in time by a period of not less than 30 minutes unless otherwise specified 572 146 p C Except for neck assembly and thorax assembly testing the dummy performance tests are conducted at any temperature from 18 9 C 66 F to 25 6 C 78 F and at any relative humidity from 10 to 70 after exposure of the dummy to these conditions for a period of not less than 4 hours For the neck assembly and thorax assembly
142. SET UP SPECIFICATIONS PENDULUM ACCELEROMETER TORQUE TWO FEMUR LOAD CELL WITH SENSITIVE AXIS PARALLEL SIMULATOR MOUNTING BOLTS TO PENDULUM LONGITUDINAL 9000535 REF AND 9000133 REF camsusa P N 127 4010 REF TO 45 Nm 40 in lb FEMUR LOAD CELL SIMULATOR P N 127 4007 REF OR LOAD CELL 8A572 810 HORIZONTAL 41 RIGID MOUNTING PLATE PENDULUM HORIZONTAL 21 LOWER LEG ASS Y P N 127 4014 REF KNEE IMPACT PROBE INCL INSTRUMENTATION AND 1 3 OF SUPPORT CABLE WEIGHT 0 824 02 kg 1 80 04 Ib ADJUST KNEE JOINT TORQUE 241 FOOT ASS Y TO 1 2 g RANGE BEFORE P N 127 4030 1 REF EACH TEST Probe specifications 572 127 b 1 2 Rigid metallic construction concentric in shape and symmetric about is longitudinal axis A mass of 0 82 0 02 kg 1 8 0 05 Ibs 1 3 of the weight of the suspension cables and any attachments to the impact probe must be included in the calculation of mass and such components may not exceed 5 percent of the total weight of the test probe Minimum mass moment of inertia of 34 kg cm 0 03 Ibs in sec in yaw and pitch about the center of gravity The impacting end of the probe 1s perpendicular to and concentric with the longitudinal axis It must have a flat continuous and non deformable face with diameter of 76 2 0 2 mm 3 00 0 01 in and an edge radius of 7 6 12 7 mm 0 3 0 5 in The impactor 15 a cylinder with a diameter of 76 77 mm 3 0 3 1 in and i
143. STIFFENER AS NEEDED MOUNTING SURFACE PLATE STIFFENER AS NEEDED HANGER PLATE PART DLAB 100 105 MOUNTING SURFACE HYBRID 3 YEAR OLD T 2 7 HANGER PLATE 1 PART 4DLAB1G9 105 12 MONTH OLD UMS ARL ir mm NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION pue GANGER FIGURE 2D 05 These dummies shall be stored in a secured room 15 kept between 55 F and 85 F The contractor will check dummy components for damage after each NCAP test and complete a dummy damage checklist that will be included with the final test report The contractor will check dummy components for damage after each crash test and complete a dummy damage checklist as part of the NCAP procedure which will be included with the dummy calibration if requested The COTR will be kept informed of the dummies condition so that replacement parts can be provided The dummies will be calibrated by the contractor according to the schedule indicated in the NCAP test procedure CALIBRATION AND TEST INSTRUMENTATION Before the contractor initiates the dummy performance calibration test program a test instrumentation calibration system must be implemented and maintained in accordance with established calibration practices The calibration system shall be set up and maintained as follows A Standards for calibrating the measuring and test equipment shall be stored and used under appropriate environmental conditions to assure
144. SUBPART O EXTERNAL DIMENSIONS DIMENSION DESCRIPTION DETAILS DIMENSION ACTUAL en MEASUREMENT TOTAL SITTING HEIGHT Seat surface to highest point on top of the head 538 5 553 7 SHOULDER PIVOT HEIGHT Centerline of shoulder pivot bolt to the seat surface 307 4 322 6 H POINT LOCATION FROM SHOULDER PIVOT FROM Center of the shoulder pivot bolt to the fixture s rear vertical 60 9 71 1 BACKLINE surface THIGH CLEARANCE Fixture s seat surface to hightest point on the upper leg segment 81 0 91 2 BACK OF ELBOW TO WRIST Back of the elbow flesh to the finger tip in line with the elbow 247 4 262 6 PIVOT and wrist centerlines Measure from the highest point on top of the shoulder to the DEE lowest part of the flesh on the elbow in line with the shoulder 185 4 200 6 LENGTH and elbow pivot bolts ELBOW REST HEIGHT from the flesh below the elbow pivot bolt to the seat 133 6 148 8 BUTTOCK TO KNEE The forward most part of the knee flesh to the fixture s rear 284 8 300 LENGTH vertical surface in line with the knee and hip pivots POPLITEAL HEIGHT Seat surface to the horizontal plane of the bottom of the feet 218 5 233 7 KNEE PIVOT HEIGHT Centerline of knee pivot bolt to the horizontal plane of the 241 6 256 8 bottom of the feet BUTTOCK POPLITEAL The most forward portion of the crevice between the upper and LENGTH lower legs behind knee to the fixture s rear verical surface H HEAD BACK TO BACKLINE Rearmost s
145. Steering Power Power Window Auto Reverse Power Window Auto Reverse Reverse Driver Frontal Pee Driver Curtain Bens UM Driver Driver Torso Driver Torso Airbag Driver Torso Pelvis Airbag poner eeu Driver Pelvis DEED MERE Driver Knee Driver Knee Airbag Front Pass Front Pass Frontal Airbag front Fass Front Pass Curtain Hemp be Front Pass Head Torso Front Pass Head Torso Airbag Front Pass Torso from Pass Torso Front Pass Torso Pelvis Ampas m Front Pass Pelvis Front Pass Pelvis Airbags Front Pass Knee ront Pas E Pretensioner DriverLoadLimiter Limiter E Pass Pretensioner e Pass Front Pass Load Limiter Limiter 5 5 5 25020 DATA FROM CERTIFICATION LABEL Type of Seats GVWR kg GAWR Front kg GAWR Rear kg Number of Occupants Capacity Wt VCW kg Cargo Wt RCLW kg N25 DATA SHEET NO 1 CONTINUED GENERAL TEST AND VEHICLE PARAMETER DATA Test Vehicle NHTSA No Test Program Test Date Collect items circled in red tire manufacturer and tire name readwear traction and temperature grades Tire ply compoeition and materials used Max cold inflation amp load limit U S DOT safety standard code EN Width of tire mim amea 25 4 Ratio of height f in inches width aspect ratio R
146. THE HONEYCOMB w MATFRIAL WITH THE PENDULUM TO ASSURE THAT 90 TO 100 OF THE HONEYCOMB SURFACE 15 CONTACTING THE PENDULUM STRIKER PLATE 4 ft 38 1 mm REF 1 5 in MOUNTING PLATE PENDULUM STRIKER PLATE SHARP EDGES 76 2 x 152 4 x 9 5 mm 3 x 6 x 3 8 in FIGURE amp A A33 FLEXION TEST SET UP SPECIFICATIONS PENDULUM CENERLINE BRACKET ASS Y NECK ADJUSTING UPPER P N 78051 307 13 5 0 5 0 53 INCHES 0 02 BIB SIMULATOR P N 78051 84 CENTERLINE MOUNTING SCREW NECK ASS Y REF DWG 78051 104 P N 78051 90 BRACKET NECK ADJUSTING LOWER P N 78051 303 OCCIPITAL CONDYLES PLANE SQ REF DWG 78051 77X HEAD ASS Y TO PENDULUM CENTERLINE 1 NOTE PENDULUM SHOWN AT TIME ZERO POSITION FIGURE 9A A34 EXTENSION TEST SET UP SPECIFICATIONS PENDULUM CENERLINE I BRACKET ASS Y NECK ADJUSTING UPPER PIN 78051 307 37 3 0 5 1 47 0 02 CENTERLINE MOUNTING SCREW REF DWG 78051 104 BRACKET NECK ADJUSTING LOWER P N 78051 303 BIB SIMULATOR P N 78051 84 NECK ASS Y P N 78051 90 OCCIPITAL CONDYLES PLANE REF DWG 78051 77X HEAD ASS Y PERPENDICULAR P N 78051 61X TO PENDULUM CENTERLINE 1 NOTE PENDULUM SHOWN AT TIME ZERO POSITION FIGURE 10A ROTATION TRANSDUCER ASSEMBLY A36 DATA SHEET A6 THORAX IMPACT TEST 572 34 50 Male Dummy Serial Number Test Date Technician
147. U S DEPARTMENT OF TRANSPORTATION NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION LABORATORY TEST PROCEDURE FOR NEW CAR ASSESSMENT PROGRAM FRONTAL IMPACT TESTING August 2013 OFFICE VEHICLE SAFETY OFFICE OF CRASHWORTHINESS STANDARDS 1200 NEW JERSEY AVE SE ROOM W43 410 WASHINGTON DC 20590 This publication 15 distributed U S Department of Transportation National Highway Traffic Safety Administration in the Interest of information exchange The opinions findings and conclusions expressed in this publication are those of the author s and not necessarily those of the Department of Transportation or the National Highway Traffic Safety Administration The United States Government assumes no liability for its contents or use thereof If trade or manufacturers name or products are mentioned it is because they are considered essential to the object of the publication and should not be construed as an endorsement The United States Government does not endorse products or manufacturers NCAP LABORATORY TEST PROCEDURE TABLE OF CONTENTS 1l PURPOSEAND APPLICATION 1 2 GENERALE REQUIREMENTS 1 3 SECURITAS 2 3 1 RULES F R CONTRACT RS passed iss 2 4 GOOD HOUSEKEEPING
148. UMMY INSTRUMENTATION HEAD ACCELEROMETERS NECK ROTATION TRANSDUCER 1 OPTIONAL NECK ROTATION TRANSDUCER 2 OPTIONAL LABORATORY TECHNICIAN APPENDIX PART 5720 58 PERCENTILE FEMALE DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE APPENDIX PART 572 SUBPART O DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE PURPOSE AND APPEICATION uuu 1 2 GENERAL REQUIREMENTS use ee 1 Bo SECURE Shuyana m buna ae 1 4 GOOD HOUSBREBEPING Lada oben 2 5 TEST SCHEDULING AND MONITORING crt ttti 2 6 TEST DATA DISPOSITION a ite ten ben 2 7 GOVERNMENT FURNISHED PROPERTY GFP e ent 3 8 CALIBRATION AND TEST 24444 441 46 ntt 3 9 PHOTOGRAPHIC DOCUMENTATION rreren 4 uui Sere c oM OA uU pipuy p yki E 4 11 PRETESTREGUREMENTS Leones ete erue 5 lti TRANSDUCER REQUIREMENTS UU samt oce Ud RA UA 5 11 2 OTHER TRANSDUCER CONDITIONS a erect pectet ttd da 6 13 THORAX IMPACTOR PROBE 572 137 6 11 4 KNEE IMPACTOR PROBE 572 137 b entrent 7 11 5 GENERAL TEST CONDITIONS apps 10 CALIBRATION TEST EXECUTION aA d EAR 10 13 POSTTEST REQUIREMENTS 10 4 ARP ORGS sc SLM
149. URE AND TORSO ASSEMBLY CENTERLINE OF FIXTURE AND MIDSAGITTAL PLANE OF CENTERLINE OF PELVIS LEVER ARM TO MIDSAGITTAL PLANE er oL jo Ed LEVER ARM UPPER PELVIS RIGID SUPPORT ins Lj NS NS E Ca 4 4 3 lq 7 24 CENTERLINE OF CENTERLINE OF H POINT FRONT VIEW UPPER FEMURS FIGURE 18A 51 HIP JOINT TEST FIXTURE AND TORSO ASSEMBLY A F e UPPER TORSO OPTIONAL UPPER TORSO STRAP OPTIONAL 30 UPPER PELVIS SUPPORT FLEXION SOCKET HEAD SHOULDER SCREW UPPER LEG STRUCTURAL ASSY 7 EE Bits LE HE Al TT lt 4 SK oa LEVER ARM Y F UPPER FEMUR CENTERLINE OF e a 5 1 PELVIC ASSY lt 30 CENTER OF HIP ROTATION H POINT EXTENSION MEASURE ROTATION OF MOMENT ARM SIDE VIEW ABOUT THIS POINT FIGURE 19A 52 DATA SHEET A10 PART 572 INSTRUMENTATION CALIBRATION INFORMATION DATE OF LAST DATE OF NEXT MANUFACTURER MODEL NO SERIAL NO CALIBRATION CALIBRATION D
150. WARD CHEST REARWARD FZ RIGHT ARM SHOULDER DOWNWARD CHEST UPWARD LUMBAR SPINE FX FY FZ MX MOMENT MY MOMENT MZ MOMENT PUBIC FX SHEAR PUBIC REARWARD CHEST FORWARD FZ AXIAL PUBIC UPWARD CHEST DOWNWARD CHEST REARWARD PELVIS FORWARD CHEST LEFTWARD PELVIS RIGHTWARD CHEST UPWARD PELVIS DOWNWARD LEFT SHOULDER TOWARD LEFT HIP STERNUM TOWARD FRONT OF LEGS RIGHT SHOULDER FORWARD LEFT SHOULDER REARWARD NOTE DIRECTIONS ARE DEFINED IN RELATION TO A SEATED DUMMY 1 4 12 13 14 14 1 Ell GENERAL TEST CONDITIONS A Surfaces of dummy components are not painted unless otherwise specified 572 155 n B Dummy performance tests of the same component segment assembly or fully assembled dummy are separated in time by a period of not less than 30 minutes unless otherwise specified 572 155 m dummy head performance 1 515 conducted at temperature from 18 9 C 66 to 25 6 C 78 F and at any relative humidity from 10 to 70 after exposure of the dummy to these conditions for a period of not less than 4 hours For the neck headform assembly and thorax assembly the temperature range Is 20 6 C 69 F to 22 2 C 72 F and at any relative humidity from 10 to 70 after exposure of the dummy to these conditions for a of not less than 4 hours D Dummy limb joints are set at 1 G barely restraining the weight of the limb when it is extended horizontally The forc
151. a minimum the following information for all measurement and test equipment 1 Type of equipment manufacturer model number etc 10 4 2 Measurement range 3 Accuracy 4 Calibration interval 5 Type of standard used to calibrate the equipment calibration traceability of the standard must be evident 6 The actual procedures and forms used to perform calibrations E The contractor shall keep records of calibrations for all test instrumentation in a manner that assures the maintenance of established calibration schedules such records shall be readily available for inspection when requested by the COTR The calibration system will need the written acceptance of the COTR before testing begins Test equipment shall receive calibration check immediately prior to and after each test This check shall be recorded by the test technician s and submitted with the final report G Anthropomorphic test devices shall be calibrated as indicated in NCAP test procedure These calibrations shall be submitted with the final report PHOTOGRAPHIC DOCUMENTATION Provide still photographs color prints properly focused for clear images no more than two 2 per 8 5 x11 sheet of post test damage resulting from the vehicle crash test DEFINITIONS PADI Procedures for Assembly Disassembly and Inspection 1 5 PRETEST REQUIREMENTS TRANSDUCER REQUIREMENTS The contractor shall provide and install the following
152. adial Measured Parameter Maximum Tire Pressure kPa Cold Pressure kPa Recommended Tire Size Tire Size on Vehicle Tire Manufacturer Tire Model Treadwear Traction Temperature Grades Tire Plies Sidewall Tire Plies Body Load Index Speed Symbol Tire Material DOT Safety Code Left DOT Safety Code Right N26 DATA SHEET NO 1 CONTINUED GENERAL TEST AND VEHICLE PARAMETER DATA Test Vehicle NHTSA No Test Program Test Date TEST VEHICLE WEIGHTS As Delivered UVW Axle As Tested ATW Axle Units Front Rear Total Front Rear Total Left Right Ratio Totals TARGET TEST WEIGHT CALCULATION Measured Parameter Units Total Delivered Weight UVW kg Weight of 1 P572E ATD amp 1 P5720 ATD kg Rated Cargo Luggage Weight RCLW kg Calculated Vehicle Target Weight TVTW kg TEST VEHICLE ATTITUDES AND CG CG aft of Units front axle As Delivered As Tested mm Post Test mm Measurement Description Total Vehicle Wheel Base Total Vehicle Length at Left Side Total Vehicle Length at Centerline Total Vehicle Length at Right Side Weight of Ballast in Cargo Area Weight of Vehicle Components Removed Amount of Stoddard Solvent in Fuel Tank LIST OF COMPONENTS REMOVED TO MEET TEST WEIGHT N27 DATA SHEET NO 1 CONTINUED GENERAL TEST AND VEHI
153. all tests except side MDB and pole tests with manual transmissions which are placed in 24 gear N64 YES If YES please describe each affecting system s operation below and be prepared to disable the specific CA system on test day If a representative will not be present you must provide the laboratory with detailed instructions on how to deactivate the system prior to test day N65 DESCRIPTIONS OF DUMMY MEASUREMENTS When level is to be used it is to ensure that the line containing the two paints described is either parallel or perpendicular to the ground measurement to be made is less than 10 inches ignore the directions to use a level and approximate a level measurement Also when a measurement is to be taken to or from the center of a bolt on the dummy take the measurement from the center of the bolt hole if the balt is recessed The following measurements are to be made within a vertical longitudinal plane HH Head to Header taken from the point where the dummy s nose meets his forehead between his eyes to the furthest point forward the header CS Steering Wheel to Chest taken from the center of the steering wheel hub to the dummy s chest Use a level NR Nose to Rim taken from the tip of the dummy s nose to the closest point on the top of the steering wheel rim Also indicate the angle this line makes with respect to the horizontal NA KDL KDR Left and Right Kne
154. amera 15 Pit Camera Fuel Tank View 16 amp 17 Frontal Airbag Deployments Optional N34 DATA SHEET NO 6 CONTINUED HIGH SPEED CAMERA LOCATIONS AND DATA Test Vehicle NHTSA No Test Program Test Date CAMERA LOCATIONS fps Real Time Left Overall Driver Close Up Left Front Half Left Angle Steering Column Top Steering Column Bottom Right Overall Passenger Close Up Right Angle Right Front Half Windshield Driver Windshield Passenger Windshield Pit Front Pit Rear Onboard Driver Airbag Optional Onboard Passenger Airbag Optional 1 2 3 4 5 6 7 8 COORDINATES X forward of Impact plane Y right of monorail center Z Into ground N35 DATA SHEET NO 7 VEHICLE ACCELEROMETER DATA Test Vehicle NHTSA No Test Program Test Date Accelerometer Location Left Rear Accelerometer x Direction Right Rear Accelerometer x Direction Engine Top x Engine Bottom x Left Rear Accelerometer z Direction Right Rear Accelerometer z Direction Left Rear Accelerometer x Direction Redundant Right Rear Accelerometer x Direction Redundant Reference Points x Rear Surface of Vehicle forward Vehicle Centerline to right z Ground Plane down N36 DATA SHEET 8 PHOTOGRAPHIC REFERENCE TARGET LOCATIONS T
155. amera should be included as part of the documentation movie Y TRANSMISSION ENGAGEMENT l Manual Transmission Place manual transmissions in neutral 2 Automatic Transmission Place automatic transmissions in neutral Z PARKING BRAKE DISENGAGEMENT Disengage the parking brake AA IGNITION SWITCH The key shall be in the ignition and switched to the ON position Check to ensure that the Airbag Readiness Indicator shows the airbag system as being functional BB LAP AND SHOULDER BELT LOAD CELLS l Load cells if allowed by the vehicle manufacturer per the provided Form 1 shall be mounted on the front outboard lap and shoulder belts 4 load cell units required Attachment of load cells shall not affect seat belt positioning or function in any way Lap Belt Units The lap belt load cells shall be positioned on the belt webbing so as to avoid contact with any objects other than the lap belt to which they are attached These may also be omitted as per the instructions provided on Form 1 via the COTR Shoulder Belt Units The shoulder belt load cells shall be mounted immediately behind the dummy s outboard shoulder according to the distance provided by the COTR the vehicle s setup information Form1 such that during the frontal crash test they do not come in contact with anything other than the belt to which they are attached These may also be omitted as per the instructions provided on Form 1 via the COTR Each
156. angle determined in 1 8 S16 2 10 3 3 520 1 9 4 S22 1 2 822 1 7 4 S22 3 1 S24 1 2 524 3 1 1 18 Is seat a bucket seat _ Yes go to 1 19 and skip 1 20 No go to 1 20 and skip 1 19 1 19 Bucket seats Locate and mark for future reference the longitudinal centerline of the seat cushion The intersection of the vertical longitudinal plane that passes through the SgRP and the seat cushion upper surface determines the longitudinal centerline of a bucket seat cushion 516 3 1 10 amp S20 1 10 20 Bench seats Locate and mark the longitudinal centerline of the passenger seat cushion The longitudinal centerline is the same distance from the longitudinal centerline of the vehicle as the center of the steering wheel S20 2 1 4 522 2 1 3 24 2 3 S20 4 4 522 2 2 1 5 S22 2 2 3 b 522 2 2 4 522 2 2 5 522 2 2 6 522 2 2 7 524 2 Record distance from longitudinal centerline of the vehicle to center of the steering wheel Record the distance from the longitudinal centerline of the vehicle to the longitudinal centerline of the seat cushion F8 2 Head Restraint Position N A Vehicle contains automatic head restraints N A there is no head restraint adjustment Go to 3 2 1 Adjust the head restraint to its lowest position 516 2 10 2 S20 1 9 6 20 4 1 S22 1 7 6 522 4 2 1 822 4 3 1 824 4 3 1 26 2 3 S26 3 1 2 2 adjustments of the head restraint shall be used to position
157. any repairs or replacements are made No damage Damage from crash test no repairs or replacement because this is a post test calibration verification Record damage The following repairs or replacement was performed Record 6 Seat the dummy chest skin still removed without back and arm supports on the test fixture surface as shown in Figure 12A The surface must be long enough to support the pelvis and outstretched legs 572 34 c 2 7 Level the ribs both longitudinally and laterally 0 5 and adjust the pelvis angle to 13 2 The angle may be measured using the special H point tool 78051 532 that inserts ee 210 12 13 14 215 7 into pelvic structure extends outward beyond pelvic skin surface using the surface of the pelvic adaptor block 572 34 c 2 The midsagittal plane of the dummy 15 vertical within 1 572 134 c 3 The longitudinal centerline of the test probe is centered within 2 5 mm of the midsagittal plane of the dummy and 15 12 7 mm Imm below the horizontal peripheral centerline of the No 3 rib and is within 0 5 of a horizontal line in the dummy s midsagittal plane 572 34 c 4 Align the adjustable neck bracket index marks to the zero position Figure 12A Record locations such as the rear surfaces of the thoracic spine and the lower neck bracket reference with respect to locations such as the rear surfaces of the
158. ap with respect to the outside surface of the pelvis flesh 572 135 c 5 Flex the dummy forward and back 3 times such that the angle reference plane moves between 0 and 30 with respect to the vertical transverse plane 572 135 c 6 Support the dummy such that the angle reference plane is at or near 0 vertical with respect to the vertical transverse plane Wait at least 30 minutes before continuing 572 135 c 6 Remove all external support that was implemented in 9 above 572 135 c 7 Measure the initial orientation angle of the torso reference plane of the seated unsupported dummy 572 135 c 7 Record reference plane angle max allowed 20 Attach the pull cable and the load cell 572 135 c 8 13 14 15 16 B39 Apply a tension force in midsagittal plane to the pull cable at any upper torso deflection rate between 0 5 and 1 5 per second until the angle reference plane is at 45 0 5 of flexion relative to the vertical transverse plane 572 135 c 9 Maintain angle reference plane at 45 0 5 of flexion for 10 seconds 572 135 c 10 As quickly as possible release the force applied to the attachment bracket 572 135 c 11 3 minutes after the release of the force measure the reference plane angle 572 135 c 11 Complete the following table Torso Flexion Results 572 135 b 572 135 c 7 572 135 9 Parameter Specification Result Initial ref
159. are of technical interest should also be included The contractor should include as much detail as possible in the report Instructions for the preparation of the first three pages of the final test report are provided below for standardization purposes FIRST THREE PAGES l Front Cover The information required on the cover is as follows a Final Report Number such as NCAP ABC XX 001 where NCAP is the test ABC are the initials for the laboratory XX are the last two digits of the fiscal year of the test program 001 is the test number for that fiscal year 001 for the Ist test conducted in the fiscal year 002 for the 2nd test 003for the 3rd test etc b Final Report Title and Subtitle such as NEW CAR ASSESSMENT PROGRAM NCAP Frontal Barrier Impact Test World Motors Corporation 200X XYZ 4 door sedan NHTSA No CX0401 Contractor s Name and Address such as XYZ TESTING LABORATORIES INC 4335 West Dearborn Street Detroit Michigan 48090 N6 NOTE DOT SYMBOL WILL BE PLACED BETWEEN ITEMS C AND D d Date of Final Report completion e The words FINAL REPORT f The sponsoring agency s name and address as follows U S DEPARTMENT OF TRANSPORTATION National Highway Traffic Safety Administration Office of Crashworthiness Standards 1200 New Jersey Ave SE Room W43 410 Washington DC 20590 2 First Page After Front Cover A disclaimer statement and an acceptance signature block for the
160. asher 210 2050 neck mounting plate TE 250 021 two jam nuts 9001336 load moment transducer SA572 19 and headform TE 208 000 572 143 a __3 The assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to a test 572 143 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity __4 Visually inspect neck assembly for cracks cuts and separation of the rubber from metal segments Note If the damage resulted from the vehicle crash test the damaged area is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions 6 Torque the jam nut 9001336 on the neck cable 210 2040 between 0 2 Nm and 0 3 Nm 572 143 c 2 7 data acquisition system including transducers conforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 146 1 8 The test fixture pendulum conforms to the specifications in Figure 8D 9 head neck assembly is mounted on the pendulum so the midsagittal plane of the headform is vertical and coincides with the plane of motion of the pendulum as shown in Figure 10D for the extension test 572 143 c 3 10 Install the transducers or other devices for measuring the D plane rotation with respect
161. assembled dummy are separated in time by a period of not less than 30 minutes unless otherwise specified 572 137 q C Except for neck assembly and thorax assembly testing the dummy performance tests are conducted at any temperature from 18 9 C 66 F to 25 6 C 78 F and at any relative humidity from 10 to 70 after exposure of the dummy to these conditions for a period of not less than 4 hours For the neck assembly and thorax assembly the temperature range is 20 6 C 69 F to 22 2 C 72 F D Dummy limb joints are set at 1G barely restraining the weight of the limb when it is extended horizontally The force required to move a limb segment does not exceed 2 Gs throughout the range of limb motion 572 137 Also see Appendix B of the PADI for guidelines for setting the joints to 1G E Dummies will be clothed for the thorax calibration tests with a form fitting cotton stretch above the elbow sleeved shirt and above the knee pants The weight of the shirt and pants shall not exceed 0 14 kg 0 30 1b each 572 134 1 CALIBRATION TEST EXECUTION Complete the Data Sheets in section 15 POST TEST REQUIREMENTS The contractor shall verify all instrumentation and check data sheets and photographs Make sure data is recorded in all data blocks on every performance calibration test data sheet REPORTS APPARENT NONCONFORMANCE During calibration verification any indication of apparent nonconformance to the requirements of R
162. ate insert 910420 048 and the nylon shoulder bushing 9001373 and replace if they are torn or worn When replacement is necessary ONLY replace during pre test calibration Record findings and actions Torque the jam nut 9000341 on the neck cable 127 1016 to 0 23 0 02 Nm 2 0 0 2 in Ib 572 123 c 2 25 7 The data acquisition system including transducers conforms to requirements of SAE Recommended Practice J211 1 MAR95 572 127 k 8 test fixture pendulum conforms to the specifications in Figure 6C 572 123 c 3 9 The head neck assembly is mounted on the pendulum so the midsagittal plane of the head is vertical and coincides with the plane of motion of the pendulum longitudinal centerline as shown in Figure 7C for the flexion test 572 123 c 3 10 With the pendulum resting against the honeycomb material the neck bracket was adjusted until the longitudinal centerline of the pendulum was perpendicular 1 degree to plane D on the dummy s head 11 Release the pendulum and allow it to fall freely from a height to achieve an impact speed of 4 83 m s to 5 07 m s as measured at the center of the pendulum accelerometer 572 123 c 4 1 12 Complete the following table Neck Flexion Test Results 572 123 b 1 amp 572 123 c 4 1 amp ii Parameter Specification Result Pendulum impact speed 4 83 m s speed lt 5 07 m s Pendulum 10ms 1 2 m s AV lt 1 6 m s
163. ated above is greater than 136 kg use 136 kg as the RCLW 5 Calculate the Test Vehicle Target Weight by adding the As Delivered weight the RCLW and the total actual weight of the dummies Record on the applicable data sheet FULLY LOADED VEHICLE WEIGHT CONDITION 1 With the vehicle in the As Delivered UVW condition load the vehicle with the RCLW placed in the luggage or load carrying cargo area Center the load over the longitudinal centerline of the vehicle 2 Place the weight of the dummies in the appropriate front outboard seating positions 3 Record the vehicle weight at each wheel to determine the Fully Loaded weight VEHICLE ATTITUDE MEASUREMENTS FULLY LOADED WEIGHT CONDITION 1 With the vehicle in the Fully Loaded weight condition place it on a flat level 2 NCAP 29 surface Measure the perpendicular distance from the level surface to the four 4 points previously marked on the vehicle and record each L AS TESTED VEHICLE WEIGHT CONDITION 1 With the test vehicle Fully Loaded test weight condition drain fuel system and operate the engine until the fuel system is dry NOTE The removal process must prevent solvent contact with substances which may be soluble in the Stoddard solvent i e undercoating paints used for identifying under vehicle components etc Slowly refill the entire fuel system with Stoddard solvent which has been dyed purple having the physical and che
164. ation data shall be released to anyone except the COTR unless specifically authorized by the COTR or the COTR s Branch or Division Chief NOTE No Individuals other than contractor personnel directly involved in the dummy calibration test program shall be allowed to witness dummy calibration tests unless specifically authorized by the COTR GOOD HOUSEKEEPING Contractors shall maintain the entire dummy calibration laboratory test fixtures and instrumentation in a neat clean and painted condition with test instruments arranged in an orderly manner consistent with good test laboratory housekeeping practices TEST SCHEDULING AND MONITORING The Part 572 Subpart R dummies are being calibrated as test tools to be used in NCAP vehicle crash tests The schedule for these performance calibration tests must be correlated with that of the vehicle tests All testing shall be coordinated to allow monitoring by the COTR TEST DATA DISPOSITION The contractor shall make all dummy calibration data available to the COTR for review and analysis as required calibration test data for each particular Part 572 Subpart R dummy will be sent to the COTR with each test report backup data sheets strip charts recordings plots technicians notes etc shall be either sent to the COTR or destroyed at the conclusion of each delivery order purchase order etc GOVERNMENT FURNISHED PROPERTY GFP Part 572 Subpart R test dummies will be furni
165. ature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 1090 to 7096 for a period of at least four 4 hours prior to this test 572 145 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity __5 Unzip the torso jacket and remove the lumbar load transducer or its structural replacement from the dummy Attach the rigid pelvis attachment fixture to the lumbar spine 572 145 2 1 amp 11 5 Secure the fixture to the table so that pelvis lumbar joining surface is horizontal within 1 and the buttocks and upper legs of the seated dummy are in contact with test surface 572 145 c 2 11 6 Attach the loading adapter bracket to the upper part of the torso as shown in Figure 13D and zip up the torso jacket 572 145 c 2 iv 7 Place the upper arms parallel to the torso and the lower arms extended horizontally and forward parallel to the midsagittal plane 572 145 c 2 v 8 Flex the dummy forward and back 3 times such that the angle of the torso reference plane moves between 0 and 30 2 The torso reference plane is defined by the transverse plane tangent to the posterior surface of the upper backplate of the spine box weldment 210 8020 572 145 c 3 1 9 Remove all externally applied flexion forces and support the dummy such that the torso reference plane is at or near 0 Wait at least 30 minutes before conti
166. be stored and used under appropriate environmental conditions to assure their accuracy and stability B All measuring instruments and standards shall be calibrated by the Contractor or a commercial facility against a higher order standard at periodic intervals not exceeding 12 months for instruments and 12 months for the calibration standards Records showing the calibration traceability to the National Institute of Standards and Technology NIST shall be maintained for all measuring and test equipment 1 Accelerometers shall be calibrated at a minimum of every six 6 months or after a vehicle fails to meet any minimum performance requirements or after any indication from calibration checks or recent test data that there may be a problem with the accelerometer whichever comes sooner 2 Load cells shall be calibrated at a minimum of every twelve 12 months or after a vehicle fails to meet any minimum performance requirements or after any indication from calibration checks or recent test data that there may be a problem with the load cell whichever comes sooner 3 Potentiometers shall be calibrated at a minimum of every six 6 months or after a vehicle fails to meet any minimum performance requirements or after any indication from calibration checks or recent test data that there may be a problem with the potentiometer whichever comes sooner C measuring and test equipment and measuring standards will be labeled with the follo
167. bel photograph of certification label ensure that all text can be seen clearly without glare or blurring No 004 Tire Placard photograph of tire placard ensure that all text can be seen clearly without glare or blurring include photograph of the reduced load carrying capacity as No 004a if applicable No 005 lt Year gt lt Make gt lt Model gt Frontal As Delivered No 006 Left Rear 3 4 View as Received No 007 Pre test Front View of Test Vehicle No 008 Post test Front View of Test Vehicle No 009 Pre test Left View of Test Vehicle taken with vehicle at barrier No 010 Post test Left View of Test Vehicle taken without moving vehicle post test No 011 Pre test Right View of Test Vehicle No 012 Post test Right View of Test Vehicle No 013 Pre test Right Front 3 4 View No 014 Post test Right Front 3 4 View No 015 Pre test Left Rear 3 4 View taken with vehicle at barrier 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 N15 Post test Left Rear 3 4 View taken without moving vehicle post test Pre test Windshield View looking through windshield at dummies Post test Windshield View looking through windshield at dummies Pre test Engine Compartment View Post test Engine Compartment View Pre test Fuel Filler Cap View Post test Fuel Filler Cap View Pre test Front Underb
168. bles and must conform to the most recent requirements of SAE Recommended Practice J211 1 NOTE In the event of a failure to meet these minimum performance requirements additional calibration checks of some critically sensitive test equipment and instrumentation may be required for verification of accuracy The necessity for the calibration will be at the COTR s discretion and will be performed without additional cost An instrument calibration system capable of performing individual tests on all data NCAP 12 channels used in acquiring the acceleration and force data shall conform to appropriate section of the most recent version of SAE J211 1 K A full face GFE load cell barrier will be mounted onto the face of the Contractor s fixed barrier assembly questions regarding the load cell barrier assembly maintenance and calibration shall be directed to Safety Performance Standards Office of Crashworthiness Standards NVS 110 1200 New Jersey Avenue SE Washington D C 20590 202 366 1740 Load cells shall be calibrated on an needed basis and a minimum of one 1 time per year Accelerometers shall be calibrated on an as needed basis and a minimum of once every six 6 months Need shall be established by pre and post test shunt calibration If bridge balance remains unchanged pre and post test and if full scale shunt calibration results in the same factor then the transducer characteristics are within
169. blished versions of all FMVSS test procedures may be found at J3 http www nhtsa gov Vehicle Safety Test Procedures In Protected Below Protected Zone Zone Vehicle Component Penetration Maximum of 0 25 Must not penetrate inner inch into template surface of windshield The word partial is used since 219 Styrofoam windshield protected zone template has been eliminated for all NCAP 56 3kph 35mph frontal impact tests in order that the forward motion of the driver and passenger dummies can be filmed through the vehicle s windshield However the lower boundary of the protected zone shall be marked on the windshield glass which accounts for a partial standard test When passenger car multipurpose passenger vehicle MPV light truck or bus GVWR of 10 000 pounds or less traveling longitudinally forward at 35 mph 0 5 mph impacts a fixed collision barrier that is perpendicular to the line of travel of the vehicle PERPENDICULAR FRONTAL IMPACT TEST no part of the vehicle outside the occupant compartment except windshield molding and other components designed to be normally in contact with the windshield shall penetrate the protected zone to a depth of more than 0 25 inch No such part of the vehicle shall penetrate the inner surface of that portion of the windshield within the Daylight Opening DLO below the protected zone The protected zone must be checked directly after frontal barrier impact
170. bration verification l 2 Remove the dummy s chest jacket and the abdominal insert Seat the dummy on a flat rigid smooth clean dry horizontal surface as shown in Figure 3B and 4B The seating surface is at least 406 mm 16 in wide and 406 mm 16 in in depth with a vertical section at least 406 mm 16 in wide and 914 mm 36 in high attached to the rear of the seating fixture The dummy s midsagittal plane is vertical and centered on the test surface Remove the four 4 20 x 5 8 SHCS that attach the lumbar spine to the thoracic spine Lift the upper torso off of the lower torso Check the torque on the 2 20 jam nut that attaches to the end of the lumbar spine cable The torque should be 1 13 1 35 NM 10 12 in Ibs NOTE At this point the thorax is to be inspected for damage The thorax displacement transducer may be removed for calibration if required pretest calibration only Extreme caution must be used so as not to damage the instrumentation cables Reassemble the upper torso to the lower torso Secure the dummy to the test fixture so that the button head screws that attach the top rib to the spine box and the adapter plate that connects the upper torso to the lower torso are against the vertical surface of the fixture The rear surface of the buttocks now contacts the fixture Position the dummy s H point so it is 83 8 2 5 mm 3 3 0 1 in above the horizontal seating surface and 147 3 2 5 mm 5 8 0 1 in
171. by 5 equal lengths 2 Post test repeat the measurements taken in step 1 and record 3 Compute the difference between the measurements taken in steps 1 and 2 Record on the applicable data sheet NOTE When computing the Collision Deformation Classification Flat frontal 12FDEWX where the value for X is calculated by taking the longitudinal distance from the tip of the front of bumper to base of the windshield and dividing it into 5 equal zones with Zone beginning at the bumper Whatever zone the maximum longitudinal crush reaches into is the number that is reported for X Typically it will be zone 2 3 or 4 in a frontal NCAP test NCAP 49 Figure 10 Vehicle Crush Profile Measurements D FMVSS 301 305 STATIC ROLLOVER TESTING 11 5 Record details from the 301 static fuel system integrity test on Data Sheets 15 and 16 in Appendix N Electric vehicles evaluated under FMVSS 305 require the Contractor to submit a test report under the separate Laboratory Test Procedure for the New Car Assessment Program Indicant Test for FMVSS No 305 ELECTRONIC DATA RECORDER EDR REMOVAL Immediately following the test the Contractor shall also remove the Event Data Recorder EDR for the vehicle using the information supplied on Form 1 by the vehicle manufacturer The EDR shall be handled with care and labeled It shall also be protected from the elements and retained by the test C
172. calibration If loads become suspect linearity of the load cell shall be checked with a universal compression testing machine If the load cell is non linear or if pre and post test calibration results in a drift the load cell shall be returned to the manufacturer for check out and calibration Notify the COTR whenever calibration problems arise NOTE Load cells are prone to corrosion when exposed to damp environments Therefore extra precautions shall be taken to prevent moisture entering the cells CAUTION Weep holes are provided for equalization of barometric pressure and must be directed downward If cells are found with the hole pointing upward the cell must be removed and calibrated by compression testing If they are found to be non linear they must be returned to the manufacturer The load cell barrier shall be covered between tests When the load cell barrier will not be used for a period of time it shall be removed from the barrier area and placed in a dry storage area The plywood blocks shall be intact and completely bonded to the backup support If these blocks receive significant damage during crash testing they shall be replaced or repaired such that a full surface is present M Normal practice shall be employed with recorders and equipment calibrations for load cells When load cells are calibrated a system calibration procedure shall be employed where the load cell is calibrated in the system used for amplifying recor
173. cation Test attempt no when successive flexion tests are necessary 1 2 It has been at least 30 minutes since the last neck test 572 127 o __ N A ONLY one neck test performed The components required for the neck tests include the head assembly 127 1000 neck 127 1015 pivot pin 78051 339 bib simulator TE127 1025 neck bracket assembly 127 8221 six axis neck transducer SA572 S11 neck mounting adaptor TE 2208 001 and three accelerometers 5 572 54 installed in the head assembly as specified im S572 122 Data from the accelerometers are not required 572 123 b The assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to a test 572 123 1 Record maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Visually inspect neck assembly for cracks cuts and separation of the rubber from the metal segments Note If the damage resulted from the vehicle crash test in which the dummy was an occupant the damaged area is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions Inspect the nodding blocks 127 1020 127 1021 for splits or deformation Inspect the Neck Cable 127 1016 for deformation Inspect the mounting pl
174. ccuracy 4 Calibration interval 5 Type of standard used to calibrate the equipment calibration traceability of the standard must be evident 6 The actual procedures and forms used to perform calibrations The contractor shall keep records of calibrations for all test instrumentation in a manner that assures the maintenance of established calibration schedules such records shall be readily available for inspection when requested by the COTR The calibration system will need the written acceptance of the COTR before testing begins F Test equipment shall receive a calibration check immediately prior to and after each test This check shall be recorded by the test technician s and submitted with the final report G Anthropomorphic test devices shall be calibrated before and after each test These calibrations shall be submitted with the final report PHOTOGRAPHIC DOCUMENTATION Provide still photographs color prints properly focused for clear images no more than two 2 per 8 5 x11 sheet of post test damage resulting from the vehicle crash test DEFINITIONS NONE 1 PRETEST REQUIREMENTS TRANSDUCER REQUIREMENTS The contractor shall provide and install the following instrumentation to the GFP dummies excluding chest displacement transducer A HEAD The head accelerometers shall have dimensions response characteristics and sensitive mass locations specified in drawing 78051 136 revision
175. ce to the performance requirements of FMVSS 208 Each Part 572 Subpart R dummy used in an NCAP test must meet the specifications and performance criteria of Part 572 before and after each vehicle crash test in order to be an acceptable test tool The Part 572 Subpart R Hybrid III CRABI 12 Month Old Dummy consists of components and assemblies specified in the drawing and specifications package which is available from Reprographics Technologies 9000 Virginia Manor Beltsville MD 20705 telephone 301 419 5070 SECURITY NHTSA Part 572 Subpart R test dummies delivered to the contract laboratory as Government Furnished Property GFP will be stored in a safe and secure area such as a dummy calibration laboratory The contractor is financially responsible for any acts of theft and or vandalism that occur during the storage of GFP Any security problems shall be reported by telephone to the Industrial Property Manager IPM Office of Contracts and Procurement within two working days after the incident A letter containing specific details of the security problem will be sent to the IPM with copy to the COTR within 48 hours E2 The contractor 15 responsible for maintaining the NHTSA test dummies in good working order and shall protect and segregate the data that evolves from conducting Part 572 Subpart R dummy calibration tests before and after each vehicle test usage No Information concerning the Part 572 Subpart R dummy calibr
176. characteristics and sensitive axis locations specified in drawing SA572 S11 and shall be mounted in the head neck assembly as shown in drawing 880105 000 sheet 3 of 6 572 137 d CHEST The chest accelerometers shall have the dimensions response characteristics and sensitive mass locations specified in drawing SA572 S4 and be mounted in the torso assembly in traxial configuration within the spine box instrumentation cavity as shown drawing 880105 000 sheet 3 of 6 The chest accelerometers are not required for dummy calibration testing but are required for NCAP testing 572 137 e The chest deflection transducer shall have the dimensions and response characteristics specified in drawing SA572 S51 and be mounted to the upper torso assembly as shown in drawings 880105 300 and 880105 000 sheet 3 of 6 572 137 LEGS single axis femur force transducer shall have dimensions response characteristics and sensitive axis locations specified in drawing SA572 S14 and be mounted in assemblies 880105 560 1 and 880105 560 2 The femur transducers are not required for calibration of the dummy but are required for NCAP testing 572 137 1 TEST FIXTURE The neck pendulum thorax and knee probe accelerometers shall have the dimensions and characteristics of drawing SA572 S4 1 2 OTHER TRANSDUCER CONDITIONS 11 3 A TRANSDUCER MOUNTS The mountings for sensing devices shall have no resonance frequency less than 3 ti
177. ck will be performed The pre and post test zero and shunt calibration check will be recorded and the data submitted with the report as shown below CHANNEL PRE PRE POST POST Heay y 123abc ima 0 045 2 202 0 045 2 203 B As a secondary check it is suggested that just prior to vehicle testing ATD instrumentation vehicle accelerometers and onboard signal conditioning equipment be lightly tapped with a rubber mallet to ensure that sensors are recording especially with the correct polarity and that instrumentation connections are secure Prior to initiation of the testing program and periodically thereafter on board equipment should be drop tested and performance checked at G levels expected in the NCAP environment The equipment should be sufficiently shock hardened to function in the adverse environment In addition it is recommended that on a periodic basis the instrumentation be energized with the sensors removed from the system The system should then be subjected to a shock equivalent to that in the crash test event The output voltages should remain stable confirming system integrity The data recording equipment shall have a sufficient number of channels available for recording the necessary time histories of all instrumentation from each test dummy used D A precision time system compatible with the test equipment shall be used to provide a time reference for all recorded data A system that identifies the p
178. cord the maximum humidity Record the minimum humidity Visually inspect neck assembly for cracks cuts and separation of the rubber from the metal segments Note If the damage resulted from the vehicle crash test in which the dummy was an occupant the damaged area is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions Inspect the nodding blocks 78051 351 for any deterioration but when replacement is necessary ONLY replace during pre test calibration Using a Shore A type Durometer verify the hardness of the nodding blocks is between 80 and 90 Ensure the nodding blocks are installed correctly 880105 250 and PADI 17 Record findings and actions Pre test calibration Neck cable torque Torque the jam nut 78051 64 on the neck cable 78051 301 to 1 0 0 2 Ib ft by loosening the jam nut and relaxing the neck cable before torquing 572 33 c 2 The data acquisition system including transducers conforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 36 1 The test fixture pendulum conforms to the specifications in Figure 8A 572 33 c 3 A31 The head neck assembly is mounted on the pendulum so the midsagittal plane of the head is vertical and coincides with the plane of motion of the pendulum longitudinal centerline as shown in Figure 10A for the extension test 572
179. ctions 7 Clean the impact surface of the skin and the impact surface of the fixture with isopropyl alcohol trichloroethane or equivalent prior to the test 572 152 c 2 210 1 _12 187 14 215 21 Suspend and orient head assembly as shown in Figure 5E The lowest point on forehead is 376 0 1 0 mm 14 8 0 04 inch from the impact surface 572 152 c 3 1 Record the actual distance NOTE The masses of the suspension device and the accelerometer cables are to be kept as lightweight as possible to minimize their effect on the test results The 3 3 mm 0 13 inch diameter holes located on either side of the dummy s head are equidistant within 2 mm from the impact surface 572 152 c 3 1 Record the right side distance Record the left side distance The angle between the lower surface plane of the neck transducer mass simulator 910420 003 and the plane of the impact surface is 45 1 degrees 572 152 c 3 1 Record the angle The impact surface is clean and dry and has a micro finish in the range of 203 2 10 mm 8 micro inches to 2032 0 10 mm 80 micro inches RMS 572 152 c 4 Record actual micro finish The impact surface is a flat horizontal steel plate 50 8 mm 2 inches thick and 610 mm 24 inches square 572 152 c 4 Record thickness Record width Record length Drop the head assembly from a height of 376 0 1 0 mm 14 8 inches 0 04 inches by a means tha
180. d 1f approved by the COTR The vehicle interior may require auxiliary on board lighting to ensure adequate exposure Real Time Camera The Contractor shall use a real time color digital video camera that operates at 24 30 frames per second to document the views indicated below The video shall be transferred to the FTP site compact disc CD or DVD as AVI MPEG or WMV files with standard or generally available codec NCAP 14 14 Camera Engine Compartment View B Real Time Camera 15 Pit Camera Fuel Tank View 16 amp 17 Frontal Airbag Deployments Optional Figure 2 Camera Positions for Frontal Impacts Camera 1 Camera 2 Camera 3 Filename Camera No 1 REAL TIME LEFT OVERALL Real time 24 30 fps left side view camera to follow the test vehicle down the tow road across the photographic pit and into the barrier face Filename Camera No 2 DRIVER CLOSE UP High speed left side view camera to cover the vehicle s left side from the barrier face to a point rearward of the vehicle s front seat backs The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle Filename Camera No 3 LEFT FRONT HALF High speed left side view camera positioned adjacent to the vehicle s A post to document the driver dummy s head movement during the impact event in the windshield area and windshield zone intrusion area The centerline of the camera shall be perpendicular
181. d 610 mm 24 inches square 572 132 c 4 Record thickness Record width Record length Drop the head assembly from a height of 376 0 1 0 mm 14 8 inches 0 04 inches by a means that ensures a smooth instant release onto the impact surface 572 132 b amp 572 132 c 4 Complete the following table using channel class 1000 data 572 132 b Parameter Specification Result Peak resultant acceleration 250 lt lt 300 g Resultant versus time history Unimodal Oscillations after the main pulse Less than 10 of the peak resultant acceleration Lateral acceleration y axis acceleration lt 15 g Plots of the x y z and resultant acceleration data follow this sheet Signature Date 23 HEAD DROP TEST SETUP SPECIFICATIONS RIGID SUPPORTED FIXTURE QUICK RELEASE MECHANISM ADJUSTMENT TURNBUCKLE HEAD SUPPORT CABLES LIGHT WEIGHT ACCELEROMETER CABLES ROUTE THREADED CABLES SUCH THAT THEY DO NOT INSERT INFLUENCE HEAD MOTION DURING Plastic THE DROP Nylon etc NECK TRANSDUCER OR STRUCTURAL REPLACEMENT 0 5 y DROP HEAD M 8 0 r FLAT HORIZONTAL STEEL PLATE 14 8 2 x 24 x 24 WITH SURFACE FINISH WITHIN THE RANGE OF 8 TO 80 MICROINCHES IMPACT SURFACE TO BE CLEAN AND DRY mx NE CENTERLINE OF 0 062 DIAMETER HOLES IN SKULL DISTANCE A DISTANCE FIGURE 5B HEAD TEST
182. d along with the tape supports for the shoulder belt load cells Particular attention must be exercised to fully document the proper closing of all vehicle doors including any rear hatchback or tailgate 9 4 9 5 B NCAP 18 The removal installation and tightening of the vehicle s fuel filler cap and the cap s rotation to its locked position by Contractor s personnel will be documented This video footage shall appear in the final released movie print to show that filler cap was properly installed and tightened prior to the crash test The real time camera 24 30 fps shall be used to record any Stoddard solvent spillage from the test vehicle after the impact event or during the static rollover test IMPACT EVENT MARKERS Strobe lights or taped photoflash bulbs cloth tape on bulb exterior to form small slit for light passage shall be placed in the field of view of all cameras to mark the beginning time zero of the crash test Light from the impact detectors SHOULD NOT COVER MORE THAN 3 FRAMES OF HIGH SPEED VIDEO Suggested locations for impact detectors or time zero markers are as follows Vehicle s roof panel along longitudinal centerline above windshield header Top surface of vehicle s instrument panel along longitudinal centerline Adjacent to engine oil pan Adjacent to vehicle s fuel tank PHOTOGRAPHIC TARGETS AND TAPE FOR TEST VEHICLE NCAP 19 REFERENCE PHOTO TARGETS MONORAIL COVERED P
183. d metallic construction concentric about its longitudinal axis 2 A mass of 2 86 0 02 kg 6 3 0 05 Ibs 1 3 of the weight of the suspension cables and any attachments to the impact probe are included in the calculation of mass and such components may not exceed 5 percent of the total weight of the test probe 3 Minimum mass moment of inertia of 160 kg cm 0 141 Ibs in sec in yaw and pitch about the center of gravity 4 The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It has a flat continuous and non deformable face with diameter of 101 6 0 25 mm 4 00 0 01 in and a edge radius of 7 6 12 7 mm 0 3 0 5 in 5 The impactor is a cylinder with diameter of 101 103 mm 4 0 4 1 in and it is at least 12 5 mm 0 5 in long 6 The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe Ta The impact probe shall have a free air resonant frequency of not less than 1000 Hz in the direction of the longitudinal direction of the impactor FIGURE 9C C35 PART 572N HYBRID IIl 6C THORAX CALIBRATION HYSTERESIS Y 1600 5 0 mm 0 mm 6C test 1400 1200 Deflection 1 000 EE 38 46 800 s Force Corridor 600 1150 1380 N tc 400 lt 200 Force prior to Deflection n 0
184. de Record findings and actions Inspect the nodding blocks 78051 351 for any deterioration but when replacement is necessary ONLY replace during pre test calibration Using a Shore A type Durometer verify the hardness of the nodding blocks is between 80 and 90 Ensure the nodding blocks are installed correctly 880105 250 and PADI Record findings and actions 28 6 Torque jam nut 9000018 on neck cable 880105 206 to 1 4 0 2 Nm 12 0 2 0 1 572 133 c 2 7 The data acquisition system including transducers conforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 137 m 8 test fixture pendulum conforms to the specifications in Figure 7B 572 133 c 3 9 The head neck assembly is mounted on the pendulum so the midsagittal plane of the head is vertical and coincides with the plane of motion of the pendulum longitudinal centerline as shown in Figure 9B for the extension test 572 133 c 3 10 Install the transducers or other devices for measuring D plane rotation with respect to the pendulum longitudinal centerline Note Plane D is the bottom horizontal surface of the skull These measurement devices should be designed to minimize their influence upon the performance of the head neck assembly An example of a measurement device is shown in Figure 10B __11 With the pendulum resting against the honeycomb material the neck bracket
185. de Record findings and actions 6 Torque the jam nut 9001336 on the neck cable 210 2040 between 0 2 Nm and 0 3 Nm 572 143 c 2 7 data acquisition system including transducers conforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 146 1 8 test fixture pendulum conforms to the specifications in Figure 8D 9 head neck assembly is mounted on the pendulum so the midsagittal plane of the headform is vertical and coincides with the plane of motion of the pendulum as shown in Figure 9D for the flexion test 572 143 c 3 10 Install the transducers or other devices for measuring the D plane rotation with respect to the pendulum longitudinal centerline Note Plane D is the top horizontal surface of 025 neck load cell These measurement devices should designed to minimize their influence upon the performance of the head neck assembly 11 Plane D is perpendicular 1 degree to the centerline of the pendulum 12 Set the instrumentation so that the moment and rotation are defined to be zero when the longitudinal centerline of the neck and pendulum are parallel 572 143 b 1 Gii 13 Release the pendulum and allow it to fall freely from a height to achieve an impact speed of 5 4 m s to 5 6 m s as measured at the center of the pendulum accelerometer 572 143 c 4 __14 Complete the following table Neck Flexion Test Results 572 143 b 1 amp 572 1
186. ding the load cell output signal Alternatively the system may be calibrated separately but this is not the desired method 9 1 NCAP 13 PHOTOGRAPHIC DOCUMENTATION CAMERAS High Speed Digital Cameras The Contractor shall document the frontal crash event with high speed digital cameras arranged as shown in Figure 2 that operate at 1000 frames per second fps for 50 ms before the vehicle contacts the barrier and for 300 ms after vehicle contacts the barrier The minimum resolution for these cameras shall be 1536 CMOS sensors per every two rows of pixels with 8096 of the horizontal distance of the two rows covered by effective light sensors There shall be a minimum of 1024 rows of sensors Glare or lights showing on any glass area closed windows or vents must be minimized so that views of the dummies during the test are visible for video analysis A time zero mark must be registered in a frame to indicate when contact with the barrier occurs Each frame shall contain the camera speed and the frame number beginning with the time zero frames labeled as Frame 0 The frame numbers prior to time zero shall be negative numbers If hard copies are needed digital video files shall be transferred to a compact disc CD or DVD as AVI or MPEG format with standard or generally available codec These are also the acceptable formats for video files being transferred to the FTP site Other types of files can be use
187. dressed in a form fitting cotton stretch above the elbow sleeved shirt and above the knee pants The weight of the shirt and pants shall not exceed 0 14 kg 572 134 c 1 The dummy assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 7096 for a period of at least four 4 hours prior to this test 572 134 c 2 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Remove the chest skin and visually inspect the thorax assembly for cracks cuts abrasions etc Particular attention should be given to the rib damping material chest displacement transducer assembly and the rear rib supports Inspect for rib deformation using the chest depth gage If any damage is noted repair and or replace the damaged components unless the damage resulted from the vehicle crash test in which the dummy was an occupant in which case the damage must be documented and post test calibration verification testing completed before any repairs or replacements are made No damage Damage from crash test no repairs or replacement because this is a post test calibration verification Record damage The following repairs or replacement was performed Record Seat the dummy chest skin still removed without back and arm supports on the test fixture surface as shown in Figure 11B The surface must be long enough to support th
188. e pelvis and outstretched legs 572 134 c 3 Level the ribs both longitudinally and laterally 0 5 and adjust the pelvis angle to 7 2 The angle may be measured using the special H point tool TE 2504 that inserts into the pelvic structure and extends outward beyond the pelvic skin surface or by using the surface of the pelvic adaptor block 210 _ 12 13 14 215 34 The midsagittal plane of the dummy 15 vertical within 1 572 134 3 The longitudinal centerline of the test probe 15 centered within 2 5 mm of the midsagittal plane of the dummy and 15 12 7 mm Imm below the horizontal peripheral centerline of the No 3 rib and is within 0 5 of a horizontal line in the dummy s midsagittal plane 572 134 c 4 Align the adjustable neck bracket index marks to the zero position Record locations such as the rear surfaces of the thoracic spine and the lower neck bracket reference with respect to the laboratory coordinate system These reference measurements are necessary to ensure the dummy is in the same position after the chest skin is installed The reference locations must be accessible after installation of the chest skin It may be necessary to leave the chest skin zipper unfastened until the references are checked and fasten it just prior to the test Install the chest skin and reposition the dummy as described in the preceding paragraph using the reference measurements recorded Place the arm assembl
189. e velocity A FMVSS 212 GENERAL REQUIREMENTS This standard establishes windshield retention requirements for motor vehicles during crashes Vehicles equipped with passive restraints must retain 50 percent of each side of the windshield on each side of the longitudinal centerline after they are subjected to a 56 3kph 35 mph frontal barrier impact Vehicles not equipped with passive restraints must retain not less than 75 percent of the windshield during the 56 3kph 35 mph frontal barrier impact It is the contractor s responsibility to follow the most updated FMVSS 212 test procedure when conducting this assessment as part of NCAP testing The latest published versions of all FMVSS test procedures may be found at http www nhtsa gov Vehicle Safety Test Procedures PROCEDURE Windshield retention must be checked directly after a frontal barrier impact Loss of windshield protection can be determined when a piece of paper can pass between the windshield edge and the vehicle body Photographs of the windshield periphery should be taken before the vehicle is placed in the FMVSS 301 static rollover machine 3 FMVSS 219 PARTIAL GENERAL REQUIREMENTS This standard specifies limits for the displacement of vehicle components into the windshield area during a crash It is the contractor s responsibility to follow the most updated FMVSS 219 test procedure when conducting this assessment as part of NCAP testing The latest pu
190. e any replacement or repairs are made Record findings and actions Inspect the nodding blocks 78051 351 for any deterioration but when replacement is necessary ONLY replace during pre test calibration Using a Shore A type Durometer verify the hardness of the nodding blocks is between 80 and 90 Ensure the nodding blocks are installed correctly 880105 250 and PADI 17 Record findings and actions 26 6 Torque jam nut 9000018 on neck cable 880105 206 to 1 4 0 2 Nm 12 0 2 0 1 572 133 c 2 7 The data acquisition system including transducers conforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 137 m 8 test fixture pendulum conforms to the specifications in Figure 7B 572 133 c 3 9 The head neck assembly is mounted on the pendulum so the midsagittal plane of the head is vertical and coincides with the plane of motion of the pendulum longitudinal centerline as shown in Figure 8B for the flexion test 572 133 c 3 10 Install the transducers or other devices for measuring the D plane rotation with respect to the pendulum longitudinal centerline Note Plane D is the bottom horizontal surface of the skull These measurement devices should be designed to minimize their influence upon the performance of the head neck assembly An example ofa measurement device is shown in Figure 10 11 With the pendulum resting against the
191. e honeycomb material 572 143 c 4 iii Plots of pendulum acceleration pendulum velocity neck y axis moment and neck rotation about the y axis follow this sheet Signature Date 028 PENDULUM SPECIFICATIONS 101 6 mm t ini STRUCTURAL STEEL TUBE boo mm 4 8 mm 10 1875 in p 31 8 mm PIVOT 50 8 mm 2 in DIA 11 25 in INERTIAL PROPERTIES OF PENDULUM MOUNTING PLATE AND MOUNTING HARDWARE WITHOUT TEST SPECIMEN T PENDULUM X 7 ACCELEROMETER CENTERLINE WEIGHT 29 57 165 21 156 198 1 mm MOMENT OF INERTIA 33 2 kg m roy 8 294 in Ib sec ABOUT PIVOT AXIS P 7 4 8 mm GE 188 in mm 38 1 mm 8 28 mm f 7 F 11 5 in 132 6m3 A i f i ON 886 2 mm 188 6 mm CG OF PENDULUM SES 9225 in 7 75 in APPARATUS WITHOUT 7 Eu 463 6 NE RADIOS HEXCEL 28 8 kg m zw 1 8 1b ft REF ACCELEROMETER BEFORE TESTING RECRUSH THE HONEYCOMB w MATFRIAL WITH THE PENDULUM TO ASSURE THAT 90 TO 100 OF THE HONEYCOMB SURFACE 15 CONTACTING THE PENDULUM STRIKER PLATE 4 ft 38 1 mm REF 1 5 in MOUNTING PLATE PENDULUM STRIKER PLATE SHARP EDGES 76 2 x 152 4 x 9 5 mm 3 x 6 x 3 8 in FIGURE 8D 029 NECK FLEXION TEST SET UP SPECIFICATIONS DIRECTION OF i vir Ee PENDULUM REF FIGURE 22 SUBPART E NECK MOUNTING PLATE TE 250 021
192. e required to move a limb segment does not exceed 2 Gs throughout the range of limb motion 572 155 1 E Dummies will be clothed for the thorax calibration tests with a form fitting cotton polyester based tight fitting sweat shirt with long sleeves and ankle length pants The total weight of the shirt and pants shall not exceed 0 25 kg 0 55 Ib 572 154 c 2 CALIBRATION TEST EXECUTION Complete the Data Sheets in section 15 POST TEST REQUIREMENTS The contractor shall verify all instrumentation and check data sheets and photographs Make sure data is recorded in all data blocks on every performance calibration test data sheet REPORTS APPARENT NONCONFORMANCE During the a calibration verification any indication of apparent nonconformance to the requirements of Regulation P572 shall be communicated by telephone to the COTR within 24 hours with written notification mailed within 48 hours Saturdays and Sundays excluded Written notification shall be submitted with a copy of the particular test data sheet s and preliminary data plot s 14 2 14 2 1 E12 In the event of an apparent nonconformance a calibration check of some critically sensitive test equipment and instrumentation may be required for verification of accuracy The necessity for the calibration shall be at the COTR s discretion and shall be performed without additional costs to the OCWS FINAL PERFORMANCE CALIBRATION REPORTS COPIES A report containing the ca
193. e seat cushion reference point whose projection in the vehicle vertical longitudinal plane is straight and has a known angle with respect to the horizontal Q Telltale A display that indicates the actuation of a device a correct or defective functioning or condition or a failure to function 571 101 S4 R Type 1 seat belt assembly A lap belt for pelvic restraint 571 209 S3 S Type 2 seat belt assembly A combination of pelvic and upper torso restraints 571 209 53 T Unloaded vehicle weight The weight of a vehicle with maximum capacity of all fluids necessary for operation of the vehicle but without cargo occupants or accessories that are ordinarily removed from the vehicle when they are not in use 571 3 U Vehicle capacity weight The rated cargo and luggage load plus 68 kilograms times the vehicle s designated seating capacity 571 110 S3 V Vehicle fuel tank capacity The tank s unusable capacity 1 the volume of fuel left at the bottom of the tank when the vehicle s fuel pump can no longer draw fuel from the tank plus its usable capacity 1 e the volume of the fuel that can be pumped into the tank through the filler pipe with the vehicle on a level surface and with the unusable capacity already in the tank The term does not include the vapor volume of the tank i e the space above the fuel tank filler neck nor the volume of the fuel tank filler neck 571 3 W Windshield trim Molding of any material between th
194. e their installation on the rigid barrier wall The following serves to describe a few typical load cell wall arrangements 36 LOAD CELL BARRIER One typical load cell wall contains 36 load cells 250mm x 250mm in size arranged in 4 rows of 9 load cells in each as seen in Figure 1 The load cells are single axis and record force in the x direction An 18 x 83 inch extension can be added to the top of the load cell barrier illustrated as seen in Figure 1 to prevent vehicle hood override The rigid steel frame shall be faced with 4 inch thick plywood _Fixed Barrier Centerline Extension Assembly Plywood Face on Steel Frame 837 18 4 a Ground Surface VIEW Figure 1 Load Cell Locations a 36 Load Cell Barrier with Plywood Height Extension 2 HIGH RESOLUTION 144 LOAD CELL BARRIER Another load cell wall NHTSA may furnish contains 144 load cells 125mm x 125mm in size arranged in 9 rows of 16 load cells in each as seen in Figure 2 The load cells are single axis and record force in the x direction An 18 x 83 inch extension can be added to the top of the load cell barrier illustrated seen in Figure 1 to prevent vehicle hood override The rigid steel frame shall be faced with 74 inch thick plywood centerline 2000 mm 4 SNE es e ss ss e en o n emen rn en 4 8
195. e will be collected for the 5 minute period from the beginning of rotation plus any additional 1 minute collection periods that are required Containers for the collection of possible Stoddard solvent spillage and a calibrated stopwatch for timing the fluid collection intervals are required Containers must be labeled before they are photographed C FUEL SYSTEM INTEGRITY After the vehicle impact fuel system Stoddard solvent leakage will be collected by hand and documented with a real time 24 30 fps motion picture camera and stopwatch The tea cup method involves simply placing a collection vessel beneath the leakage source and timing the intervals of several collected volumes The collected Stoddard solvent samples can subsequently be measured and spillage rates calculated If the cup method is used the test personnel must be in position to scramble to observation points around the test vehicle at the instant the vehicle comes to rest after the impact event NOTE It is the Contractor s responsibility to collect any suspect liquids leaking from the vehicle post test and analyze the contents if necessary D STATIC ROLLOVER PROCEDURE The Contractor must conduct a static rollover test within 30 minutes after the vehicle impact The Contractor must keep the test vehicle under constant observation for Stoddard solvent leakage during the transition between impact and static rollover testing When the test vehicle is rotated in a
196. e windshield glazing and the exterior roof surface including material that covers a part of either the windshield glazing or exterior roof surface 571 216 S3 11 TEST EXECUTION 11 1 TEST VEHICLE PREPARATION A TEST VEHICLE INFORMATION NCAP 25 Using owner s manual certification labels information provided by the and any other data available determine the following vehicle information and record on the applicable data sheet 1 Model Year make model and body style 2 Body Color and VIN 3 NHTSA No supplied by COTR 4 Build date or month and year of manufacture 5 Engine data Number of cylinders displacement CID liters or cc and placement longitudinal or lateral 6 Transmission Data Number of speeds manual or automatic and whether it is equipped with overdrive 7 Final Drive rear front or four wheel drive 8 Current odometer reading 9 Safety Restraints List and describe all available front occupant restraints 10 Options List major options TIRE DATA RECORDED FROM FMVSS 110 VEHICLE PLACARD OR OPTIONAL TIRE INFLATION PRESSURE LABEL Record the following information onto the applicable data sheet Recommended tire size Recommended cold tire pressure Number of occupants Vehicle Capacity Weight VCW a a DATA RECORDED FROM TIRE SIDEWALL Record the following information onto the applicable data sheet 1 Size of tires Verify that the tire size s meet the manu
197. ecification Result Test Probe Speed 6 59 m s lt speed lt 6 83 m s Chest Compression 38 0 mm lt compression lt 46 0 mm Peak force between 38 0 and 46 0 mm chest compression 1150N lt peak force lt 1380N Peak force between 12 5 and 38 0 mm chest compression Peak force lt 1500 N Internal Hysteresis 65 lt hysteresis lt 85 Time zero is defined as time of initial contact between the test probe and chest skin Force impactor mass x acceleration Area under loading curve minus the area under the unloading curve divided by the area under the loading curve Figure 10C 18 Plots of chest compression acceleration force force versus deflection follow this sheet Signature Date C34 THORAX IMPACT TEST SET UP SPECIFICATIONS IMPACT PROBE SUIT RT CABLES N lt PENDULUM ACCULLUROMUJUR MOUNTED WLILLSENSITIVI N AXIS PARALLEL PENDULUM LONGILUDINAI CENTERT TNF ALI RIBS HORIZONTAL P CENTERLINE OF IMPACT PRORE S 12 751 can 0 5470 Min BELOW HORLZONTAIL CENTERLINE OF THIRD RIB IMPACT PROBE WEIGHT 77 INCLUDING ALL INSTRUMENTATION AND 165 OE SUPPORT CABLE WEIGHTS 2 ROMEO hp 6 VL Th PLEVIC ANGE P889 a1 FROM HORIZONTAL 127 3012 TA CABLE WEIGHT NOT TO RXCRED 5 OF THF TOTAL IMPACT WEICIHT 5 PELVIS LUMBARHR JOINING SD REACE Probe specifications l Rigi
198. eets are not part of the Final Test Report The Contractor is not restricted from using other tools or expanding the forms outlined in this section A FORM NO 1 Test Vehicle Information A Test Vehicle Information form will be supplied by the COTR to the Contractor before testing preparation Information on this form is supplied by the automobile manufacturer to aid in the initial test setup and shall be considered as reference material After vehicle preparation is complete the Test Vehicle Information form shall be discarded FORM NO 2 Vehicle Condition Report A Vehicle Condition Report form must be submitted to the COTR with the copies of the Final Test Report The first page of the form shall be completed when the test vehicle arrives at the testing laboratory The second page of the form is completed after the test The forms shall be legible hand written forms are unacceptable and complete all information requested is filled out FORM NO 3 Laboratory Notice of Test Failure A Laboratory Notice of Test Failure form will be submitted to the NHTSA COTR to report a test failure The failure shall be described thoroughly in the space provided FORM 4 Monthly Vehicle Status Report A Monthly Vehicle Status Report form shall be submitted to the COTR each month until all vehicles have been discarded FORM NO 5 Quicklook Report A Quicklook Report of pertinent test data should be prepared and
199. egulation P572 shall be communicated by telephone to the COTR within 24 hours with written notification mailed within 48 hours Saturdays and Sundays excluded Written notification shall be submitted with a copy of the particular test data sheet s and preliminary data plot s In the event of an apparent nonconformance a calibration check of some critically sensitive test equipment and instrumentation may be required for verification of accuracy 14 2 14 2 1 B11 The necessity for the calibration shall be at the COTR s discretion and shall be performed without additional costs to the OCWS CALIBRATION DOCUMENTATION COPIES Copies of the data sheets containing the calibration data for each Part 572 Subpart O dummy used in the vehicle crash test shall be submitted with the final NCAP test report for the vehicle Contractors are required to PROOF READ all Final Test Reports before submittal to the COTR The OCWS will not act as a report quality control office for contractors Reports containing a significant number of errors will be returned to the contractor for correction and a hold will be placed on invoice payment for the particular test 12 15 DATA SHEETS DATA SHEET B1 DUMMY DAMAGE CHECKLIST Dummy Serial Number Test Date Technician This check sheet is completed as part of the calibration verification Perform general cleaning Dummy Item Inspect for Comments Damaged OK Outer skin
200. ehead against the seat back surface Place the centerlines of the upper arms vertical Place the centerlines of the lower arms horizontal Position the upper legs so that they are parallel to one another Position the lower legs so that they are perpendicular to the upper legs and the bottom of the foot is horizontal Record the dimensions listed in following table except for dimension Q reference figure 4E Place the dummy in supine position on the measurement surface Place a block that is perpendicular to the table at both the head and feet of the dummy Position the blocks perpendicular to the midsaggital plane of the dummy Position the blocks so they are in contact with the head and the heels of the dummy Measure the distance between the blocks for Q Signature Date E16 HYBRID PART 572 SUBPART O EXTERNAL DIMENSIONS DIMENSION DESCRIPTION DETAILS DIMENSION ACTON MEASUREMENT A TOTAL SITTING HEIGHT Seat surface to highest point on top of the head with head pulled 456 471 2 back to touch vertical surface of fixture SHOULDER HEIGHT Centerline of shoulder pivot bolt to the seat surface 276 6 291 8 HIP PIVOT HEIGHT Centerline of hip pivot bolt to seat surface 27 9 38 1 HIP PIVOT FROM BACKLINE Centerline of hip pivot bolt to vertical surface of seat 40 1 50 3 E SHOULDER PIVOT FROM Center of the shoulder pivot bolt to the fixture s rear vertical 50 3 60 5 BACKLINE surface i THIGH CLEA
201. el All dimensions in mm o EN EH 16 EA 18 RD Co N42 DATA SHEET NO 13 ACCIDENT INVESTIGATION DIVISION DATA Test Vehicle Test Program VEHICLE INFORMATION VIN Vehicle Size Category ACCELEROMETER DATA Accelerometer Locations NHTSA No Test Date Wheelbase Test Weight kg Cal Procedure Interval Integration Algorithm Linearity Impact Velocity km h Velocity Change km h Time of Separation ms CRUSH PROFILE Collision Deformation Classification Midpoint of Damage Damage Region Length mm Impact Mode Measurement Description Crush zone 1 at left side Crush zone 2 at left side Crush zone 3 at left side Crush zone 4 at right side Crush zone 5 at right side Crush zone 6 at right side C1 to C6 N43 DATA SHEET NO 14 VEHICLE INTRUSION MEASUREMENTS Test Vehicle NHTSA No Test Program Test Date DOOR OPENING WIDTH Description Units Post Test Left Side Upper Left Side Lower Right Side Upper Right Side Lower WHEELBASE MEASUREMENTS Left Side Wheelbase F Right Side Wheelbase N44 DATA SHEET NO 14 CONTINUED VEHICLE INTRUSION MEASUREMENTS Test Vehicle NHTSA Test Program Test Date DRIVER COMPARTMENT INTRUSION Description Units Post Test
202. eleration versus time and force versus time follow this sheet Signature Date B43 DATA SHEET B9 RIGHT KNEE IMPACT TEST 572 136 5 Female Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive knee impact tests are necessary 1 It has been at least 30 minutes since the last knee impact test 572 137 q __ N A ONLY one knee impact test performed 2 test fixture conforms to the specifications in Figure 14B 3 knee assembly 880105 528R lower leg structural replacement 880105 603 lower leg flesh 880105 601 ankle assembly 880105 660 foot assembly 880105 651 and femur load transducer SA572 S14 may use the load cell structural replacement 78051 319 were used 572 136 b 1 __4 knee assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to this test 572 136 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity __5 Mount the test specimen and secure it to the rigid test fixture 572 136 c 2 6 No parts of the foot or tibia contact any exterior surface 572 136 c 2 7 Align the test probe so that throughout its stroke and at contact with the knee it is within 2 degrees of horizontal and colli
203. enger Pelvis Y Passenger Pelvis Z Passenger Left Femur Redundant Passenger Right Femur Redundant Passenger Left Upper Tibia Moment X Passenger Left Upper Tibia Moment Y Passenger Left Upper Tibia Force Z Passenger Left Lower Tibia Moment X Passenger Left Lower Tibia Moment Y Passenger Left Lower Tibia Force Z Passenger Right Upper Tibia Moment X Passenger Right Upper Tibia Moment Y Passenger Right Upper Tibia Force Z Passenger Right Lower Tibia Moment X Passenger Right Lower Tibia Moment Y Passenger Right Lower Tibia Force Z Passenger Left Foot Fore Z Passenger Left Foot Aft X Passenger Left Foot Aft Z Passenger Right Food Fore Z Passenger Right Foot Aft X Passenger Right Foot Aft Z Passenger Shoulder Belt Force Passenger Lap Belt Force Left Rear Seat Crossmember X Left Rear Seat Crossmember Z Right Rear Seat Crossmember X Right Rear Seat Crossmember Z Left Rear Seat Crossmember X Redundant Right Rear Seat Crossmember X Redundant Vehicle Engine Top X Vehicle Engine Bottom X Load Cell Barrier A1 A9 Load Cell Barrier B1 A9 Load Cell Barrier C1 A9 Load Cell Barrier D1 A9 N21 N22 REPORT AREA 5 DUMMY CALIBRATION AND PERFORMANCE VERIFICATION Data sheets from Frontal NCAP Laboratory Test Procedure Appendix Part 572E 50th Male Dummy Performance Calibration Test Procedure and Appendix B Part 572O 5th Female Dummy Performance Calibration Test Procedure shall be used to document dummy calibration in Appendix
204. erature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 1096 to 7096 for a period of at least four 4 hours prior to a test 572 32 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Visually inspect the head skin for cracks cuts abrasions etc Repair or replace the head skin if the damaged area is more than superficial Note If the damage resulted from the vehicle crash test in which the dummy was an occupant the damaged area 15 to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions Clean the impact surface of the skin and the impact surface of the fixture with isopropyl alcohol 1 1 1 trichloroethane or equivalent prior to the test 572 32 c 2 210 11 2 209 48 14 215 16 17 A24 Suspend and orient the head assembly as shown in Figure 6A The lowest point on the forehead is 0 5 in below the lowest point on dummy s nose when the midsagittal plane is vertical 572 32 c 3 Record the actual distance NOTE The masses of the suspension device and the accelerometer cables are to be kept as lightweight as possible to minimize their effect on the test results The 1 6 mm 0 062 inch diameter holes located on either side of the dummy s head are equidistance within 2 mm
205. es to Dashboard taken from the center of the knee pivot bolt s outer surface to the closest point forward acquired by swinging the tape measure in continually larger arcs until it contacts the dashboard Also reference the angle of this measurement with respect to the horizontal for the outboard knee KDA SH Striker to Hip this measurement is to be taken in the X Z plane measured from the forward most center point on the striker to the center of the H point When taking this measurement a firm device that can be rigidly connected to the striker should be used The measurement in the Y itransverse direction from the striker to the H point should also be taken SHY The following measurements are to be made within a vertical transverse plane HS Head to Side Window taken from the point where the dummy s nose meets his forehead between his eyes to the outside of the side window In order to make this measurement roll the window down to the exact height which allows a level measurement Use a level SHY Striker to H point taken from a rod rigidly connected to the forward most center point on the striker to the H point Use a level N66 DUMMY MEASUREMENTS FOR FRONT SEAT PASSENGERS HH Head to Header SHY Striker to H Point Y Dir NR Nose to Rim CS Steering Wheel to Chest KDL KDR Knee to Dash SH Striker to H Point HS Head to Side Window July 10 1992 N67 FORM NO 2 REPORT OF VEHICLE CONDITION
206. est Vehicle NHTSA No Test Program Test Date af gt p sfo Fey ou EN EE EM BE s t M pg E SHE All units in millimeters N37 DATA SHEET NO 9 LOAD CELL LOCATIONS ON FIXED BARRIER Test Vehicle NHTSA No Test Program Test Date Insert Schematic of Load Cell Barrier as Applicable Also see Appendix P Barrier Centerline lt Extension Assembly i f Plywood Face on Steel Frame 4 18 FRONT VIEW Ground Surface centerline 2000 mm epp Te peer pene es eos en on on oo emm em p een rns ono enn rf pene fsb fa fraa es ener een emen ee ene ee ENE Ed EK en en nen pem e en enn preparare enn ene fm penne es ees esee en en nen em e ene n afee eae ae oa peeps n dili ground 1125 mm N38 DATA SHEET NO 10 TEST VEHICLE SUMMARY OF RESULTS Test Vehicle NHTSA No Test Program Test Date INSTRUMENTATION Instrumentation 1 Driver Dummy Accelerometers Passenger Dummy Accelerometers Vehicle Structure Accelerometers Total CAMERA COVERAGE Type of Camera High Speed Vehicle Onboard High Speed Offboard Real Time Panning Total N39 DATA SHEET NO 11 POST TEST OBSERVATIONS Test Vehicle NHTSA No Test Program Test Date TEST DUMMY INF
207. f the dummy is vertical within 1 572 144 c 3 210 wae 319 E 14 215 032 The longitudinal centerline of test probe 15 centered within 2 5 mm of midsagittal plane of the dummy and 15 centered on the center of the No 2 rib within 2 5 mm within 0 5 of a horizontal line in dummy s midsagittal plane 572 144 c 4 Record locations such as the rear surfaces of the thoracic spine and the lower neck bracket reference with respect to the laboratory coordinate system These reference measurements are necessary to ensure the dummy is in the same position after the chest skin is rolled up and zipped and the arms installed The reference locations must be accessible after the chest skin is rolled up and the arms installed It will be necessary to leave the chest skin zipper unfastened until the references are checked and then fasten it just prior to the test Install the chest skin and arms and reposition the dummy using the reference measurements recorded Place the upper arms parallel to the torso Place the lower arms horizontal and forward and parallel to the midsagittal plane 572 144 c 3 The data acquisition system including transducers must conform to the requirements of SAE Recommended Practice 1211 1 MAR95 572 146 1 Impact the anterior surface of the thorax with the test probe so the longitudinal centerline of the probe is within 2 of a horizontal line in the dummy s midsagittal plane at the m
208. facturer s specification as listed on the vehicle placard or optional tire label 2 Tire Manufacturer 3 Tire Pressure for maximum load carrying capacity Verify that this pressure exceeds or is equal to the recommended cold tire pressure listed on the vehicle placard 4 Treadwear traction and temperature ratings SEAT TYPE Record the following information onto the applicable data sheet Visually inspect the seat to verify seat type 1 Type of front seat bucket bench or split bench NCAP 26 2 Type of front seat back fixed or adjustable with lever or knob 3 Type of rear seat bucket bench or split bench 4 Type of rear seat back fixed or adjustable with lever or knob E VEHICLE ACCELEROMETERS 5 VIEW CUSHION ASSY SUPPORT DISC BRAKE CALIPER LEFT SIDE VIEW Figure 5 Vehicle Accelerometer Locations F Place the following accelerometers in the test vehicle according to Figure 5 Record NCAP 27 coordinates and accelerometer responses applicable data sheet 1 Left Rear Seat Crossmember Accelerometers mounted on the left rear seat crossmember to measure Ax redundant Ax and Az Right Rear Seat Crossmember Accelerometers mounted on the right rear seat crossmember to measure Ax redundant Ax and Az Top of Engine One uniaxial accelerometer mounted on the top of the en
209. fixture on its longitudinal axis to each successive increment of 90 following an impact crash Stoddard solvent spillage 76 from onset of rotational motion shall not exceed a total of 5 ounces weight for the first 5 minutes of testing at each successive 90 increment For the remaining testing period at each increment of 90 solvent spillage during any minute interval shall not exceed lounce by weight E STATIC ROLLOVER TEST CONDITIONS Within 30 minutes after a vehicle impact the vehicle is rotated in a test fixture about its longitudinal axis with the axis kept horizontal to each successive increment of the following at a uniform rate with 90 of rotation taking place in any time interval from 1 to 3 minutes 1 90 2 180 3 270 4 360 After reaching each 90 increment the vehicle is held in that position for 5 minutes The rollover machine must be capable of rotating the barrier impacted test vehicle about its longitudinal axis with the axis kept horizontal to each successive increment of 90 180 and 270 at a uniform rate Leakage will be collected for the 5 minute period from the beginning of rotation plus up to three 1 minute collection periods Containers for the collection of possible Stoddard solvent spillage and a calibrated stopwatch for timing the fluid collection intervals are required Containers must be labeled before they are photographed FMVSS 305 A GENERAL REQUIREMENTS This standa
210. forward of the rear vertical surface of the fixture Note the H point is located 68 6 mm 2 7 in forward and 58 4 mm 2 3 in downward from the center of the square hole in the pelvis Extend the dummy s neck so that the base of the skull is level both fore and aft and side to side within 0 5 degrees The rear surface of the skull cap should be 45 7 2 5 mm 1 8 0 1 in from the vertical surface of the test fixture A strap or bungee cord may be placed around the forehead of the dummy to stabilize the head in this position Position the upper and lower legs parallel to the midsagittal plane so the centerline between the knee pivot and the screw attaching the ankle to the lower tibia is vertical Position the feet parallel to the dummy s midsagittal plane with the bottoms horizontal and parallel to the seating surface Position the upper arms downward vertically so the centerline between the shoulders and elbow pivots is parallel to the rear vertical surface of the fixture 23 13 14 B15 Position the lower arms horizontally so the centerline between the elbow and wrist pivots is parallel to the seat surface Record the dimensions listed in following table except for dimension Y and Z reference figure 2B Install the abdominal insert and chest jacket Reposition the dummy on the test fixture The head need not be level as previously specified Mark the locations AA and BB and record the dimensions Y Z as specified
211. from the impact surface A typical test setup is shown in Figure 7A Record the right side distance Record the left side distance The impact surface is clean and dry and has a micro finish in the range of 203 2 10 mm 8 micro inches to 2032 0 10 mm 80 micro inches RMS 572 32 4 Record actual micro finish The impact surface is rigidly supported 572 32 c 4 The impact surface is a flat horizontal steel plate 50 8 mm 2 inches thick and 610 mm 24 inches square Figure 6A Record thickness Record width Record length Drop the head assembly from a height of 376 0 1 0 mm 14 8 inches 0 04 inches by a means that ensures a smooth instant release onto the impact surface 572 32 b amp 572 32 c 4 Complete the following table using channel class 1000 data 572 36 1 Parameter Specification Result Peak resultant acceleration 225 g lt x lt 275 g Resultant versus time history curve Unimodal Oscillations after the main pulse Less than 10 of the peak resultant acceleration Lateral acceleration y axis acceleration lt 15 g Plots of the x y z and resultant acceleration data follow this sheet Signature Date 25 TEST SET UP SPECIFICATIONS RELEASE CONNECTING HEAD SUPPORT CRADLE DROP HEIGHT 376 mm 14 8 in STEEL BLOCK 50 8 x 610 mm 2 x 24 x 24 in 8 TO 80 rms MICROINCH INCH FINISH CENTERLINE OF 1 6 mm 0 062 in
212. g out of the retractor and allow it to retract repeat this four times 510 9 27 3 Apply a 2 to 4 pound tension load to lap belt 510 9 pound load applied 27 4 Is the belt system equipped with a tension relieving device Yes continue No go to 28 27 5 Introduce the maximum amount of slack into the upper torso belt that is recommended the vehicle manufacturer in the vehicle owner s manual S10 9 28 Place the left upper arm adjacent to the torso with the centerline as close to a vertical plane as possible S10 2 1 29 Place the right hand with the palm in contact with the steering wheel at the rim s horizontal centerline and with the thumb over the steering wheel 510 3 1 30 Place the left hand with the palm in contact with the steering wheel at the rim s horizontal centerline and with the thumb over the steering wheel 510 3 1 31 Tape the thumb of each hand to the steering wheel by using masking tape with a width of 0 25 inch The length of the tape shall only be enough to go around the thumb and steering wheel one time 2 Seating and Dummy Positioning Procedures for the 5 Female Passenger Dummy Part 572 Subpart O all section references refer to FMVSS No 208 Check this item ONLY if it applies to this vehicle The passenger seat adjustments are controlled by the adjustments made to the driver s seat Therefore positioning of the passenger dummy is made
213. g the longitudinal plane Then measure the acute angle of the straight edge with respect to the horizontal SCA Steering Column Angle measured with respect to the horizontal by placing an inclinometer the center of underside of the steering column NA Nose to Rim Angle Measure the angle made when taking the measurement NR with respect to the horizontal KDA Knee to Dash Angle Measure the angle that KD is taken at with respect to the horizontal Only get this angle for the outboard knee NCAP 43 xi KDA Knee to Dash Angle 7 WA Windshield Angle Place an inclinometer along the transverse center of the windshield exterior measurement is made with respect to horizontal 8 TA Tibia Angle Use a straight edge to connect the dummy s knee and ankle bolts Then place an inclinometer on the straight edge and measure the angle with respect to the horizontal NCAP 44 dummy joints should be inspected for mobility prior to each crash test and reset to hold 1G This amount of friction will just barely restrain the weight of the individual limb when it is extended horizontally TEST DUMMIES SHOULD BE PLACED IN THE TEST VEHICLE ON THE MORNING OF TEST DAY DO NOT PLACE THE DUMMIES IN THE VEHICLE THE DAY BEFORE TESTING FOR OVERNIGHT STORAGE The final positions of the driver and passenger dummies shall be recorded using the appropriate final report data sheet and the occupant clearances to vehicle i
214. ght supported by the internal structure of the pelvis The dummies shall be held upright by using a strap around the chest or the base of the neck so that the neck is not supporting the weight of the dummy If used Subpart P 3 year old and R 12 month old dummies shall be stored in a hanging position using the bracket and positioning shown in figures and 2 The dummies shall be stored in a secured room which is kept between 55 F and 85 F and 10 70 relative humidity The Contractor shall check the dummy components for damage after each crash test and complete a Dummy Damage Checklist that will be included with the post test dummy calibration The COTR will be kept informed of the dummies condition in order that replacement parts can be provided The Contractor shall keep a detailed record for each dummy describing parts replaced 7 3 NCAP 9 and the results of calibration tests LOAD CELL BARRIER A barrier will be provided to the contract laboratory by the NCAP Details on some typical load cell barriers can be found in Appendix P Load Cell Barrier Configurations NCAP 10 CALIBRATION AND TEST INSTRUMENTATION Before the Contractor initiates the NCAP test program a test instrumentation calibration system must be implemented and maintained in accordance with established calibration practices The calibration system shall include the following as a minimum A Standards for calibrating the measuring and test equipment will
215. gine block to measure Ax Bottom of Engine One uniaxial accelerometer mounted on the bottom of the engine block to measure Ax Right Front Disc Brake Caliper Not currently collected Center of Instrument Panel Not currently collected Left Front Disc Brake Caliper Not currently collected NOTE The location of the accelerometers as well as the acceleration versus time output shall be recorded and included in the final test report and tape disk AS DELIVERED VEHICLE WEIGHT CONDITION 1 the transmission with transmission fluid to full capacity Drain fuel from vehicle Run the engine until fuel remaining in the fuel delivery system is used and the engine stops Record the useable fuel tank capacity supplied by the COTR Record the fuel tank capacity supplied by the owner s manual Using purple dyed Stoddard solvent having the physical and chemical properties of Type 1 solvent or cleaning fluid Table 1 ASTM Standard D484 71 Standard Specifications for Hydrocarbon Dry cleaning Solvents or gasoline fill the fuel tank Record the amount NOTE Stoddard solvent shall be free of debris It is considered debris free only if upon filtering with a 10 micron filter no solid debris is retained on the filter media or in any conduit container or vessel upstream from the filter paper e g debris is not allowed to be present in the funnel pump or container The solvent used for NHTSA testing must be designated for
216. h max S10 4 2 1 222 vertical inches from the point 0 25 below the determined H point 0 5 inch max S10 4 2 1 pelvic angle 20 to 25 S10 4 2 2 22 5 Adjust the neck bracket of the dummy the minimum amount necessary from the nonadjusted 0 setting until the head is level within 0 5 S10 1 Record the following then go to 23 horizontal inches from the point 0 25 below the determined H point 0 5 inch max S10 4 2 1 vertical inches from the point 0 25 below the determined H point 0 5 inch max S10 4 2 1 pelvic angle 20 to 25 S10 4 2 2 23 Set the distance between the outboard knee clevis flange surfaces at 10 6 inches measured distance 10 6 inches S10 5 24 Can the right foot be placed on the accelerator _ Yes go to 24 1 and skip 24 2 4 to 24 2 24 1 To extent practicable keep the right thigh and leg in a vertical plane S10 5 while resting the foot on the undepressed accelerator pedal with the rearmost point of the heel on the floor pan in the plane of the pedal S10 6 1 1 242 Initially set the foot perpendicular to the leg and then place it as far forward as possible in the direction of the pedal centerline with the rearmost point of the heel resting on the floor pan S10 6 1 1 242 1 Move the adjustable pedal to its most rearward position or until the right foot is flat on the pedal whichever occurs first S10 6 1 1 N A the accelerator pedal
217. h the center of gravity CG of the dummy head S16 3 4 3 243 If the above position is not attainable move the vertical center of the head restraint to the closest detent below the center of the head CG S16 3 4 3 midpoint position attained in previous step Headrest set at nearest detent below the head CG 24 4 If the head restraint has a fore and aft adjustment place the restraint in the foremost position or until contact with the head is made whichever occurs first S16 3 4 4 25 Manual belt adjustment for tests conducted with a belted dummy 516 3 5 __N A Unbelted test 25 1 If an adjustable seat belt D ring anchorage exists place it in manufacturer s design position for a 5th percentile adult female This information will be supplied by the COTR S16 3 5 1 Manufacturer s specified position 252 Place the Type 2 manual belt around the test dummy and fasten the latch S16 3 5 2 253 Ensure that dummy s head remains as level as possible 516 3 5 3 25 4 Remove all slack from the lap belt Pull the upper torso webbing out of the retractor and allow it to retract repeat this operation four times Apply a 9 N 2 lbf to 18 N 4 Ibf tension load to the lap belt If the belt system is equipped with a tension relieving device introduce the maximum amount of slack into the upper torso belt that is recommended by the manufacturer If the belt system is not equipped with a tension relieving dev
218. h the longitudinal axis of the probe The impact probe shall have a free air resonant frequency of not less than 1000 Hz in the direction of the longitudinal direction of the impactor FIGURE 11D PART 572P HYBRID THORAX CALIBRATION HYSTERESIS 1000 12 5 mm 32 0 mm 38 0 mm e EE EN AT z Vr 777 600 1 5 400 x 200 5 10 20 30 200 LOAD DISPLACEMENT mm Point A Maximum Force in Deflection Corridor 3C test Deflection Corridor 32 38 mm Force Corridor 680 810 N Force Prior to Deflection Corridor 12 5 32 mm Point B Max Force between 12 5 mm 32 0 mm shall not exceed 860 N FIGURE 120 D35 036 DATA SHEET 07 TORSO FLEXION TEST 572 145 3 YEAR OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive torso flexion tests are necessary 1 It has been at least 30 minutes since the last torso flexion test 572 146 p __ N A ONLY torso flexion test performed 2 test fixture conforms to the specifications in Figure 13D 3 complete assembled dummy 210 0000 is used with or without the lower legs 572 145 2 __ with legs below femurs _ without legs below the femurs 4 dummy assembly soaked at a temper
219. h the longitudinal axis of the probe The impact probe shall have a free air resonant frequency of not less than 1000 Hz in the direction of the longitudinal direction of the impactor KNEE IMPACTOR PROBE 572 127 b A B The test probe for knee impacts shall be of rigid metallic construction concentric in shape and symmetric about is longitudinal axis It shall have a mass of 0 82 0 02 kg 1 8 0 05 Ibs 1 3 of the weight of the suspension cables and any attachments to the impact probe must be included in the calculation of mass and such components may not exceed 5 percent of the total weight of the test probe It shall have a minimum mass moment of inertia of 34 kg cm 0 03 Ibs in sec in yaw and pitch about the center of gravity The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It must have a flat continuous and non deformable face with a diameter of 76 2 0 2 mm 3 00 0 01 in and a maximum edge radius of 7 6 12 7 mm 0 3 0 5 m The impactor is a cylinder with a diameter of 76 77 mm 3 0 3 1 in and it is at least 12 5 mm 0 5 in long The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe The impact probe shall have a free air resonant frequency of not less than 1000 Hz in the direction of the longitudinal direction of the impactor SIGN CO
220. h to the rear vertical LENGTH surface of the fixture POPLITEAL HEIGHT Seat surface to the horizontal plane at the bottom of the feet KNEE PIVOT HEIGHT Centerline of knee pivot bolt to the horizontal plane of the bottom of the feet HYBRID III SUBPART N EXTERNAL DIMENSIONS continued 17 8 22 8 215 9 231 1 157 4 177 8 370 8 391 2 269 2 289 6 307 4 322 6 C17 ASSEMBLY ACTUAL DIMENSION DESCRIPTION DETAILS SRI MEASUREMENT N BUTTOCK POPLITEAL The rearmost surface of the lower leg to the same point on the 320 0 340 4 LENGTH rear surface of the buttocks used for dim K i CHEST DEPTH WITHOUT Measured 330 2 5 1 mm above seat surface 129 6 144 8 4 FOOT LENGTH Tip of toe to rear of heal 170 2 185 4 Q STATURE THEORETICAL Q A C D R M 1099 9 1181 1 The rear surface of the buttocks to the knee pivot bolt FOOT BREADTH The widest part of the foot 62 3 77 5 WAIST CIRCUMFERENCE with chest jacket and Measured 158 8 5 1 mm above seat surface 558 8 584 2 abdominal insert REFERENCE LOCATION FOR MEASUREMENT OF Reference 325 1 335 3 CHEST CIRCUMFERENCE REFERENCE LOCATION FOR MEASUREMENT OF Reference 153 7 163 9 WAIST CIRCUMFERENCE HEAD CIRCUMFERENCE Measured at the point as in dim T 510 5 530 9 CHEST CIRCUMFERENCE WITH CHEST JACKET Measured 3330 2 5 1 mm above seat surface 596 9 622 3 18 EXTERNAL DIMENSION SPECIFICATIONS
221. hall calibrate the dummies before and verify the calibration after every crash test CALIBRATION AND TEST INSTRUMENTATION Before the contractor initiates the dummy performance calibration test program a test instrumentation calibration system must be implemented and maintained in accordance with established calibration practices The calibration system shall be set up and maintained as follows A Standards for calibrating the measuring and test equipment shall be stored and used under appropriate environmental conditions to assure their accuracy and stability B measuring instruments and standards shall be calibrated by the contractor or a commercial facility against a higher order standard at periodic intervals not exceeding 12 months for instruments and 12 months for calibration standards Records showing the calibration traceability to the National Institute of Standards and Technology NIST shall be maintained for all measuring and test equipment C All measuring and test equipment and measuring standards shall be labeled with the following information 1 Date of calibration 2 Date of next scheduled calibration 3 Name of the technician who calibrated the equipment 10 5 D The contractor shall provide a written calibration procedure that includes as a minimum the following information for all measurement and test equipment 1 Type of equipment manufacturer model number etc 2 Measurement range 3 A
222. he dummy calibration if requested The COTR will be kept informed of the dummies condition so that replacement parts can be provided The dummies will be calibrated by the contractor according to the schedule indicated in the NCAP test procedure CALIBRATION AND TEST INSTRUMENTATION Before the contractor initiates the dummy performance calibration test program a test instrumentation calibration system must be implemented and maintained in accordance with established calibration practices The calibration system shall be set up and maintained as follows A Standards for calibrating the measuring and test equipment shall be stored and used under appropriate environmental conditions to assure their accuracy and stability B measuring instruments and standards shall be calibrated by the contractor or a commercial facility against a higher order standard at periodic intervals not exceeding 12 months for instruments and 12 months for calibration standards Records showing the calibration traceability to the National Institute of Standards and Technology NIST shall be maintained for all measuring and test equipment measuring test equipment measuring standards shall labeled with the following information 1 Date of calibration 2 Date of next scheduled calibration 3 Name of the technician who calibrated the equipment D The contractor shall provide a written calibration procedure that includes as
223. he impact probe are included in the calculation of mass and such components may not exceed 5 percent of the total weight of the test probe Minimum mass moment of inertia of 3646 kg cm 3 22 165 in yaw and pitch about the center of gravity The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It has a flat continuous and non deformable face with diameter of 152 4 0 25 mm 6 00 0 01 in and a maximum edge radius of 7 6 to 12 7 mm 0 3 to 0 5 in The impactor is a cylinder with a diameter of 152 4 152 6 mm 6 0 6 1 in and it is at least 25 mm 1 0 in long The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe The impact probe shall have a free air resonant frequency of not less than 1000 Hz FIGURE 11B PART 5720 HYBRID 5 THORAX CALIBRATION P HYSTERESIS T Sth 0 mm 0 mm 0 mm 5000 4600 N gt 4400 mi 4000 3900 N o Deflection Corridor 3000 50 58 mm gt LE 2000 i Corridor 1000 lt 2 0 Deflection Corridor 1000 18 50 mm LOAD DISPLACEMENT mm Point A Maximum Force in Deflection Corridor Point B Max Force between 18 0 mm 50 0 mm shall not exceed 4600 N FIGURE 12B B37 B38 DATA SHEET B7 TORSO FLEXION TEST 572
224. iameter cylinder weighing 11 pounds including instrumentation 572 36 b The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It has an edge radius of 0 02 inches 572 36 b The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal centerline of the cylinder 572 36 b 9 TABLE SIGN CONVENTIONS FOR PART 572 SUBPART E TEST DUMMIES C G POSSIBLE TARGET A 3 UNIAXIAL ACCELEROMETERS LOCATED AT THE C G OF THE HEAD ASSEMBLY Ay Ap A A A Gs tA 3 UNIAXIAL ACCELEROMETERS LOCATED AT THE C G OF THE CHEST ASSEMBLY RIGHT FEMUR LOAD CELL Fa LEFT FEMUR LOAD CELL F FIGURE 2A 10 SIGN CONVENTION FOR TRANSDUCER OUTPUTS BODY SEGMENT MEASURED FORCE POSITIVE OUTPUT DIRECTION NECK FX SHEAR HEAD REARWARD OR CHEST FORWARD FY SHEAR HEAD LEFTWARD CHEST RIGHTWARD FZ AXIAL HEAD UPWARD CHEST DOWNWARD MX MOMENT ROLL LEFT EAR TOWARD LEFT SHOULDER MY MOMENT PITCH CHIN TOWARD STERNUM MZ MOMENT YAW CHIN TOWARD LEFT SHOULDER FEMUR FX SHEAR FY SHEAR FZ AXIAL KNEE UPWARD UPPER FEMUR DOWNWARD KNEE RIGHTWARD UPPER FEMUR LEFTWARD KNEE FORWARD TENSION PELVIS REARWARD KNEE LEFTWARD HOLD UPPER FEMUR IN PLACE KNEE UPWARD HOLD UPPER FEMUR IN PLACE MYST MENT PT TD KNEE ROTATED CCW WHEN FACING FRONT
225. ice allow the excess webbing in the shoulder belt to be retracted by the retractive force of the retractor 516 3 5 4 APPENDIX REDUNDANT ACCELEROMETERS RECOMMENDED PRACTICE Gl APPENDIX G REDUNDANT HEAD CHEST AND FEMUR ACCELEROMETERS RECOMMENDED PRACTICE The following guideline is intended to serve as an interim measure for use in affixing the redundant accelerometers in the head chest and femurs of the Hybrid III dummies Standard procedures for obtaining redundant data are currently being developed The contractor is expected to closely follow this guideline until such standard procedures are available Contact the COTR if difficulty arises in meeting the guideline or more details are needed 1 The locations of the primary accelerometers head chest or femur as specified in the test procedure shall not be altered as a result of installing the redundant accelerometer set In addition the center of gravity C G of the head chest or femur with the redundant accelerometers installed shall stay within the allowable range as indicated in Hybrid III specifications 2 The weight increase due to installation of the redundant accelerometers in the head chest or femur shall be within the allowable weight variation specified for these body regions in the Hybrid drawing documentation 3 To simplify and facilitate the installation the following recommendations are provided A Use of SAE572 S4 accelerometers and
226. ich would affect the positioning of the P572 test dummies in the test vehicle The second 100 feet approximate of tow road shall be used for dummy stabilization At this juncture the test vehicle should have reached the desired impact velocity and should be experiencing zero acceleration The remaining 300 feet approximate of tow road will be used for test vehicle speed stabilization The width of the tow road should be approximately 8 to 14 feet and should be straight and level so that the test vehicle does not oscillate vertically in excess of 0 29 G s A photographic pit will be located in the tow road at the stationary barrier face so that structural crush and possible fluid leakage of Stoddard solvent can be photographed during the impact event The pit shall be covered using the following guidelines 1 Use a material that allows for use of pit cameras 2 The covering and its supports should simulate road strength in case the vehicle structure should come in contact with it during the NCAP test 3 The entire pit should be covered except for the area needed for the tow system to operate 4 Precautions must be taken to ensure there is no electromagnetic interference generated by the pit cover material TEST VEHICLE PREPARATION BUILDING STRUCTURE The following applies to labs with outdoor impact surfaces In order that the test vehicle can be prepared for crash testing at the head of the tow road during hot or cold weather
227. icular test C12 15 DATA SHEETS DATA SHEET C1 DUMMY DAMAGE CHECKLIST 6 YEAR OLD Dummy Serial Number Test Date Technician This check sheet is completed as part of the calibration verification Perform general cleaning Dummy Item Inspect for Comments Damaged OK Outer skin Gashes rips cracks Head Ballast secure General appearance Neck Broken or cracked rubber Upper neck bracket firmly attached to the lower neck bracket Looseness at the condyle joint Nodding blocks cracked or out of position Spine Broken or cracks in rubber Ribs Broken or bent ribs Broken or bent rib supports Damping material separated or cracked Rubber bumpers in place Chest Displacement Assembly Bent shaft Slider arm riding in track Abdomen Proper positioning Transducer leads Torn cables C13 Dummy Inspect for Comments Damaged OK Accelerometer Head mounting secure Mountings Chest mounting secure Knees Skin condition Insert do not remove Casting Limbs Normal movement and adjustment Knee Sliders Wires intact Rubber returned to at rest position Pelvis Broken Other If upon visual examination damage is apparent in any of these areas the appropriate engineer or engineering technician is to be consulted for a decision
228. ies horizontal 2 and parallel to midsagittal plane The arms are held in place by tightening the adjustment nut that holds the arm yoke to the clavicle assembly The data acquisition system including transducers must conform to the requirements of SAE Recommended Practice J211 1 MAR95 572 136 m Class 180 Impact the anterior surface of the thorax with the test probe so the longitudinal centerline of the probe is within 2 of a horizontal line in the dummy s midsagittal plane at the moment of impact 572 134 c 5 The velocity of the test probe at the time of impact 15 6 71 m s 0 12m s 572 134 b The probe is guided so there is no significant lateral vertical or rotational movement during the impact 572 134 c 6 Neither the suspension hardware suspension cables nor other attachments to the probe including the velocity vane make contact with the dummy 572 134 c 7 _ 16 Complete following table B35 Thorax Impact Results 572 134 b and 572 134 b 1 amp 2 Parameter Specification Result Test Probe Speed 6 59 m s lt speed x 6 83 m s Chest Compression 50 0 mm lt compression lt 58 0 mm Peak force between 50 0 and 58 0 mm chest compression 3900N lt peak force 4400N Peak force between 18 0 and 50 0 mm chest compression Peak force x 4600 N Internal Hysteresis 69 lt hysteresis lt 85 Time zero is defined as time of ini
229. iew camera mounted above the barrier face to document the movement of the passenger dummy during the impact event and windshield zone intrusion Filename Camera No 14 PIT FRONT High speed photographic pit camera positioned beneath the vehicle s engine compartment to record the vehicle structural crush and document any Stoddard solvent spillage Filename Camera No 15 PIT REAR High speed photographic pit camera positioned beneath the vehicle s fuel tank to document any Stoddard solvent spillage NOTE Cameras 16 and 17 see Figure 2 are optional views that may be installed in any feasible location in any NCAP test at the COTR s request It is suggested that 1f no special request is made by the COTR the Contractor install cameras 16 and 17 regardless They can be positioned inside the test vehicle over each dummy s inboard shoulder such that they may capture frontal airbag deployment In addition the outside rearview mirrors may be removed to eliminate any camera view obstructions in any NCAP test Camera view may be recorded at 500 fps if necessary 9 2 COLORING REQUIREMENTS FOR PHOTOGRAPHIC PURPOSES A Vehicle interior surfaces such as the instrument panel A post trim panels door trim panels console etc shall be painted with flat white paint The air bag indicator light on the dash shall NOT be painted so as to be visible prior to testing B Vehicle underbody components such as the floor pan frame rail members steeri
230. iming device shall monitor the velocity of the test vehicle to permit aborting the test if the vehicle s speed is outside of the specified velocity range A third timing device may be placed along the tow road at a sufficient distance from the barrier face for monitoring the velocity of the test vehicle and permitting aborting of the test if the vehicles speed is outside the velocity range specified below If the Contractor is capable of documenting the velocity recorded by this third device it may be also used as a third verification of test velocity in any test TEST BRAKE ABORT SYSTEM The laboratory shall provide an abort system capable of bringing the vehicle to a controlled stop An aborted test can be restarted only after notification is given to the COTR and dummy positioning and vehicle preparation items affected by the abort have been redone STATIC ROLLOVER DEVICE The laboratory shall provide a static rollover device used to conduct an FMVSS No 301 and or FMVSS No 305 test which must be capable of rotating the impacted test vehicle about it longitudinal axis with the axis kept horizontal to each successive increment of 90 180 and 270 at a uniform rate 90 of rotation must take place within 1 to 3 minutes 7 1 7 2 NCAP 8 GOVERNMENT FURNISHED PROPERTY TEST VEHICLES The Contractor has the responsibility of accepting NHTSA provided test vehicles The Contractor acts on NHTSA s behalf when
231. in following table and figure 2B Signature Date 16 HYBRID III PART 572 SUBPART O EXTERNAL DIMENSIONS ASSEMBLY ACTUAL DIMENSION DESCRIPTION DETAILS moe MEASUREMENT TOTAL SITTING HEIGHT Seat surface to highest point on top of the head 774 7 800 1 SHOULDER PIVOT HEIGHT Centerline of shoulder pivot bolt to the seat surface 431 8 457 2 H POINT HEIGHT Reference 81 3 86 3 H POINT LOCATION FROM BACKLINE Reference 144 8 149 8 SHOULDER PIVOT FROM Center of the shoulder clevis to the rear vertical surface of the 68 6 83 8 BACKLINE fixture a THIGH CLEARANCE Measured at the highest point on the upper femur segment 119 4 134 6 BACK OF ELBOW TO WRIST back of the elbow flesh to the wrist pivot in line with the elbow G 243 9 259 1 PIVOT and wrist pivots HEAD BACK TO BACKLINE Back of Skull cap skin to seat rear vertical surface Reference 43 2 48 2 SHOULDER TO ELBOW Measure from the highest point on top of the shoulder clevis to LENGTH the lowest part of the flesh on the elbow in line with the elbow 276 8 297 2 pivot bolt ELBOW REST HEIGHT 2 from flesh below elbow pivot bolt to seat 182 8 203 2 BUTTOCK TO KNEE The forward most part of the knee flesh to the rear vertical 520 7 546 1 LENGTH surface of the fixture POPLITEAL HEIGHT to the plane of the horizontal plane of the bottom of 355 6 376 KNEE PIVOT HEIGHT Centerline of knee pivot bolt to the horizontal plane of the 393 7 419 1 bott
232. in items 3 and 4 8 31 95 legal interp to Hogan and Hartson 6 Move the seat to the mid position 7 While maintaining the mid position move the seat to its lowest position Mark the height position For seats with adjustable seat cushions use the manufacturer s recommended seat cushion angle for determining the lowest height position __N A No cushion angle adjustment Manufacturers seat cushion angle Tested seat cushion angle 8 Visually mark the seat back angle if adjustable at the manufacturer s nominal design riding position for a 50th percentile adult male in the manner specified by the manufacturer N A No seat back angle adjustment Manufacturer s design seat back angle Tested seat back angle 9 Is the seat a bucket seat Yes go to 10 and skip 11 No go to 11 and skip 10 2 10 Bucket seats Locate and mark the longitudinal centerline of the seat cushion The intersection of the vertical longitudinal plane that passes through the SgRP and the seat cushion upper surface determines the longitudinal centerline of a bucket seat cushion 510 4 1 2 and 516 3 1 10 11 Bench seats Locate and mark the longitudinal line on the seat cushion that marks the intersection of the vertical longitudinal plane through the centerline of the steering wheel and the seat cushion upper surface S10 4 1 1 12 If adjustable set the head restraint at the full up position S8 1 3 If there are adjus
233. ing conducted The Contractor and the COTR will then be able to discuss the details of both test conduct and report content early in the test program FINAL TEST REPORT AND DELIVERABLES Contractors are required to review and proofread all Final Test Reports and related test materials before submittal to the COTR The OCWS will not act as a report quality control office for Contractors Reports containing a significant number of errors will be returned to the Contractor for correction and a hold will be placed on invoice payment for the particular test The Contractor shall upload a final version of the associated test data photos and videos high speed and real time as a zip file to the FTP site within two weeks of receiving preliminary test report corrections from the OCWS The format for its filename should be as follows lt NHTSANO gt lt Model Year gt lt Make amp Model gt lt Body gt lt NCAP gt Final zip The following is a summary of all NCAP test deliverable requirements Crash Test Deliverable Quicklook Report Data Tape Quality Control Package web photo and video requirements high speed and real time videos and photos Preliminary Test Report Final Deliverables Final Test Report photos and high speed and real time videos Procedure Section File Format amp Naming Convention pdf with filename format lt NHTSANO gt lt ModelYear gt lt Make amp Model gt lt Body gt lt NCAP
234. int where the dummy s nose meets his forehead between his eyes to a point on the windshield Use a level HZ Head to Roof Taken from the point where the dummy s nose meets his forehead between his eyes to the point on the roof directly above it Usea level CS Steering Wheel to Chest Taken from the center of the steering wheel hub to the dummy s chest Use a level CD Chest to Dash Place a tape measure on the tip of the dummy s chin and rotate five inches of it downward toward the dummy to the point of contact on the transverse center of the dummy s chest Measure from this point to the closest point on the dashboard either between the upper part of the steering wheel between the hub and the rim or measure to the dashboard placing the tape measure above the rim whichever is a shorter measurement i CD Chest to Dash 1 NCAP 36 ii CD Chest to Dash 2 6 RA Steering Wheel Rim to Abdomen Taken from the bottommost point of the steering wheel rim horizontally rearward to the dummy Use a level 7 NR Nose to Rim Taken from the tip of the dummy s nose to the closest point on the top of the steering wheel rim Also indicate the angle this line makes with respect to the horizontal the Nose to Rim Angle NA see below 8 KDL KDR Left and Right Knees to Dashboard Taken from the center of the knee pivot bolt s outer surface to the closest point forward acquired by swinging the tape measure in continually la
235. ion 12 2 added suggested data trace order updated documentation film requirements added item CC Floor Mats to section 11 1 updated Form 1 test photo list and Appendix P NCAP 1 PURPOSE AND APPLICATION The Office of Crashworthiness Standards OCWS provides Contractor laboratories with Laboratory Test Procedures as guidelines for obtaining crash test data The data are used to provide ratings that allow consumers to compare the crashworthiness of vehicles and make informed purchasing decisions In addition it provides market incentives for automobile manufacturers to produce safer vehicles The purpose of the OCWS Laboratory Test Procedure is to present a uniform testing and data recording format and to provide suggestions for the use of specific equipment and procedures If any Contractor views any part of an OCWS Laboratory Test Procedure to be in conflict with a Federal Motor Vehicle Safety Standard FMVSS or observes deficiencies in a Laboratory Test Procedure the Contractor is required to advise the Contracting Officer s Technical Representative COTR and resolve the discrepancy prior to the start of NCAP testing Every Contractor is required to submit a detailed internal test procedure to the COTR before initiating its NCAP test program The procedure must include a step by step description of the methodology to be used The Contractor s test procedure shall contain a complete listing of test equipment with make and model number
236. is not adjustable 25 Does the vehicle have a foot rest Yes go to 25 1 No go to 25 2 25 1 With the left thigh and leg in a vertical plane place the left foot on the foot rest with the heel resting on the floor pan S10 6 1 2 25 1 1 Is the left foot elevated above right foot __ Yes go to 25 2 and position the foot off the foot rest No go to 26 25 2 Check the ONLY one of the following that applies __ The left foot reaches the toeboard without adjusting the foot or leg To the extent practicable keep the left thigh and the leg in a vertical longitudinal plane S10 5 and place the foot on the toeboard skip 25 3 510 6 1 2 The left foot reaches the toeboard but contacts the brake or clutch pedal and must be rotated to avoid pedal contact To the extent practicable keep the left thigh and the leg in a vertical longitudinal plane 510 5 and place the foot on the toeboard The foot was rotated about the leg to avoid pedal contact skip 25 3 510 6 1 2 The left foot reaches the toeboard but contacts the brake or clutch pedal and the foot and leg must be rotated to avoid pedal contact To the extent practicable keep the left thigh and the leg in a vertical longitudinal plane 510 5 and place the foot on the toeboard The foot was rotated about the leg and the leg was rotated outboard about the hip the minimum distance necessary to avoid pedal contact skip 12 3 S10 6 1 2 N A the foot does not reach the toeboard go
237. it full forward For example if it rotates rotate it such that the head restraint extends as far forward as possible Mark the foremost position S16 2 10 2 amp 16 3 4 4 amp S20 1 9 6 S20 4 1 S22 42 1 522 4 3 1 824 4 3 1 526 2 3 526 3 1 2 3 Measure vertical distance from top most point of head restraint to bottom most point Locate and mark a horizontal plane through the midpoint of this distance S16 3 4 3 Vertical height of head restraint mm Mid point height mm _ 3 Place the SCRP in the full rearward mid height position and mid seat cushion angle 516 3 3 1 1 4 Fully recline seat back 516 3 3 1 2 __ N A seat back not adjustable 5 Place the dummy in the seat with the legs at an angle of 120 degrees to the thighs The calves should not be touching the seat cushion 516 3 3 1 2 6 Position the dummy in the seat such that midsagittal plane is coincident with the longitudinal seat cushion marking that was determined in item 1 19 or 1 20 S16 3 3 1 3 and 516 3 3 1 4 7 Hold down the dummy s thighs and push rearward on the upper torso to maximize the pelvic angle S16 3 3 1 5 8 Set the angle between the legs and the thighs to 120 degrees 516 3 3 1 6 9 Set the transverse distance between the centers of the front of the knees at 160 to 170 mm 6 3 to 6 7 inches Center the knee separation with respect to the longitudinal seat cushion marking that was dete
238. it requests from vehicle manufacturer s representatives and consumers to the Office of Crashworthiness Standards This service shall be included as an incidental part of the crash test program and will not result in any additional cost to the NHTSA The Contractor shall make his own arrangements with interested parties for expenses incurred beyond providing access and inspection services All inquiries by manufacturers concerning NCAP vehicle procedures data etc shall be directed to OCWS representatives GOOD HOUSEKEEPING Contractors shall maintain the entire vehicle testing area dummy calibration area test fixtures and instrumentation in a neat clean and painted condition with test instruments arranged in an orderly manner consistent with good test laboratory housekeeping practices TEST SCHEDULING AND MONITORING Tests shall be completed as required in the contract The COTR will make adjustments to the crash test schedule in cases of unusual circumstances such as inclement weather testing shall be coordinated to allow monitoring by the COTR 6 1 6 2 6 3 NCAP 4 FACILITY AND EQUIPMENT PRETEST REQUIREMENTS TOW ROAD The tow road should at least 500 feet in length and terminate at the face of the non energy absorbing barrier as shown in FIGURE 1 The first 100 feet approximate from the head of the tow road will be used to accelerate the test vehicle up to the specified velocity without exceeding 0 5g wh
239. ith standard test procedures for performing receiving inspection and performance calibration tests on the Part 572 Subpart P dummy so that repetitive and correlative test results can be obtained The following tests have been developed to establish a uniform calibration procedure for all users as the means of verifying the performance of the dummy A EXTERNAL DIMENSIONS PADI B HEAD DROP TEST 572 142 C NECK FLEXION TEST 572 143 b 1 D NECK EXTENSION TEST 572 143 b 2 E THORAX IMPACT TEST 572 144 F TORSO FLEXION 572 145 National Highway Traffic Safety Administration NHTSA contract laboratories performing NCAP testing for the Office of Crashworthiness Standards OCWS must use this laboratory procedure for the calibration of Part 572 Subpart P dummies GENERAL REQUIREMENTS The Code of Federal Regulations 49CFR Parts 571 and 572 was amended to adopt the Hybrid 3 Year Old Child Dummy as the means of determining a vehicle s conformance to the performance requirements of NCAP Each Part 572 Subpart P dummy used in an NCAP test must meet the specifications and performance criteria of Part 572 before and after each vehicle crash test in order to be an acceptable NCAP test tool The Part 572 Subpart P Hybrid III 3 Year Old Child Dummy consists of components and assemblies specified in the drawing and specifications package which is available from Reprographics Technologies 9000 Virginia Manor Beltsville MD 20705
240. ket on 527 1 552 5 REFERENCE LOCATION FOR DIMENSION Y Reference 254 0 5 1 MM above the seat surface 248 9 259 REFERENCE LOCATION T3 FOR DIMENSION Z Reference 165 1 5 1 MM above seat surface 160 0 170 2 018 H POINT 5 EXTERNAL DIMENSION MEASUREMENT DESIGNATIONS FIGURE 4D 019 EXTERNAL DIMENSIONS TEST SETUP 9999 90900 900609 yw FIGURE 5B 020 EXTERNAL DIMENSIONS TEST SETUP FIGURE 6D 021 DATA D3 HEAD DROP TEST 572 142 3 YEAR OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive head drops are necessary 1 It has been at least 2 hours since the last head drop 572 142 c 5 N A ONLY one head drop performed 2 The head assembly consists of the head 210 1000 adaptor plate ATD 6259 accelerometer mounting block SA572 S80 structural replacement of gt mass of the neck load transducer TE 107 001 head mounting washer A TD 6262 one 2 20 1 flat head cap screw 9000150 and three 3 accelerometers SA572 S4 572 142 a 4 Accelerometers and their respective mounts are smooth and clean 5 The head accelerometer mounting plate screws 10 32 x 5 8 SHCS are torqued to 10 2 Nm 6 The data acquisition system including transducers conforms to the requirements of
241. l Test Report The Contractor may expand upon data sheets if desired however the data must be presented in the order listed under the above SAMPLE TEST REPORT LAYOUT Any additional inclusions MUST be placed after the required sheets N14 REPORT AREA 3 PHOTOGRAPHS The following photographs should be included as Appendix of the final test report two photos per page A vehicle information placard identifying the test vehicle test date and NHTSA number along with an indication of whether the photo was taken pre test or post test shall clearly appear in each photograph A time date stamp on each photo is also highly recommended The following photographs shall be labeled as indicated The text in parenthesis is for clarification purposes only and need not be included If additional photographs are need to satisfy the requirements of report Appendix A including but not limited to photographs required for FMVSS 305 testing subsequent photos should be lettered and labeled appropriately For example if the laboratory would like to provide more than one photograph of the dummy cable routing configuration pre test the photographs should be labeled as follows 027 Pre test Dummy Cable Routing required photo 027a Pre test Dummy Cable Routing additional view No 001 Load Cell Location photograph of vehicle behind mock load cell wall No 002 Load Cell Wall photograph of barrier pre test No 003 Manufacturer s La
242. le Seat Cushion Height If the seat and or seat cushion height is adjustable at the test fore aft seat track position and can be adjusted so that the seat cushion angle can be at the angle used in the certification test describe the height used during certification testing and how to measure it Include any reference points and photographs Dummy Angle Used Additional Description Side Impact 5 Female Provide any other instructions for positioning the rear seat at the required test position Side MDB SEAT BACK ANGLE UPRIGHT POSITION Driver s Seat KE With the seat in the test fore aft seat track position what is the angle of the seat back when it is in the forward most locked position I FORWARD MOST LOSKED POSITIOR TEST POSITION i E 1 Dummy Angle SEAT CUSHION N EU Frontal Impact 50 v KUT Male ty INCLINOMETER Side Impact 50 Male Side Impact 5 Female LEFT SIDE VI W eo With the seat in the test fore aft seat track position what is the angle of the seat back when it is set to the test position Note For the frontal impact test and the side impact test with the 50 male dummy the seat back angle will be set to the Nominal Design Position For the side impact test with the 5 female dummy the seat back angle will be determined by the related dummy seating procedure 2 2 N55 Dummy Angle Fron
243. lean and painted condition with test instruments arranged in an orderly manner consistent with good test laboratory housekeeping practices TEST SCHEDULING AND MONITORING The Part 572 Subpart P dummies are being calibrated as test tools to be used in NCAP vehicle crash tests The schedule for these performance calibration tests must be correlated with that of the vehicle tests All testing shall be coordinated to allow monitoring by the COTR TEST DATA DISPOSITION The contractor shall make all dummy calibration data available to the COTR for review and analysis as required calibration test data for each particular Part 572 Subpart P dummy will be sent to the COTR with each test report backup data sheets strip charts recordings plots technicians notes etc shall be either sent to the COTR or destroyed at the conclusion of each delivery order purchase order etc GOVERNMENT FURNISHED PROPERTY GFP Part 572 Subpart P test dummies will be furnished to the contract laboratory by the OCWS The dummies shall be stored in a hanging position using the bracket and positioning shown in the following drawings D3 0487 1 25 4 50 1 5 1 4 50 IS THE MINIMUM DIMENSION REQUIRED JRS ARI NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION TO CLEAR THE DUMMIES SHOULDER AND ARM 12 UORT POP EG n0 J C FIGURE ID 04 PLATE
244. les AII such records shall be readily available for inspection when requested by the COTR The calibration system will need the written acceptance of the COTR before testing begins Test equipment shall receive calibration check immediately prior to and after each test This check shall be recorded by the test technician s and submitted with the final report G Anthropomorphic test devices shall be calibrated as indicated in NCAP test procedure These calibrations shall be submitted with the final report PHOTOGRAPHIC DOCUMENTATION Provide still photographs color prints properly focused for clear images no more than two 2 per 8 5 x11 sheet of post test damage resulting from the vehicle crash test DEFINITIONS PADI Procedures for Assembly Disassembly and Inspection 1 BS PRETEST REQUIREMENTS TRANSDUCER REQUIREMENTS The contractor shall provide and install the following instrumentation to the GFP dummies excluding the chest deflection transducer A HEAD The head accelerometers shall have dimensions response characteristics and sensitive mass locations specified in drawing SA572 S4 and be mounted in the head as shown in drawing 880105 000 sheet 3 of 6 572 137 c Three accelerometers shall be mounted in the head cavity to measure orthogonal accelerations Ax Ay Az at the center of gravity CG of the head assembly NECK The upper neck force transducer shall have the dimensions response
245. les located on either side of the dummy s head are equidistance within 2 mm from the impact surface 572 152 3 1 Record the right side distance Record the left side distance The angle between the lower surface plane of the neck transducer mass simulator 910420 003 and the plane of the impact surface is 90 1 degrees 572 152 c 3 11 Record the angle The impact surface is clean and dry and has a micro finish in the range of 203 2 10 mm 8 micro inches to 2032 0 10 mm 80 micro inches RMS 572 152 c 4 Record actual micro finish The impact surface is a flat horizontal steel plate 50 8 mm 2 inches thick and 610 mm 24 inches square 572 152 c 4 Record thickness Record width Record length Drop the head assembly from a height of 376 0 1 0 mm 14 8 inches 0 04 inches by a means that ensures a smooth instant release onto the impact surface 572 152 b amp 572 152 c 4 Complete the following table 572 152 b Parameter Specification Result Peak resultant acceleration 55g lt x lt 7lg Resultant versus time history curve Unimodal Oscillations after the main pulse Less than 17 of the peak resultant acceleration Lateral acceleration y axis acceleration lt 15 g Plots of the x y z and resultant acceleration data follow this sheet Signature Date E25 REAR HEAD DROP TEST SET UP SPECIFICATIONS NECK TRANSDUCER STRUCTURAL REPLACEMENT 910420 003 REF
246. libration data for each Part 572 Subpart R dummy used in the vehicle crash test shall be submitted with the final NCAP test report for the vehicle Contractors are required to PROOF READ all Final Test Reports before submittal to the COTR The OCWS will not act as a report quality control office for contractors Reports containing a significant number of errors will be returned to the contractor for correction and a hold will be placed on invoice payment for the particular test E13 15 DATA SHEETS DATA SHEET 1 DUMMY DAMAGE CHECKLIST 12 MONTH OLD Dummy Serial Number Test Date Technician This check sheet is completed as part of the calibration verification Indicate NA in the OK column for any components not applicable to this size dummy A Perform general cleaning Dummy Item Inspect for Comments Damaged OK Outer skin Gashes rips cracks Head Ballast secure General appearance Neck Spine Ribs Broken or cracked rubber Upper neck bracket firmly attached to the lower neck bracket Looseness at the condyle joint Nodding blocks cracked or out of position Broken or cracks in rubber Broken or bent ribs Broken or bent rib supports Damping material separated or cracked Rubber bumpers in place leads Chest Bent shaft Displacement Slider arm riding in Assembly track Transducer Torn cables 14
247. ll likely affect NCAP test performance Also please feel free to add additional items which are not listed if their removal is deemed acceptable Frontal NCAP test Side MDB NCAP test 16 17 18 N63 Side Pole NCAP test SPECIAL INSTRUCTIONS Please make note of any special instructions that you would like NHTSA to consider or be made aware of for the tested vehicle ex towing setup refrain from using seat belt load cells etc Frontal NCAP test Side MDB NCAP test Side Pole NCAP test SEAT LATCHING VERIFICATION PROCEDURE Describe in as much detail as possible your best practice for ensuring the proper engagement of any manual seat adjustment components into their proper seat track detents This may include but is not limited to a description of the functionality of the manual seat adjustment mechanisms and all possible indications of full engagement including visual audial and tactile methods of ensuring said engagement with tools such as a boroscope Photographs and or schematics along with suggestions of physical methods for ensuring engagement are highly suggested CRASH AVOIDANCE SYSTEMS Does this vehicle come equipped with any crash avoidance CA systems that could potentially affect frontal or side NCAP tests Please keep in mind the test conditions specific to each mode ignition in the ON position in all tests transmission in neutral for
248. llinear within 2 degrees with the longitudinal centerline of the femur load cell simulator except it is within 0 5 degrees horizontally 572 35 b 2 iv amp vi The probe is guided so there is no significant lateral vertical or rotational movement during the impact with the knee 572 35 b 2 v The data acquisition system including transducers must conform to the requirements of SAE Recommended Practice J211 1 MAR95 572 136 m Class 600 Contact the knee with the test probe at a speed between 6 8 ft s and 7 0 ft s 572 35 b Complete the following table Knee Impact Results 572 35 b 1 Parameter Specification Result Probe speed 6 8 ft s lt speed lt 7 0 ft s Peak resistance force 1060 Ib lt force lt 1300 Ib Force impactor mass x deceleration 572 35 b 1 42 12 Plots of pendulum acceleration pendulum speed and force follow this sheet Time zero is defined as the time of contact between the test probe and the knee 572 3 b 2 vii Signature Date A43 DATA SHEET 8 RIGHT KNEE IMPACT TEST 572 35 50 Male Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive knee impact tests are necessary 210 It has been least 30 minutes since last knee impact test 572 36 m __ N A ONLY one knee impact test performed The test fixture conforms to the specifications
249. load cell shall be suspended by a support such as masking tape so that the weight of the load cell does not introduce any slack into the belt system as the test vehicle travels down the tow road The tape should be strong enough to carry the load cell s weight but not strong enough to affect belt stretch or loading Normally if inch wide tape is used a tear across the tape approximately inch long at the center suspension point between the load cell and the vehicle s inner roof rail will be sufficient to ensure that an immediate break away condition will exist at the moment of barrier impact NOTE f a mounting distance from the D ring is not provided along with the vehicle setup information Form 1 contact the COTR for instructions on NCAP 33 whether or not to run the test with any shoulder belt load cells CC FLOOR MATS IL2 If the vehicle is equipped with optional all weather rubber floor mats remove them from the vehicle prior to the test If the vehicle is equipped with carpeted floor mats or if all weather floor mats are standard equipment place them in their proper locations prior to the test TEST DUMMY PREPARATION POSITIONING AND PLACEMENT Place a properly clothed and calibrated 50 percentile male in accordance with Appendix A and a properly clothed and calibrated 5 percentile female in accordance with Appendix B in the front outboard seating positions in accordance with Appendix DRIVER AND PASSENGER
250. lots of pendulum acceleration pendulum velocity neck y axis moment and neck rotation about the y axis follow this sheet Signature Date E30 PENDULUM SPECIFICATIONS 101 6 mm t ini STRUCTURAL STEEL TUBE boo mm 4 8 mm 10 1875 in p 31 8 mm PIVOT 50 8 mm 2 in DIA 11 25 in INERTIAL PROPERTIES OF PENDULUM MOUNTING PLATE AND MOUNTING HARDWARE WITHOUT TEST SPECIMEN T PENDULUM X 7 ACCELEROMETER CENTERLINE WEIGHT 29 57 165 21 156 198 1 mm MOMENT OF INERTIA 33 2 kg m roy 8 294 in Ib sec ABOUT PIVOT AXIS P 7 4 8 mm GE 188 in mm 38 1 mm 8 28 mm f 7 F 11 5 in 132 6m3 A i f i ON 886 2 mm 188 6 mm CG OF PENDULUM SES 9225 in 7 75 in APPARATUS WITHOUT 7 Eu 463 6 NE RADIOS HEXCEL 28 8 kg m zw 1 8 1b ft REF ACCELEROMETER BEFORE TESTING RECRUSH THE HONEYCOMB w MATFRIAL WITH THE PENDULUM TO ASSURE THAT 90 TO 100 OF THE HONEYCOMB SURFACE 15 CONTACTING THE PENDULUM STRIKER PLATE 4 ft 38 1 mm REF 1 5 in MOUNTING PLATE PENDULUM STRIKER PLATE SHARP EDGES 76 2 x 152 4 x 9 5 mm 3 x 6 x 3 8 in FIGURE 7E E31 NECK FLEXION TEST SET UP SPECIFICATIONS PENDULUM REF FIG 22 SUBPART E FLIGHT ADAPTER ASSEMBLY NECK ASSEMBLY TE300 160 REF 921022 041 REF PLANE D LOAD CELL
251. lowing title frames A The following 35 mph frontal barrier impact test was conducted under contract with the National Highway Traffic Safety Administration by name and location of test laboratory 35 MPH FRONTAL BARRIER IMPACT TEST TEST VEHICLE MODEL YEAR MAKE AND MODEL NHTSA No CXXXXX DATE OF IMPACT EVENT CONTRACT NO DTNH22 0X X XXXXX B The ending frame shall state THE END DOCUMENTATION VIDEO RECORDING AND EDITING The video shall be recorded and edited in the following sequence Title Bus 1 Pre test Coverage at barrier a b side of vehicle from front to of vehicle Right side of vehicle pan from front to rear of vehicle View of gas cap being removed and correctly replaced i Show electric charging plug if no gas cap exists Left side view of vehicle interior and driver dummy with vehicle door open Right side view of vehicle interior and passenger dummy with vehicle door open Frontal view looking through windshield at both dummies Cycling of driver airbag indicator light Cycling of passenger airbag indicator light Door closings C Real Time Pan Coverage a Speed trap primary and redundant footage D Post test Coverage a o Left side of vehicle pan from front to rear of vehicle including footage of vehicle s front end damage Driver dummy post test positioning close up with door closed Right side of vehicle pan from fron
252. lues to three decimal places For data tape Entree reporting purposes the Contractor should follow the conventions specified in the Data Tape Reference Guide see next item Software programs that can calculate various NCAP related injury measures and digitally filter the data collected from NCAP tests are also available on the NHTSA web site at http www nhtsa gov Research Databases and Software Signal Analysis Software for Windows Any questions pertaining to this software should be directed to the following organization U S Dept of Transportation NHTSA NVS 300 W46 319 1200 New Jersey Ave SE Washington DC 20590 ATTN Signal Analysis Software Tools All reports to NHTSA s technical support should receive a response within two 2 business days The COTR should be contacted if a timely response 15 not received RECOMMENDED DATA TRACE ORDER To ensure uniformity in data tape formatting the following Entr e curve order CURNO is required The exact wording in the provided Instrumentation Comments INSCOM is optional however the sentiment implied should be reflected in data tapes submitted DRIVER DATA TRACES INSCOM DRIVER HEAD X PRIMARY DRIVER HEAD Y PRIMARY DRIVER HEAD Z PRIMARY DRIVER HEAD X REDUNDANT DRIVER HEAD Y REDUNDANT DRIVER HEAD Z REDUNDANT DRIVER NECK X FORCE DRIVER NECK Y FORCE DRIVER NECK Z FORCE DRIVER NECK X MOMENT DRIVER NECK Y MOMENT DRIVER NECK Z MOMENT DRIVER
253. m s AV 2 3 m s AV with respect 20ms 3 4 m s lt AV 42 m s to impact speed 25ms 4 3 m s lt lt 5 2 m s Plane D Rotation Peak moment 36 Nm lt moment lt 45 Nm during _ degrees following rotation range 75 lt angle lt 86 Positive Moment Decay Time to decay to 5Nm Flexion 60 ms lt time lt 80ms Moment about the occipital condyle M 0 005842 m x Fy 572 153 6 1 Gii My Moment in Nm measured by the transducer Force in N measured by the transducer Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material 572 153 c 4 1 15 Plots of pendulum acceleration pendulum velocity neck y axis moment and neck rotation about the y axis follow this sheet Signature Date 28 DATA SHEET NECK EXTENSION TEST 572 153 12 MONTH OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive flexion tests are necessary 1 It has been at least 30 minutes since the last neck test 572 155 m __ N A this is the first neck test performed __2 components required for the neck tests include the neck assembly 921022 041 and headform TE 3200 160 572 153 a __3 The assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F a
254. mance of the dummy A EXTERNAL DIMENSIONS B HEAD DROP TEST 572 32 C NECK FLEXION TEST 572 33 D NECK EXTENSION TEST 572 33 E THORAX IMPACT TEST 572 34 F FEMUR IMPACT TESTS 572 35 G HIP JOINT FEMUR FLEXION 572 35 This laboratory procedure for the calibration of Part 572 Subpart E dummies must be used by National Highway Traffic Safety Administration NHTSA contract laboratories performing NCAP testing for the Office of Crashworthiness Standards OCWS GENERAL REQUIREMENTS The Code of Federal Regulations 49CFR Parts 571 and 572 was amended to adopt the Hybrid III 50th Percentile Dummy as the means of determining a vehicle s conformance to the performance requirements of FMVSS 208 This same dummy is used for NCAP testing Each Part 572 Subpart E dummy used in an NCAP test must meet the specifications and performance criteria of Part 572 before and after each vehicle test in order to be an acceptable test tool The Part 572 Subpart E Hybrid III 50th Percentile Dummy consists of components and assemblies specified in the drawing and specifications package which is available from Reprographics Technologies 9000 Virginia Manor Beltsville MD 20705 telephone 301 419 5069 SECURITY NHTSA Part 572 Subpart E test dummies delivered to the contract laboratory as Government Furnished Property GFP will be stored in a safe and secure area such as the dummy calibration laboratory The co
255. mes the frequency range of the applicable channel class 572 137 0 TRANSDUCER SIGN CONVENTION The sign convention for outputs of transducers mounted within the dummy that measure head and chest accelerations chest deflection and femur loads are located in Figure 1B For other transducers see SAE J1733DEC94 572 137 n TRANSDUCER OUTPUT FILTERING The outputs of acceleration and force sensing devices installed in the dummy and in the test apparatus specified by this part are recorded with individual data channels Each data channel will be comprised of a sensor signal conditioner data acquisition device and all interconnecting cables and must conform to the requirements of SAE Recommended Practice J211 1 MAR95 Instrumentation for Impact Test with channel classes as follows 572 137 m 1 Head acceleration Class 1000 572 137 m 1 2 Neck force Class 1000 572 137 m 2 1 except use Class 600 for calculation of neck moment about the occipital condyle 3 Neck moment Class 600 572 137 m 2 11 4 Neck pendulum acceleration Class 180 572 137 m 2 111 5 Neck rotation transducers Class 60 572 137 m 2 1v 6 Thorax and thorax pendulum Class 180 572 137 m 3 11 acceleration 7 Thorax deflection Class 600 572 137 m 3 111 8 Knee pendulum acceleration Class 600 572 137 m 6 9 Femur force Class 600 572 137 m 6 filter classes should be of the phaseless type to be compatible with the
256. mical properties of Type 1 solvent or cleaning fluid Table 1 ASTM Standard D484 71 Standard Specifications for Hydrocarbon Dry cleaning Solvents Fill the tank to 93 percent 196 of usable capacity Crank the engine to fill the fuel delivery system with Stoddard solvent Drain transmission fluid engine coolant motor oil and windshield washer fluid from the test vehicle so that Stoddard solvent leakage from the fuel system will be evident Remove RCLW from the cargo area Load the vehicle with the appropriate dummies if not already present necessary onboard test equipment including all instrumentation boxes cameras lighting etc Secure the equipment in the load carrying area and distribute it as nearly possible to obtain the proportion of axle weight indicated by the gross axle weight ratings and center it over the longitudinal centerline of the vehicle Calculate the Target Vehicle Test Weight TVTW range as follows Calculated Weight As Delivered UVW RCLW Total Weight of Dummies Maximum Test Vehicle Target Weight TVTW Calculated Weight 4 5 Minimum Test Vehicle Target Weight TVTW Calculated Weight 9 kg The As Tested weight should fall as follows TVTW 9 0kg lt As Tested weight lt TVTW 4 5kg Record the vehicle weight at each wheel Verify that the As Tested weight is within the range specified in 7 If necessary to achieve the As Tested weight adjust the weight
257. mm 3 x 6 x 3 8 in FIGURE 6C C29 NECK FLEXION TEST SET UP SPECIFICATIONS PENDULUM CENTERLINE NECK FLEXION PENDULUM STANDARD 49 CFR 572 33 FIG 22 NECK ADAPTER DIRECTION OF BRACKET PENDULUM E TE 2208 001 REF FLIGHT POSTERIOR BIB SIMULA TOR ATTACIIMENT TE 127 1025 REF BOT T CENTERI TNE ASS Y PART 29001265 SCREW 127 1015 10 24 x 7 16 NECK BRACKET ASS Y 127 8221 D PLANE REF FIG PERPENDICULAR PENDULUM CENTERLINE 43 PIVOT PIN 7805 1 339 6 15 UPPER LOAD SA572 511 HEAD COMPLETE 127 1000 HEAD ACCELEROMETER ASS Y 127 1330 NOTE PENDULUM SHOWN IN VERTICAL ORIENTATION FIGURE 7C C30 NECK EXTENSION TEST SET UP SPECIFICATIONS PENDULUM CENTERLINE NI 26 1 mm 1 028 in DIRECTION OF NECK EXTENSION PENDULUM STANDARD 49 8 572 33 116 22 PENDULUM FLIGHT NECK ADAPTER POSTERIOR BRACKET ATTACIIMENT TE 2208 001 RET BOLT CENTERLINE PART 19001265 SCREW BIB SIMULATOR SIICS 10 24 x 7 16 VE 127 1025 BRACKET ASS Y 127 8221 NECK ASS Y PIVOT PIN 127 1015 78051 339 6 AXIS UPPER NECK LOAD CELL SA572 811 D PLANE REF FIC ND PERPENDICULAR TO PENDULUM CENTERLINE 12 127 1000 NOTE _ WITII ACCELEROMETER PENDULUM SIIOWN IN VERTICAL ORIENTATION ASS Y 127 1550 FIGURE 8 C31 DATA SHEET C6
258. mmy s midsagittal plane with the bottoms horizontal and parallel to the seating surface Position the upper arms downward vertically so the centerline between the shoulders and elbow pivots is parallel to the rear vertical surface of the fixture E 6 14 17 Position lower arms horizontally so centerline between elbow wrist pivots 15 parallel to the seat surface Record the dimensions listed in the following table except for dimension Y and Z reference figure Install the abdominal insert and chest Jacket Reposition the dummy on the test fixture The head need not be level as previously specified Mark the locations AA and BB and record the dimensions Y and Z as specified in table and figure Signature Date 18 HYBRID III PART 572 SUBPART EXTERNAL DIMENSIONS ASSEMBLY ACTUAL DIMENSION DESCRIPTION DETAILS DIMENSION MEASUREMENT inches TOTAL SITTING HEIGHT Seat surface to highest point on top of the head 34 6 35 0 5 SHOULDER PIVOT HEIGHT Centerline of shoulder pivot bolt to the seat surface 19 9 20 5 H POINT LOCATION FROM Referen BACKLINE Center of the shoulder clevis to rear vertical surface of E SHOULDER PIVOT FROM BACKLINE fixture THIGH CLEARANCE Measured at the highest point on the upper femur segment OF ELBOW TO WRIST back of the elbow flesh to the wrist pivot in line with the elbow 11 4 12 0 PIVOT and wrist pi
259. mprised of a sensor signal conditioner data acquisition device and all interconnecting cables and must conform to the requirements of SAE Recommended Practice J211 1 MAR95 Instrumentation for Impact Test with channel classes as follows 572 155 1 1 Head acceleration Class 1000 572 155 1 1 2 Neck force Class 1000 572 155 1 2 1 3 Neck moment Class 600 572 155 1 2 1 4 Neck pendulum acceleration Class 180 572 155 1 2 11 5 Neck rotation transducers Class 60 572 155 1 2 6 Thorax spine acceleration Class 180 572 155 1 3 1 7 Thorax pendulum Class 180 572 155 1 3 11 8 acceleration filter classes should be of the phaseless type to be compatible with the time dependent test parameters 11 3 THORAX IMPACTOR PROBE 572 155 a A B The test probe for thoracic impacts shall be of rigid metallic construction concentric about its longitudinal axis It shall have a mass of 2 86 0 02 kg 6 3 0 05 Ibs 1 3 of the weight of the suspension cables and any attachments to the impact probe must be included in 8 calculation of mass and such components may not exceed 5 percent of total weight of the test probe It shall have a minimum mass moment of inertia of 164 kg cm 0 145 Ibs in sec in yaw and pitch about the center of gravity The impacting end of the probe is perpendicular to and concentric with the longitudinal axis The face has a diameter of 101 6 0 25 mm
260. must have a flat continuous and non deformable face with a diameter of 50 8 0 2 mm 2 00 0 01 in and a maximum edge radius of 12 7 mm 0 5 in The impactor is a cylinder with a diameter of 53 3 mm 2 1 in and it is at least 25 4 mm 1 0 in long The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe The impact probe shall have a free air resonant frequency of not less than 1000 Hz in the direction of the longitudinal direction of the impactor SIGN CONVENTION FOR PART 572 TEST DUMMIES POSSIBLE A 3 UNIAXIAL ACCELEROMETERS LOCATED AT THE C G OF THE HEAD ASSEMBLY A Ap 5 2 2 Gs 3 UNIAXIAL ACCELEROMETERS LOCATED AT THE C G OF THE CHEST ASSEMBLY RIGHT FEMUR LOAD CELL Fa FIGURE 3D C G TARGET LEFT FEMUR LOAD CELL 010 TABLE 1D SIGN CONVENTION FOR HYBRID III TRANSDUCER OUTPUTS BODY SEGMENT MEASURED FORCE POSITIVE OUTPUT DIRECTION NECK FX SHEAR HEAD REARWARD OR CHEST FORWARD FY SHEAR HEAD LEFTWARD CHEST RIGHTWARD FZ AXIAL HEAD UPWARD CHEST DOWNWARD MX MOMENT ROLL LEFT EAR TOWARD LEFT SHOULDER MY MOMENT PITCH CHIN TOWARD STERNUM MZ MOMENT YAW CHIN TOWARD LEFT SHOULDER FEMUR FX SHEAR FY SHEAR FZ AXIAL KNEE UPWARD UPPER FEMUR DOWNWARD KNEE RIGHTWARD UPPER FEMUR LEFTWARD KNEE FORWARD TENSION PELVIS REARWA
261. n be found in the R amp D section of the NHTSA website at www nhtsa dot gov Driver Head X Acceleration Redundant Driver Head Y Acceleration Redundant Driver Head Z Acceleration Redundant Driver Upper Neck Force Y Driver Upper Neck Moment X Driver Upper Neck Moment Z Driver Chest X Acceleration Redundant Driver Chest Y Acceleration Redundant Driver Chest Z Acceleration Redundant Driver Pelvis X Driver Pelvis Y Driver Pelvis Z Driver Left Femur Redundant Driver Right Femur Redundant Driver Left Upper Tibia Moment X Driver Left Upper Tibia Moment Y Driver Left Upper Tibia Force Z Driver Left Lower Tibia Moment X Driver Left Lower Tibia Moment Y Driver Left Lower Tibia Force Z Driver Right Upper Tibia Moment X Driver Right Upper Tibia Moment Y Driver Right Upper Tibia Force Z Driver Right Lower Tibia Moment X Driver Right Lower Tibia Moment Y Driver Right Lower Tibia Force Z Driver Left Foot Fore Z Driver Left Foot Aft X Driver Left Foot Aft Z Driver Right Foot Fore Z Driver Right Foot Aft X Driver Right Foot Aft Z Driver Shoulder Belt Force Driver Lap Belt Force Passenger Head X Acceleration Redundant Passenger Head Y Acceleration Redundant Passenger Head Z Acceleration Redundant Passenger Upper Neck Force X Passenger Upper Neck Force Z Passenger Upper Neck Moment Y Passenger Chest X Acceleration Redundant Passenger Chest Y Acceleration Redundant Passenger Chest Z Acceleration Redundant Passenger Pelvis X Pass
262. n the day that the test is scheduled and the representatives must be escorted by NHTSA and or Contractor personnel Test vehicle inspection by the vehicle manufacturer s representative s shall be limited to 30 minutes prior to the start of vehicle impact test Post test inspection shall be limited to hour after Contractor personnel have completed their test tasks NOTE No vehicle parts should be tampered with or removed from the vehicle without the consent of the COTR Individual data plots cannot be viewed by manufacturer representatives until they are reviewed by NHTSA personnel and granted express permission by the COTR Photographs and video of the test vehicle associated test equipment and test event shall be allowed However test personnel shall not be included in any photographic coverage and videos of vehicle preparation must be approved by OCWS The Contractor s personnel shall not respond to any questions from the manufacturer s representatives regarding NCAP questions shall be referred to the COTR an OCWS representative present at the test site or to OCWS The Contractor shall permit public access to and inspection of the test vehicles and related data during the times specified by the NHTSA COTR NHTSA shall advise interested parties that such access and inspection shall be limited to a specified day and hours and require prior approval from the Office of Crashworthiness Standards The Contractor shall refer all vis
263. nd at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to a test 572 153 1 Record maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity __4 Visually inspect neck assembly for cracks cuts and separation of the rubber from the metal segments Note If the damage resulted from the vehicle crash test the damaged area Is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions __6 Torque the jam nut 9001336 on the neck cable ATD 6206 between 0 2 Nm and 0 3 Nm 572 153 c 2 7 data acquisition system including transducers conforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 155 1 8 The test fixture pendulum conforms to the specifications in Figure 7E 9 head neck assembly is mounted on the pendulum so the midsagittal plane of the headform is vertical and coincides with the plane of motion of the pendulum as shown in Figure 9E for the flexion test 572 153 c 3 10 Install the transducers or other devices for measuring the D plane rotation with respect to the pendulum longitudinal centerline Note Plane D is the top horizontal surface of the neck load cell These measurement devices should be designed to minimize their influence upon the performance of the head neck assembly and not i
264. nd must conform to the requirements of SAE Recommended Practice 1211 1 MAR95 Instrumentation for Impact Test with channel classes as follows 572 36 1 1 Head acceleration Class 1000 572 36 1 1 2 Neck force Class 1000 572 36 1 2 For calculation of the moment about the occipital condyle use filter class 600 for the neck force 3 Neck moments Class 600 572 36 1 3 4 Neck pendulum acceleration Class 60 572 36 1 4 5 Neck rotation transducers Class 60 6 Thorax and thorax pendulum acceleration Class 180 572 36 1 5 7 Thorax deflection Class 180 572 36 1 6 8 Knee pendulum acceleration Class 600 572 36 1 7 9 Femur force Class 600 572 36 1 8 10 Hip flexion Class 60 filter classes should be of the phaseless type to be compatible with the time dependent test parameters 13 1 4 A8 THORAX IMPACTOR PROBE 572 36 a A B C The test probe for thoracic impacts is a 6 inch diameter cylinder weighing 51 5 pounds 572 36 a The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It has an edge radius of 0 5 inches 572 36 a The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal centerline of the cylinder 572 36 a KNEE IMPACTOR PROBE A B The test probe for thoracic impacts is a 3 inch d
265. nduce neck torsion 572 153 3 11 11 Plane D is perpendicular 1 degree to centerline of the pendulum 29 _ 12 Set the instrumentation so that moment and rotation are defined to be zero when longitudinal centerline of the neck and pendulum are parallel 572 153 c 3 1 13 Release the pendulum and allow it to fall freely from a height to achieve an impact speed of 2 4 m s to 2 6 m s as measured at the center of the pendulum accelerometer at the instant of contact with the honeycomb 572 153 c 4 _ 14 Complete the following table Neck Extension Results 572 143 b 1 amp 572 153 c 4 ii Parameter Specification Result Pendulum impact speed 2 4 m s speed lt 2 6 m s Pendulum 6 ms 0 8 m s AV lt 1 2 m s AV with respect 10ms_ 1 5 m s lt AV lt 2 1 m s to impact speed 14ms_ 22 lt AV lt 2 9 m s Plane D Rotation Peak moment _ Nm 2 12 Nm lt moment lt 23 Nm during the _ degrees following rotation range 80 lt angle lt 92 Negative Moment Decay Time to decay to 5Nm Extension 76 ms time lt 90ms Moment about the occipital condyle M 0 005842 m x Fx 572 153 6 Q2 Gii My Moment in Nm measured by the transducer Force in N measured by the transducer Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material 572 153 c 4 1 15 P
266. near with the longitudinal centerline of the femur 572 136 c 3 8 probe is guided so there is no significant lateral vertical or rotational movement during the impact with the knee 572 136 c 4 9 data acquisition system including transducers must conform to the requirements of SAE Recommended Practice J211 1 MAR95 572 136 m Class 600 10 Contact the knee with the test probe at a speed between 2 07 m s and 2 13 m s 572 136 5 Neither the suspension hardware suspension cables nor other attachments to the probe including the velocity vane make contact with the dummy 572 136 c 6 44 11 Complete following table Knee Impact Results 572 136 b 1 and 572 136 c 5 Parameter Specification Result Probe speed 2 07 m s lt speed lt 2 13 m s Peak resistance force 3450 N lt force lt 4060 N Force impactor mass x deceleration 572 136 b 2 12 Plots of acceleration versus time and force versus time follow this sheet Signature Date 45 KNEE IMPACT TEST SETUP SPECIFICATIONS MOUNTING BOLTS TORQUE IMPACT PROBE SUPPORT CABLES A TO 407 Niy 34 lb ADJUST KNEE PIVOT Lu A WINTTO 1 2 8 PRIOR EACH TEST RIGID FIXTURE Z a ACCELEROMETER MOUNTED WITH V SENSITIVE AXIS IN LINE WITH CENTERLINE OF TEST PROBE LONGITUDINAL AXIS M TEST PROBE CENTERLINE HORIZONTAL 22 k IMPACT PROBE W
267. nforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 155 1 5 The head assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 1090 to 7096 for a period of at least four 4 hours prior to a test 572 152 c 1 Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity 6 Visually inspect the head skin for cracks cuts abrasions etc Repair or replace the head if the damaged area is more than superficial Note If the damage resulted from the vehicle crash test in which the dummy was an occupant the damaged area is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions 7 Clean the impact surface of the skin and the impact surface of the fixture with isopropyl alcohol trichloroethane or equivalent prior to the test 572 152 c 2 210 S m M 14 215 24 Suspend and orient head assembly as shown in Figure 6E The lowest point back of the head is 376 0 1 0 mm 14 8 0 04 inch from the impact surface 572 152 c 3 11 Record the actual distance NOTE The masses of the suspension device and the accelerometer cables are to be kept as lightweight as possible to minimize their effect on the test results The 3 3 mm 0 13 inch diameter ho
268. ng 93 NCAP 17 mechanism suspension components engine oil pan and all fuel system components shall be painted with different colored paint pink green blue orange etc Parts of the anthropomorphic testing devices shall be coated with colored chalk water solutions to show contact points with the vehicle s interior with their own components such as head to knee contact and with each other The chalk water solution shall be applied after final dummy positioning CHALK COLORS TO BE USED ON TEST DUMMIES DUMMY PART DRIVER PASSENGER Nose Red Yellow Lips Red Yellow Face Blue Red Top of Head Yellow Blue Back of Head Red Yellow Left Knee Red Yellow Right Knee Blue Blue po 208 uses Lower Wheel Red N A NOTE Face chalk should extend below the chin D The driver dummy and passenger dummy clothes shall be contrasting colors so that the motion of each dummy can be identified during video analysis Tires and wheels should painted with two white perpendicular lines to reveal tire motion VEHICLE AND DUMMY PHOTOGRAPHIC COVERAGE REAL TIME A real time camera 24 30 fps shall be used to document the pre test and post test condition of the test vehicle in addition to the pre test and post test positions of the test dummies including but not limited to the placement of the lap and shoulder belts The positions of the belt load cells shall be documente
269. nstall the abdominal insert and chest jacket Reposition the dummy on the test fixture The head need not be level as previously specified Mark the locations AA and BB and record the dimensions Y Z as specified in following table and figure 2C Signature Date C16 HYBRID III PART 572 SUBPART N EXTERNAL DIMENSIONS rs DESCRIPTION DETAILS ASSEMBLY DIMENSION mm ACTUAL MEASUREMENT 622 3 647 7 348 0 363 2 TOTAL SITTING HEIGHT Seat surface to highest point on top of the head SHOULDER PIVOT HEIGHT Centerline of shoulder pivot bolt to the seat surface H POINT HEIGHT Reference H POINT LOCATION FROM Referen BACKLINE idi SHOULDER PIVOT FROM Center of the shoulder clevis to the rear vertical surface of the BACKLINE fixture THIGH CLEARANCE Measured at the highest point on the upper femur segment G BACK OF ELBOW TO back of the elbow flesh to the wrist pivot in line with the WRIST PIVOT elbow and wrist pivots 88 9 99 1 53 3 63 5 88 9 104 1 182 9 198 1 HEAD BACK TO BACKLINE Back of Skull cap skin to seat rear vertical surface Reference SHOULDER TO ELBOW Measure from the highest point on top of the broad upper LENGTH surface of clavicle link below the collar ot the lowest part of the flesh of the elbow in line with the elbow pivot bolt ELBOW REST HEIGHT from flesh below the elbow to seat BUTTOCK TO KNEE The forward most part of the knee fles
270. ntation calibration system must be implemented and maintained in accordance with established calibration practices The calibration system shall be set up and maintained as follows A Standards for calibrating the measuring and test equipment shall be stored and used under appropriate environmental conditions to assure their accuracy and stability B measuring instruments and standards shall be calibrated by the contractor or a commercial facility against a higher order standard at periodic intervals not exceeding 12 months for instruments and 12 months for calibration standards Records showing the calibration traceability to the National Institute of Standards and Technology NIST shall be maintained for all measuring and test equipment C All measuring and test equipment and measuring standards shall be labeled with the following information 1 Date of calibration 2 Date of next scheduled calibration 3 Name of the technician who calibrated the equipment D The contractor shall provide a written calibration procedure that includes as a minimum the following information for all measurement and test equipment 1 Type of equipment manufacturer model number etc 2 Measurement range 3 Accuracy 4 Calibration interval 10 11 E6 5 Type of standard used to calibrate the equipment calibration traceability of the standard must be evident 6 The actual procedures and forms used to perform calibrations
271. nted in the leg as shown in drawing 127 0000 sheet 3 The femur transducers are not required for calibration of the dummy but are required for FMVSS 208 testing 572 137 TEST FIXTURE The neck pendulum thorax and knee probe accelerometers shall have the dimensions and characteristics of drawing SA572 S4 C6 1 2 OTHER TRANSDUCER CONDITIONS A TRANSDUCER MOUNTS The mountings for sensing devices shall have no resonance frequency less than 3 times the frequency range of the applicable channel class 572 127 m TRANSDUCER SIGN CONVENTION The sign convention for outputs of transducers mounted within the dummy that measure head and chest accelerations chest deflection and femur loads are located in Figure 1C For other transducers see SAE J1733DEC94 572 127 1 TRANSDUCER OUTPUT FILTERING The outputs of acceleration and force sensing devices installed in the dummy and in the test apparatus specified by this part are recorded with individual data channels Each data channel will be comprised of a sensor signal conditioner data acquisition device and all interconnecting cables and must conform to the requirements of SAE Recommended Practice J211 1 MAR95 Instrumentation for Impact Test with channel classes as follows 572 127 k 1 Head acceleration Class 1000 572 127 1 2 Neck force Class 1000 572 127 k 2 i 3 Neck pendulum acceleration Class 180 572 127 k 2 11 4 Neck moment transducers Class 600
272. nterconnecting cables and must conform to the requirements of SAE Recommended Practice J211 1 MAR95 Instrumentation for Impact Test with channel classes as follows 572 146 1 1 Head acceleration Class 1000 572 146 1 1 2 Neck force Class 1000 572 146 0 2 3 Neck pendulum acceleration Class 180 572 146 1 2 111 4 Neck moment Class 600 572 146 1 2 1 5 Neck potentiometer Class 60 572 146 1 2 iv 6 Thorax spine acceleration Class 180 572 146 1 3 1i 7 Thorax pendulum Class 180 572 146 1 3 11 acceleration 8 Sternum deflection Class 600 572 146 D 3 11 9 Lumbar torso flexion Class 60 572 146 D 4 11 filter classes should be of the phaseless type to be compatible with the time dependent test parameters 08 11 3 THORAX IMPACTOR PROBE 572 146 A B The test probe for thoracic impacts shall be of rigid metallic construction concentric in shape and symmetric about is longitudinal axis It shall have a mass of 1 70 0 01 kg 3 75 0 02 Ibs 1 3 of the weight of the suspension cables and their attachments to the impact probe must be included in the calculation of mass and such components may not exceed 5 percent of the total weight of the test probe It shall have a minimum mass moment of inertia of 283 kg cm 0 25 Ibs in sec in yaw and pitch about the center of gravity The impacting end of the probe is perpendicular to and concentric with the longitudinal axis It
273. nterior surfaces dimensions shall be recorded on a separate data sheet The dummy calibration procedures are attached as Appendices A and B The calibration data for each dummy used in a vehicle barrier impact test shall be submitted in the preliminary and final test reports Dummies shall be calibrated before and after every NCAP test Each calibration should be available electronically in ASCII format to the COTR if requested The post test calibration obtained after the previous test can be used as the pre test calibration for a subsequent test as long as the dummy will be used in a frontal test within 8 weeks of that calibration In the event that a body region exceeds the performance standards required by FMVSS 208 that region on the ATD must be recalibrated The calibrations and calibration check shall be submitted with the final report All electronic data collected for all dummy calibrations must be saved and retained up to five years from the test date Dummy positioning procedures are detailed in Appendix F Manufacturer s representatives will be afforded the opportunity to take measurements of the dummies positions after the dummy positioning procedures are complete Any deviation from this procedure must be approved by the COTR It is recommended that dummies are rotated from one test to another For example if two 5 female dummies and two 50 male dummies have been furnished to the Contractor for NCAP testing the driver and
274. ntractor is financially responsible for any acts of theft and or vandalism which occur during the storage of GFP Any security problems shall be reported by telephone to the Industrial Property Manager IPM Office of Contracts and Procurement within two working days after the incident A letter containing specific details of the security problem will be sent to the IPM with copy to the COTR within 48 hours The contractor 15 responsible for maintaining the NCAP test dummies in good working order and shall protect and segregate the data that evolves from conducting Part 572 Subpart E dummy calibration tests before and after each vehicle crash usage No information concerning the Part 572E dummy calibration data shall be released to anyone except the COTR unless specifically authorized by the COTR or the COTR s Branch or Division Chief NOTE No individuals other than contractor personnel directly involved in the dummy calibration test program shall be allowed to witness dummy calibration tests unless specifically authorized by the COTR GOOD HOUSEKEEPING Contractors shall maintain the entire dummy calibration laboratory test fixtures and instrumentation in a neat clean and painted condition with test instruments arranged in an orderly manner consistent with good test laboratory housekeeping practices TEST SCHEDULING AND MONITORING The Part 572 Subpart E dummies are being calibrated as test tools to be used in a vehicle test
275. nuing 572 135 c 3 11 10 Remove all external support that was implemented in 9 above and wait 2 minutes 572 145 c 4 s _12 14 15 16 LUE 18 D37 Measure the initial orientation angle of the upper torso reference plane of the seated unsupported dummy 572 145 4 Record reference plane angle max allowed 15 Attach the pull cable and the load cell while maintaining the initial torso orientation 572 145 c 5 Apply a tension force in the midsagittal plane to the pull cable at any upper torso deflection rate between 0 5 and 1 5 per second until the torso reference plane reaches 45 0 5 of flexion relative to the vertical transverse plane 572 145 c 5 Maintain angle reference plane at 45 0 5 of flexion for 10 seconds and record the highest applied force during this period 572 145 c 6 As quickly as possible release the force applied to the attachment bracket 572 145 c 8 3 to 4 minutes after the release of the force measure the angle reference plane 572 145 c 8 Complete the following table Torso Flexion Results 572 145 b 1 amp 2 572 145 c 4 572 145 c 5 Parameter Specification Result Initial ref plane angle Angle lt 15 Torso rotation rate 0 5 s rate lt 1 5 s Force at 45 0 5 130 N lt force lt 180 N Final ref plane angle Initial ref plane angle 10 A plot of the force versu
276. o DINHXX XX D XXXXX The purpose of this test was to obtain vehicle crashworthiness and occupant restraint system performance data for consumer information purposes The Speed km h frontal barrier impact test was conducted in accordance with the Office of Crashworthiness Standards Frontal NCAP Laboratory Test Procedure SUMMARY A load cell barrier consisting of 36 load cells was impacted by a Year Make Model BodyStyle at a velocity of Speed km h The test was performed at XXX Engineering on Date Pre and post test photographs of the vehicle and dummies can be found in Appendix A One real time camera and 16 high speed cameras were used to document the frontal barrier impact event Camera locations and other pertinent camera information can be found in this report One Part 572E 50th percentile male anthropomorphic test device ATD was placed in the driver seating position and one Part 5720 5 percentile female ATD was placed in the right front passenger according to dummy placement instructions specified in the Frontal NCAP Laboratory Test Procedure N12 Both ATDs were fully instrumented with head chest and pelvis tri axial accelerometers chest displacement potentiometers upper neck transducers right left femur load cells and lower leg instrumentation Seat belt load cells were also on the driver s and passenger s lap and shoulder belts to measure dummy torso and pelvic section loading
277. o the first point it hits on the door In the case of a Hybrid III dummy measure from the bolt on the outer biceps When a SID is used make the measurement from the center of the bottom of the arm segment where it meets the dummy s torso HD H point to Door taken from the H point on the dummy to the closest point on the door Use a level HR Head to Side Header measure the shortest distance from the point where the dummy s nose meets his forehead between his eyes to the side edge of the header just above the window frame directly adjacent to the dummy SHY Striker to H point Taken from a rod rigidly connected to the forward most center point on the striker to the H point Use a level 6 NCAP 42 x SHY Striker to H Point Y Direction KK Knee to Knee For Hybrid III dummies measure the distance between the outboard knee clevis flange surfaces This measurement may not be exactly transverse The following angles are to be measured and recorded l SA Seat Back Angle Find this angle using the instructions provided by the COTR via the manufacturer If the manufacturer instructions aren t clear enough contact the COTR PA Pelvic or Femur Angle Taken by inserting the pelvic angle gauge into the H point gauging hole on the Hybrid III dummies and taking this angle with respect to the horizontal SWA Steering Wheel Angle Find this angle by placing a straight edge against the steering wheel rim alon
278. ody View Post test Front Underbody View Pre test Rear Underbody View Post test Rear Underbody View Pre test Dummy Cable Routing Post test Dummy Cable Routing Pre test Driver Dummy Front View taken through the windshield directly in front of the driver with the camera parallel to the longitudinal centerline of the vehicle Post test Driver Dummy Front View taken through the windshield directly in front of the driver with the camera parallel to the longitudinal centerline of the vehicle Pre test Driver Dummy Window View taken through the left window with the camera perpendicular to the longitudinal centerline of the vehicle Post test Driver Dummy Window View taken through the left window with the camera perpendicular to the longitudinal centerline of the vehicle Pre test Driver Dummy and Vehicle Interior View taken with the door open Post test Driver Dummy and Vehicle Interior View taken with the door open Pre test Driver s Seat Fore Aft Markings taken with the door open and in such a way that any seat positioning marks may be seen Post test Driver s Seat Fore Aft Markings taken with the door open and in such a way that any seat positioning marks may be seen Pre Test View of Belt Anchorage for Driver Dummy This photograph should show the position of the upper belt anchorage Detent or millimeter markings 038 039 040 041 042 043 044 045 046 047 048 049
279. of the test vehicle by either adding ballast or removing vehicle components in accordance with the manufacturer s data provided by the COTR 9 Onthe data sheet record the weight of the added ballast if any 10 On the data sheet record the weight of each vehicle component that was removed NCAP 30 NOTE Jf the calculated TEST VEHICLE TARGET WEIGHT TVTW is exceeded the Contractor should consult the vehicle setup information to determine which parts if any have been suggested for removal The Contractor must notify the COTR to confirm the removal of vehicle components If no components were provided with the vehicle setup information the Contractor must also contact the COTR for guidance about parts removal Under no circumstances shall the As Tested weight be greater than the maximum Test Vehicle Target Weight VEHICLE ATTITUDE MEASUREMENTS AS TESTED WEIGHT CONDITION 1 With the vehicle in As Tested weight condition place it on a flat level surface 2 Measure the perpendicular distance from the level surface to the four 4 points previously marked on the vehicle and record each NOTE The As Tested vehicle attitude measurements shall be taken within an hour of impact to assure the proper attitude is met SEAT ADJUSTMENT REFERENCE MARKS Prior to placing the dummies in the front seating positions consult Appendix F of this document for a check list pertaining to the proper procedures SETTING THE SEATS Prior
280. om of the feet BUTTOCK POPLITEAL The rearmost surface of the lower leg to the same point on the 414 439 4 LENGTH rear surface of buttocks used for dim HYBRID III SUBPART O EXTERNAL DIMENSIONS continued 17 ASSEMBLY ACTUAL DIMENSION DESCRIPTION DETAILS DIMENSION MEASUREMENT CHEST DEPTH WITHOUT JACKET Measured 304 8 5 1 mm above seat surface 175 3 190 5 FOOT LENGTH Tip of toe to rear of heal 218 5 233 7 STANDING HEIGHT THEORETICAL 1501 1 BUTTOCK TO KNEE PIVOT LENGTH The rear surface of the buttocks to the knee pivot bolt 457 2 482 6 HEAD BREADTH The widest part of the head 137 1 147 3 HEAD DEPTH Back of the head to the forehead 177 8 188 HIP BREADTH The widest part of the hip 299 7 314 9 SHOULDER BREADTH Outside edges of right and left shoulder clevises 350 5 365 7 FOOT BREADTH The widest part of the foot 78 8 94 HEAD CIRCUMFERENCE Measured at the point as in dim T 528 3 548 7 CHEST CIRCUMFERENCE Measured 345 4 12 7 mm above seat surface 850 9 881 3 WITH CHEST JACKET WAIST CIRCUMFERENCE Measured 165 1 5 1 mm above seat surface 759 5 789 9 REFERENCE LOCATION FOR MEASUREMENT OF Reference 332 7 358 1 CHEST CIRCUMFERENCE REFERENCE LOCATION FOR MEASUREMENT OF Reference 160 1 170 2 WAIST CIRCUMFERENCE w w M POINT EXTERNAL DIMENSION SPECIFICATIONS FIGURE 2B B18 B19 EXTERNAL DIMENSIONS TEST SETUP 0000 90900 900609 yw FI
281. oment of impact 572 144 c 5 The velocity of the test probe at the time of impact 1s between 5 9 m s and 6 1 m s 572 144 b The probe is guided so there is no significant lateral vertical or rotational movement during the impact 572 144 c 6 Neither the suspension hardware suspension cables nor other attachments to the probe including the velocity vane make contact with the dummy 572 144 c 7 033 _ 16 Complete following table Thorax Impact Results 572 144 b 1 amp 2 Parameter Specification Result Test Probe Speed 5 9 m s lt speed lt 6 1 m s Chest Compression 32 mm lt compression x 38 mm Peak force between 32 680 N lt peak force lt 810 N and 38 mm chest compression Peak force between 12 5 Peak force lt 910 N and 32 0 mm chest compression Internal Hysteresis 65 lt hysteresis lt 85 Time zero is defined as the time of initial contact between the test probe and the chest skin Force impactor mass x acceleration 572 144 b 3 Area under loading curve minus the area under the unloading curve divided by the area under the loading curve Figure 12D 17 Plots of chest compression pendulum acceleration pendulum force and force versus deflection follow this sheet Signature Date 034 IMPACT TEST SET UP SPECIFICATIONS NOTES 1 MIDDLE RIB LEVEL 1 SUPPORT CABLES 2 MIDSAGITTAL PLANE VERTICAL WITHIN 1 3
282. on repair or replacement of parts Repair or Replacement approved by Signature Date Describe the repair or replacement of parts Checked by Signature Date C14 DATA SHEET C2 EXTERNAL MEASUREMENTS 6 YEAR OLD See the PADI Dummy Serial Number Test Date Technician __ Pretest calibration Post test calibration verification 1 2 Remove dummy s chest Jacket and abdominal insert Seat the dummy on a flat rigid smooth clean dry horizontal surface as shown in Figure 3C and 4C The seating surface is at least 215 9 mm 8 5 in wide and 330 2 mm 13 in in depth with a vertical section at least 215 9 mm 8 5 In wide and 635 mm 25 in high attached to the rear of the seating fixture The dummy s midsagittal plane is vertical and centered on the test surface Remove the four 4 20 x 7 8 SHCS that attach the lumbar spine bracket to the pelvis Torque the spine cable to 0 22 02 NM 2 0 0 2 in Ibs NOTE At this point the thorax is to be inspected for damage The thorax displacement transducer may be removed for calibration if required pretest calibration only Extreme caution is to be used so as not to damage the instrumentation cables Reassemble the lumbar spine bracket to the pelvis Secure the dummy to the test fixture so that the rear surfaces of the upper thorax and the buttock are tangent to the rear vertical surface of the fixture or as near tangent as possible The dummy
283. ontractor shall verify all instrumentation and check data sheets and photographs Make sure data is recorded in all data blocks on every performance calibration test data sheet REPORTS APPARENT NONCONFORMANCE During a calibration verification any indication of apparent nonconformance to the requirements of Regulation P572 shall be communicated by telephone to the COTR within 24 hours with written notification mailed within 48 hours Saturdays and Sundays excluded Written notification shall be submitted with a copy of the particular test data sheet s and preliminary data plot s In the event of an apparent nonconformance a calibration check of some critically sensitive test equipment and instrumentation may be required for verification of accuracy The necessity for the calibration shall be at the COTR s discretion and shall be performed without additional costs to OCWS 14 2 14 2 1 C11 CALIBRATION DOCUMENTATION COPIES Copies of the data sheets containing the calibration data for each Part 572 Subpart N dummy used in the vehicle test shall be submitted with the final NCAP test report for the vehicle Contractors are required to PROOF READ all Final Test Reports before submittal to the COTR The OCWS will not act as report quality control office for contractors Reports containing a significant number of errors will be returned to the contractor for correction and a hold will be placed on invoice payment for the part
284. ontractor until requested by the COTR ELECTROMAGNETIC INTERFERENCE The laboratory shall take all necessary precautions to ensure electromagnetic interference with the test data does not occur The following vehicle procedures shall be included in those adopted by the laboratory A Ground the head thorax and both femurs of the anthropomorphic test devices This 15 accomplished by connecting the four components with a wire A single wire then exits the dummy and is attached to a grounding block on the vehicle Connect the grounding block to earth ground The actual wire size and connections are left to the laboratory based on the system it uses 12 12 1 NCAP 50 TEST DATA DISPOSITION The Contractor shall make all crash test data available within two hours of the crash test event if so requested by NHTSA personnel Under no circumstances shall this data be furnished to non NHTSA personnel The Contractor shall analyze the preliminary test results as directed by the COTR TEST DATA LOSS INVALID TEST DESCRIPTION The Part 572E and Part 5720 test dummies and the test vehicle are instrumented in order to obtain data needed for the New Car Assessment Program NCAP The dummy data from 35 mph 56 km h frontal barrier impact tests for evaluation against FMVSS No 208 injury criteria and the visual record of dummy kinematics are absolutely essential to NCAP An invalid NCAP test is one which does not conform precisely to all requiremen
285. or for a minimum of 60 days so that OCWS and vehicle manufacturer personnel can be given an inspection opportunity NCAP 59 12 7 DATA AVAILABILITY TO THE PUBLIC The Contractor shall provide interested parties with copies of the test report test CDs or DVDs test data tapes test videos and test still photographs at a reasonable cost to the purchaser but only after the Office of Crashworthiness Standards representative has advised the Contractor that the results of that particular New Car Assessment Program test have been released to the public by the Agency APPENDIX PART 572E 508 Male DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE Em OU oos ONU vicus 12 13 14 15 APPENDIX PART 572 SUBPART DUMMY PERFORMANCE CALIBRATION PROCEDURE TABLE OF CONTENTS PURPOSE AND APPLICATION 1 GENERAL REQUIREMENTS anan l tes cba M Ee UE iL 3 GOOD HOUSEKEEPING ude ette ee etel e leet 3 TEST SCHEDULING AND MONITORING cte 3 TEST DATA DISPOSITION SZ au Me ME 3 GOVERNMENT FURNISHED PROPERTY GFP eee 4 CALIBRATION AND TEST INSTRUMENTATION en 4 PHOTOGRAPHIC DOCUMENTATION ttt 5 DEFINEONS uA Ee eR M IE 5 PRETEST REQUIRE MENS o seme ar 6 11 1 TRANSDUCER REQUIREMENTS entente 6 11 2 OTHER
286. or any reason even if the primary channel fails and is required for a resultant injury reading e Resultant injury readings should be calculated using as many primary channels as possible If a required primary channel fails its corresponding redundant should be used in the resultant calculation along with the remaining preserved primary channels In the case of a failed primary head Z acceleration for example HIC should be calculated using the primary X and Y along with the redundant Z Entr e INSCOM fields indicating the channels used in a resultant calculation are encouraged for clarity In the case of a failed head Z acceleration for example the Contractor should indicate in the INSCOM field that the redundant Z channel was used to calculate the HIC reported for that occupant M Ifa test signal contains intermittent noise the original data channel as recorded should still be added to the appropriate slot in the data tape NCAP staff will edit the signal as necessary and provide it to the Contractor if it is to be included it in the test report or other final deliverables NOTE It is RARE that a data channel would require editing of this nature The Contractor should not edit test data unless instructed to do so in a dialogue with the COTR or other NCAP staff N For Quicklook and test report purposes injury measures shall be presented in accordance 12 3 NCAP 55 with standard rounding convention and by rounding all va
287. orms to the requirements of SAE Recommended Practice J211 1 MAR95 572 155 1 8 The test fixture pendulum conforms to the specifications in Figure 7E 9 head neck assembly is mounted on the pendulum so midsagittal plane of the headform is vertical and coincides with the plane of motion of the pendulum as shown in Figure 8E for the flexion test 572 153 c 3 10 Install the transducers or other devices for measuring the D plane rotation with respect to the pendulum longitudinal centerline Note Plane D is the top horizontal surface of the neck load cell These measurement devices should be designed to minimize their influence upon the performance of the head neck assembly and not induce neck torsion 572 153 c 3 11 11 Plane D is perpendicular 1 degree to the centerline of the pendulum 27 _ 12 Set the instrumentation so that moment and rotation are defined to be zero when longitudinal centerline of the neck and pendulum are parallel 572 153 c 3 1 13 Release the pendulum and allow it to fall freely from height to achieve an impact speed of 5 1 m s to 5 3 m s as measured at the center of the pendulum accelerometer at the instant of contact with the honeycomb 572 153 c 4 _ 14 Complete the following table Neck Flexion Test Results 572 143 b 1 amp 572 153 4 Parameter Specification Result Pendulum impact speed 5 1 m s speed x 5 3 m s Pendulum 10ms 1 6
288. ost test calibration checks conducted after an NCAP test may serve as the pre test calibration checks for the next test the dummy is used in provided the ATD is used within weeks It is acceptable to submit a post test calibration set that does not meet all requirements and or corridors as long as the issues with the ATD or instrumentation are investigated and rectified prior to it being used in the next test The failed post test calibration should be included in all deliverables However prior to the next NCAP test the ATD must undergo recalibration until all body regions achieve a passing result The COTR should also be notified of the failed calibration result as soon as possible The pre test data for the subsequent NCAP test using that ATD MUST show compliance with all calibration requirements NOTE In the event an ATD body region exceeds the performance standards required by FMVSS 208 that region on the ATD must also be recalibrated The Contractor Furnished data acquisition shall have a sufficient number of channels available for recording and processing signals from ATD and vehicle sensors It must record time histories of the head and chest acceleration chest displacement neck forces and moments right and left femur axial loads and any additional instrumentation specified for each test dummy used in the test Each data channel shall be comprised of a sensor signal conditioner data acquisition device and all interconnecting ca
289. otational movement during the impact 572 154 c 6 Neither the suspension hardware suspension cables nor other attachments to the probe including the velocity vane make contact with the dummy 572 154 c 7 12 Complete following table Thorax Impact Results 572 154 b E34 Parameter Specification Result Test Probe Speed 4 9 m s lt speed lt 5 1 m s Peak force 1514 N lt peak force lt 1796 N Time zero is defined as the time of initial contact between the test probe and chest skin Force impactor mass x acceleration 572 144 b 3 13 Plots of pendulum acceleration and pendulum force follow this sheet Signature Date E35 THORAX IMPACT TEST SET UP SPECIFICATIONS IMPACT PROBE SUPPORT CABLES NOTES 1 MIDSAGITTAL PLANE VERTICAL WITHIN 1 2 IMPACT POINT OF LONGITUDINAL IMPACT PRORE WEIGHT CENTERLINE OF PROBE INCLUDING ALL COINCIDES WITH MIDSAGITTAL INSTRUMENTATION TORSO ASSEMBLY PLANE OF DUMMY 2 ABOVE TABLE WITHIN 05 OF n HORIZONTAL PLANE 2 86 50 02 Kp 63 0058 4 BACK PLATE OF SPINE BOX AT 90 1 FROM HORIZONTAL DUMMY ASSEMBLY ACCELEROMETER 901022 000 REF SHIM TO MAINTAIN 196 mm 7 7 in UPRIGHT POSITION ras 1 3 OF CABLE WEIGHT NOT TO EXCEED 5 OF THE TOTAL IMPACT PROBE WEIGHT Probe specifications 1 Rigid metallic construction and concentric about its longitudinal axis
290. ove the competitive position of United States industry 3 Harmonization considerations will be taken into account where appropriate Canadian and UK standards will be used as guides where applicable 4 Conversion will be done a case by case basis Equivalent rather than exact conversion will be given preference except where there is a clear safety need for an exact conversion Here equivalent means a close nominal value in contrast to exact which means a precise mathematical conversion 5 Whenever appropriate procedures for determining the number of significant figures will follow the practice shown in SAE J916 May 1991 To the extent possible test procedures developed by NHTSA s Office of Enforcement will be used to determine the implied precision required as part of the significant figure determination 6 SAE J916 May 1991 will be used as the primary source for conversion factors NIST Special Publication 811 will be used as a backup source PREFERRED UNITS The following listing shows units preferred for use within NHTSA and the acceptable abbreviation Most of the units on this list refer to quantities used in mechanical automotive engineering practice plus some other units normally used by the agency For quantities used in electrical engineering heat power engineering lighting or quantities not listed see SAE J916 May 1991 K2 METRIC CONVERSATION ACCELERATION radians per second squared acceptable
291. ove the seat cushion reference point to the rearmost position S16 2 10 3 1 S20 1 9 3 __ N A No independent fore aft seat cushion adjustment 1 8 Use any part of any control other than the parts just used for fore aft positioning to determine the range of angles of the seat cushion reference line and to set the seat cushion reference line at the mid angle 516 2 10 3 1 Maximum angle Minimum angle Mid angle 1 9 If the seat and or seat cushion height is adjustable use any part of any control other than the parts which primarily move the seat or seat cushion fore aft to put the seat cushion reference point in its lowest position with the seat cushion reference line angle at the mid angle found in 1 8 S16 2 10 3 1 N A No seat height adjustment 1 10 Use only the controls that primarily move the seat in fore aft direction to verify the seat is in the rearmost position __ 1 11 Use only the controls that primarily move the seat in fore aft direction to mark the F7 fore aft seat positions Mark each position so that there is a visual indication when the seat Is at a particular position For manual seats move the seat forward one detent at a time and mark each detent For power seats mark only the rearmost middle and foremost positions Label three of the positions with the following F for foremost M for mid position if there is no mid position label the closest adjustment position to the rear of the mid point
292. ow View taken through the right window with the camera perpendicular to the longitudinal centerline of the vehicle Post test Passenger Dummy Window View taken through the right window with the camera perpendicular to the longitudinal centerline of the vehicle Pre test Passenger Dummy and Vehicle Interior View taken with the door open Post test Passenger Dummy and Vehicle Interior View taken with the door open Pre test Passenger s Seat Fore Aft Markings taken with the door open and in 057 058 059 060 061 062 063 064 065 066 067 068 069 070 071 072 073 074 075 076 077 078 N17 such a way that any seat positioning marks may be seen Post test Passenger s Seat Fore Aft Markings taken with the door open and in such a way that the seat positioning marks may be seen Pre Test View of Belt Anchorage for Passenger Dummy This photograph should show the position of the upper belt anchorage Detent or millimeter markings should be shown and labeled if applicable Post Test View of Belt Anchorage for Passenger Dummy This photograph should show the position of the upper belt anchorage Detent or millimeter markings should be shown and labeled if applicable Pre test Passenger Dummy Feet taken with the door open Post test Passenger Dummy Feet taken with the door open Pre test Passenger s Side Knee Bolster glove compartment without dummy present Post
293. owing tests have been developed to establish a uniform calibration procedure for all users as the means of verifying the performance of the dummy A EXTERNAL DIMENSIONS drawing 127 0000 sheet 5 of 6 amp PADI B HEAD DROP TEST 572 122 C NECK FLEXION TEST 572 123 b 1 D NECK EXTENSION TEST 572 123 b 2 E THORAX IMPACT TEST 572 124 TORSO FLEXION 572 125 G KNEE IMPACT TESTS 572 126 This laboratory procedure for the calibration of Part 572 Subpart N dummies must be used by National Highway Traffic Safety Administration NHTSA contract laboratories performing NCAP testing for the Office of Crashworthiness Standards OCWS GENERAL REQUIREMENTS The Code of Federal Regulations 49CFR Parts 571 and 572 was amended to adopt the Hybrid 6 Year Old Child Dummy as the means of determining a vehicle s conformance to the performance requirements of FMVSS 208 Each Part 572 Subpart N dummy used in an NCAP test must meet the specifications and performance criteria of Part 572 before and after each vehicle crash test in order to be an acceptable test tool The Part 572 Subpart N Hybrid 6 Year Old Child Dummy consists of components and assemblies specified in the drawing and specifications package which is available from Reprographics Technologies 9000 Virginia Manor Road Beltsville MD 20705 telephone 301 419 5070 SECURITY All NHTSA Part 572 Subpart N test dummies delivered to the contract laborator
294. p 002 by removing 3 8 16 Socket Head Cap Screw and retaining the structural assembly of the upper legs 78051 43 amp 44 3 2 remove the abdominal insert 78051 52 3 3 replace the instrument cover plate 78051 13 in the pelvic bone with a rigid pelvic bone stabilizer insert Figure 15A and attach the pelvis upper support device Figure 16A 4 The assembly soaked at a temperature between 18 9 C 66 F and 25 6 C 78 F and at a relative humidity from 10 to 70 for a period of at least four 4 hours prior to this test 572 35 c v Record the maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity 5 Seat dummy on the rigid seat fixture 572 35 c 2 11 6 Secure the dummy by bolting the stabilizer insert and the pelvis upper support device to the seat back of the test fixture as shown in Figures 17A 18A and 19A 572 35 c 2 1 7 Adjust the threaded rods until plane B is horizontal 8 Secure the lever arm into the left femur shaft opening of the upper leg structure assembly 78051 43 and firmly secure it using the 3 8 16 socket head cap screws Figure 19A 572 35 c 2 11 9 Lift the lever arm parallel to midsagittal plane at a rotation rate between 5 and 10 degrees per second while maintaining the gt in shoulder bolt longitudinal centerline horizontal throughout the range of motion until the 150 ft Ibf torque level is reached Figures 18A and
295. part O dummy will be sent to the COTR with each test report backup data sheets strip charts recordings plots technicians notes etc shall be either sent to the COTR or destroyed at the conclusion of each delivery order purchase order etc B3 GOVERNMENT FURNISHED PROPERTY GFP Part 572 Subpart O test dummies will be furnished to the contract laboratory by the OCWS The dummies shall be stored in an upright sitting position with the weight supported by the internal structure of the pelvises The dummies heads shall be held upright by using a strap around the chest or the base of the neck so that the neck 15 not supporting the weight of the dummy The dummies shall be stored in a secured room that is kept between 55 F and 85 F The contractor will check dummy components for damage after each crash test and complete a dummy damage checklist as part of the NCAP procedure which will be included with the dummy calibration if requested The COTR will be kept informed of the dummies condition so that replacement parts can be provided The dummies will be calibrated by the contractor according to the schedule indicated in the NCAP test procedure CALIBRATION AND TEST INSTRUMENTATION Before the contractor initiates the dummy performance calibration test program a test instrumentation calibration system must be implemented and maintained in accordance with established calibration practices The calibration system shall be set
296. polarity of channels will serve to increase the confidence that polarities have been correctly determined The polarities in this document are the same as those of the SAE J211 SAE J211 Procedure The body coordinate system used for reference is attached to the dummy and is x positive pointing forward y positive pointing to the right and z positive pointing down To check the polarity of the upper and lower neck load cells the head and chest must be moved in opposite directions to make a measurable force in the neck Moving the head rearward and the chest forward should result in a positive Fx Moving the head left and the chest right should result in a positive Fy Lifting the head upward and the chest downward should result in a positive F A similar methodology is applied with determining the polarity of the moment measuring load cells Moving the left ear toward the left shoulder should result in a positive Mx Moving the chin toward the sternum results in a positive M and moving the chin toward the left shoulder will have a positive M If any of these motions do not result in a positive reading the polarity needs to be changed to agree with the sign convention A sign change in the software may be the simplest solution 12 Dummy Upper Neck and Lower Neck Load Cell Polarity Check gt ty Left Side View Front View 13 Polarity Check Data Sheet For Upper and Lower Neck Load Cells Dumny Type Serial No
297. position cannot used for seating For sole purpose of determining classification of any vehicle sold or introduced into interstate commerce for purposes that include carrying students to and from school or related events any location in such vehicle intended for securement of an occupied wheelchair during vehicle operation shall be regarded as four designated seating positions 571 3 Emergency locking retractor A retractor incorporating adjustment hardware by means of a locking mechanism that 15 activated by vehicle acceleration webbing movement relative to the vehicle or other automatic action during an emergency and is capable when locked of withstanding restraint forces 571 209 S3 Fixed Collision Barrier A flat vertical unyielding surface with the following characteristics 1 The surface is sufficiently large that when struck be a tested vehicle no portion of the vehicle projects or passes beyond the surface 2 The approach is horizontal surface that is large enough for the vehicle to attain a stable attitude during its approach to the barrier and that does not restrict vehicle motion during impact 3 When struck by a vehicle the surface and its supporting structure absorb no significant portion of the vehicle s kinetic energy so that a performance requirement described in terms of impact with a fixed collision barrier must be met no matter how small an amount of energy is absorbed by the barrier 571 3 F
298. practices TEST SCHEDULING AND MONITORING The Part 572 Subpart N dummies are being calibrated as test tools to be used in NCAP vehicle crash tests The schedule for these performance calibration tests must be correlated with that of the vehicle tests In addition all testing shall be coordinated to allow monitoring by the COTR TEST DATA DISPOSITION The contractor shall make all dummy calibration data available to the COTR for review and analysis as required calibration test data for each particular Part 572 Subpart N dummy will be sent to the COTR with each test report backup data sheets strip charts recordings plots technicians notes etc shall be either sent to the COTR or destroyed at the conclusion of each delivery order purchase order etc GOVERNMENT FURNISHED PROPERTY GFP Part 572 Subpart N test dummies will be furnished to the contract laboratory by the OCWS The dummies shall be stored in an upright sitting position with the weight supported by the internal structure of the pelvises The dummies heads shall be held upright by using a strap around the chest or the base of the neck so that the neck is not supporting the weight of the dummy These dummies shall be stored in a secured room that is kept between 55 F and 85 F The contractor will check dummy components for damage after each crash test and complete a dummy damage checklist as part of the NCAP procedure which will be included with t
299. quired for any test which 15 determined to be invalid unless NHTSA specifically decides in writing to require the Contractor to submit such report The test data from the invalid test must be safeguarded until the data from the retest has been accepted by the COTR The report and other required deliverables for the retest vehicle are required to be submitted to the COTR within 2 weeks after completion of the retest Invalidated test reports will not be publicly released G DEFAULT The Contractor is subject to the default and subsequent re procurement costs for non delivery of valid or conforming tests pursuant to the Termination for Default clause in the contract NCAP 52 H CONDITIONS FOR PARTIAL PAYMENT 12 2 The Contractor shall exercise reasonable and foreseeable control to insure that no data 1s lost or rendered useless If some non critical data such as camera failure etc and critical data acceleration and load data are not obtained for the crash test and the test 1s accepted by the Agency the Agency will not pay for the missing or lost data DATA PROCESSING NOTE PARTS OF THE FOLLOWING MAY NOT APPLY TO ON BOARD DATA ACQUISITION SYSTEMS A Prior to the vehicle crash test a null reference and a shunt calibration adjustment are performed to set all analog and direct digitized data devices including FM magnetic tape recorders Immediately following the crash test a post impact null reference and shunt calibration che
300. r adjustable panels in front of the windshield are in the position used under normal operation during inclement weather U SUNROOF Place sunroof s in the full closed position V DOOR LOCKS Vehicles without automatic door locks should remain unlocked during the event If the vehicle has automatic door locks ADLs they will also remain unlocked UNLESS the equipment is standard and the dealer is the only entity that can deactivate the system NOTE If there are any instructions in the owner s manual describing how a consumer may deactivate the ADLs the vehicle must be left unlocked during the event W CONVERTIBLE TOPS Place convertible tops in the closed passenger compartment configuration X DOORS l Place all doors hatchback or tailgate in the fully closed and latched position Check instrument panel telltales just prior to ensure than all doors and hatches are closed Do not lock any door hatchback or tailgate Before performing the act of door closing knowledge of the door configuration and operation must be acquired from test vehicle preparation data submitted by vehicle manufacturer Particular care must be exercised to close doors with 2 stage primary NCAP 32 and secondary latch systems Confirm that all doors are properly closed by checking indicators in vehicle instrument panel if so equipped Also as indicated in Section 9 7 of this document a full documentation of door closings with a real time c
301. r the calibration of Part 572 Subpart O dummies must be used by National Highway Traffic Safety Administration NHTSA contract laboratories performing NCAP testing for the Office of Crashworthiness Standards OCWS GENERAL REQUIREMENTS The Code of Federal Regulations 49CFR Parts 571 and 572 was amended to adopt the Hybrid III 5th Percentile Female Dummy Each Part 572 Subpart O dummy used in an NCAP test must meet the specifications and performance criteria of Part 572 before and after each vehicle crash test in order to be an acceptable test tool The Part 572 Subpart O Hybrid III 5th Percentile Female Dummy consists of components and assemblies specified in the drawing and specifications package which is available from Reprographics Technologies 9000 Virginia Manor Beltsville MD 20705 telephone 301 419 5070 SECURITY NHTSA Part 572 Subpart O test dummies delivered to the contract laboratory as Government Furnished Property GFP will be stored in a safe and secure area such as a dummy calibration laboratory The contractor is financially responsible for any acts of theft and or vandalism which occur during the storage of GFP Any security problems shall be reported by telephone to the Industrial Property Manager IPM Office of Contracts and Procurement within two working days after the incident A letter containing specific details of the security problem will be sent to the IPM with copy to the COTR within 48 hour
302. r torso off of the lower torso Check the torque on the two spine cables The torque should be 1 2 1 4 NM 11 12 in Ibs NOTE At this point the thorax is to be inspected for damage The thorax displacement transducer may be removed for calibration if required pretest calibration only Extreme caution to be used so as not to damage the instrumentation cables Reassemble the upper torso to the lower torso Secure the dummy to the test fixture so that the rear surfaces of the upper thorax and buttock are tangent or as near tangent as possible to the rear vertical surface of the fixture and the dummy s midsagittal plane is vertical Position the dummy s H point so it is 3 4 0 1 in above the horizontal seating surface and 5 4 0 1 in forward of the rear vertical surface of the fixture Note the H point is located 1 83 in forward and 2 57 in downward from the center of the pelvic angle reference hole in the lumbar pelvic adaptor Extend the dummy s neck so that the base of the skull is level both fore and aft and side to side within 0 5 degrees The rear surface of the skull cap should be 1 7 0 1 in from the vertical surface of the test fixture A strap or bungee cord may be placed around the forehead of the dummy to stabilize the head in this position Position the upper and lower legs parallel to the midsagittal plane so the centerline between the knee pivot and the ankle pivot is vertical Position the feet parallel to the du
303. ra shall be perpendicular to the longitudinal centerline of the vehicle Filename Camera No 8 PASSENGER CLOSE UP High speed right side view camera positioned adjacent to the vehicle s A post to document the passenger dummy s head movement in the windshield area during the impact event and windshield zone intrusion The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle Filename Camera No 9 RIGHT ANGLE High speed right side view camera positioned adjacent to the vehicle s B post or center post at an angle to document the movement of the passenger dummy during the impact event Filename Camera No 10 RIGHT FRONT HALF High speed right side view camera positioned adjacent to the vehicle s right front door to document the movement of the 1 12 Camera 13 14 15 NCAP 16 passenger dummy during the impact event Filename Camera No 11 WINDSHIELD High speed overhead camera positioned directly above the vehicle s windshield centerline to cover the windshield area during the entire crash event A polarizing filter may be used to eliminate windshield glare Filename Camera No 12 DRIVER WINDSHIELD High speed front view camera mounted above the barrier face to document the movement of the driver dummy during the impact event and windshield zone intrusion Filename Camera No 13 PASSENGER WINDSHIELD High speed front v
304. rd specifies performance requirements for limitation of electrolyte spillage retention of propulsion batteries and electrical isolation of the chassis from the high voltage system during the crash event This standard applies to vehicles that use electricity as propulsion power It is the contractor s responsibility to follow the most updated FMVSS 305 test procedure when conducting this assessment as part of NCAP testing The latest published versions of all FMVSS test procedures may be found at http www nhtsa gov Vehicle Safety Test Procedures APPENDIX K METRIC CONVERSIONS Kl APPENDIX K NHTSA PREFERRED PRACTICE FOR METRIC CONVERSIONS NHTSA is converting to the metric system of measurement The authority for this conversion is DOT Order1020 1D which was issued in response to 5164 of the Omnibus Trade and Competitiveness Act of 1988 PL 100 418 and Executive Order 12770 The agency s plan for conversion was approved by the Secretary of Transportation on October 21 1991 and were published on April 21 1992 S7FR77 14619 This preferred practice provides general guidance for the conversion and includes a listing of the preferred units for the quantities most frequently used by the agency GENERAL GUIDELINES 1 Safety levels shall not be decreased as a result of a change to the metric system of units 2 Due consideration will be given to the effects of conversion on the nation s economy since the intent of PL 100 418 is to impr
305. recise instant of barrier contact will be incorporated with the time reference signal An instrumentation self checking system that simultaneously monitors all data channels and displays on a single indicator will provide the GO NO GO status of the sensor system NCAP 53 Test data should NOT pre filtered and should be submitted at a class that is higher than Class 1000 It should be digitized at a minimum rate of 10 000 samples per second Additionally the data should begin at a maximum of 50 ms and be truncated at 300 ms The data is then placed onto permanent storage media after the application of appropriate calibration scale factors As the data is recalled for integration or graphical reporting purposes the appropriate filter is applied These filters are in accordance with the most recent version of SAE Recommended Practice J211 1 Instrumentation for Impact Tests Vehicle acceleration data is plotted after the application of an SAE Class 60 filter and velocity and displacement data 15 plotted after the application of an SAE Class 180 filter Before plotting the Contractor s program manager or engineer shall determine the time zero for all data which is verified with the trigger signal When a velocity or displacement trace is to be plotted integration for the appropriate acceleration signal is performed digitally Time zero bias should also be removed from all signals prior to submission of the data tape to NHTS
306. rence targets are to be positioned vertically from the roadway surface on the driver and passenger sides of the vehicle in the camera view and at about door midpoint to assist in high speed video evaluation of the event The dummies shall have targets on each side of the head with the center of the target as close as possible to the center of gravity of the head in the x and z direction relative to the measuring directions of the accelerometers Targets shall be placed on the outboard shoulder of each dummy Cut away a section of the sleeve do not remove the sleeve of the dummy and place the target as high up on the arm as possible at the intersection of the arm and the shoulder The top portion of the steering wheel shall have tape with 1 inch squares the squares having alternating colors such as black and yellow placed on it TARGET VEHICLE INFORMATION PLACARDS Vehicle identification placards shall be positioned so that at least 1 placard will be visible in the field of view for each of the high speed cameras The following information will be shown Vehicle s NHTSA Number The words NCAP 35 MPH FRONTAL Date of crash test Vehicle year make and model NOTE The name of the test laboratory should not be present on any vehicle placards used in photos and videos submitted to NHTSA 9 7 9 8 NCAP 21 DOCUMENTATION VIDEO TITLE AND SEQUENCE The pre and post test real time documentation video shall include the fol
307. rger arcs until it contacts the dashboard Also reference the angle of this measurement with respect to the horizontal for the outboard Knee to Dash Angle KDA NCAP 37 iii KDL KDR Knee to Dash Left Right 9 SH SK ST Striker to H Point Knee and Head These measurements are to be taken in the X Z plane measured from the forward most center point on the striker to the center of the H point outer knee bolt and head target When taking this measurement a firm device that can be rigidly connected to the striker should be used Use a level The angles of these measurements with respect to the horizontal should also be recorded The measurement in the Y transverse direction from the striker to the H point designated Striker to H Point SHY see below should also be taken NCAP 38 iv SH Striker to H Point 1 v SH Striker to H Point 2 NCAP 39 vi SK Striker to Knee 1 vii ST Striker to Knee 2 NCAP 40 viii ST Striker to Head The following measurements are to be made within a vertical transverse plane 1 HS Head to Side Window Taken from the point where the dummy s nose meets his forehead between his eyes to the outside of the side window In order to make this measurement roll the window down to the exact height that allows a level measurement Use a level NCAP 41 ix HS Header to Side Window AD Arm to Door Taken from the outer surface of the elbow pivot bolt on a Hybrid II dummy t
308. rmined item 1 19 or 1 20 516 3 3 1 6 Record Knee Separation 10 Push rearward on the dummy s knees until the pelvis contacts the seat back or the backs of the calves contact the seat cushion whichever occurs first S16 3 3 1 6 Pelvis contacted seat back Calves contacted seat cushion __ 11 Gently rock the upper torso 5 degrees approximately 51 mm 2 inches side to side three times S16 3 3 1 7 12 If needed extend the legs until the feet do not contact the floor pan The thighs should 9 resting seat cushion 516 3 3 1 8 13 Use seat controls to line up seat markings determined during completion of item 1 to set the foremost fore aft position mid height position and the seat cushion mid angle If the dummy contacts the interior move the seat rearward until a maximum clearance of 5 mm 0 2 inches is achieved or the seat is in the closest detent position that does not cause dummy contact S16 3 3 1 8 Foremost mid height position and the seat cushion mid angle reached Dummy contact Clearance set at maximum of 5mm Measured Clearance Dummy Contact Seat set at nearest detent position Seat position detent positions rearward of foremost foremost is position zero _ 14 If the seat back is adjustable rotate the seat back forward while holding the thighs in place Continue rotating the seat back forward until the transverse instrument platform of the dummy head is level
309. rmined with doors and windows closed and the wheels in the straight ahead position 571 3 Rated cargo and luggage capacity weight RCLW RCLW vehicle capacity weight 68 kg x designated seating capacity Maximum RCLW used in testing a NCAP 24 truck MPV or bus is 136 kg N Seating reference point SgRP The unique design H point as defined in SAE J1100 June 1984 which 1 Establishes the rearmost normal design driving or riding position of each designated seating position which includes consideration of all modes of adjustment horizontal vertical and tilt in a vehicle 2 Has X Y and Z coordinates as defined in SAE J1100 June 1984 established relative to the designed vehicle structure 3 Simulates the position of the pivot center of the human torso and thigh and 4 Is the reference point employed to position the two dimensional drafting template with the 95th percentile leg described in SAE J826 May 1987 or if the drafting template with the 95 percentile leg cannot be positioned in the seating position is located with the seat in its most rearward adjustment position 571 3 O Seat cushion reference point SCRP A point placed on the outboard side of the seat cushion at a horizontal distance between 150 mm 5 9 in and 250 mm 9 8 in from the front edge of the seat used as a guide in positioning the seat P Seat cushion reference line SCRL A line on the side of the seat cushion passing through th
310. rometers SA572 S4 installed in the head assembly as specified in 5572 122 Data from the accelerometers are not required 572 123 b The assembly soaked at a temperature between 20 6 C 69 F and 22 2 C 72 F and at a relative humidity from 10 to 7096 for a period of at least four 4 hours prior to a test 572 123 1 Record maximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity Visually inspect neck assembly for cracks cuts and separation of the rubber from the metal segments Note If the damage resulted from the vehicle crash test in which the dummy was an occupant the damaged area is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions Inspect the nodding blocks 127 1020 127 1021 for splits or deformation Inspect the Neck Cable 127 1016 for deformation Inspect the mounting plate insert 910420 048 and the nylon shoulder bushing 9001373 and replace if they are torn or worn When replacement is necessary ONLY replace during pre test calibration Record findings and actions Torque the jam nut 9000341 on the neck cable 127 1016 to 0 23 0 02 Nm 2 0 0 2 in Ib 572 123 c 2 27 7 The data acquisition system including transducers conforms to requirements of SAE Recommended Practice J211 1 MAR95 572
311. ront Disc Second Row Load Limiters Rear Disc Automatic Door Locks Other Power Windows Power Seats N68 FORM NO 2 CONTINUED REPORT OF VEHICLE CONDITION Remarks Equipment that is no longer on the test vehicle as noted on the previous page Explanation for equipment removal Test vehicle condition 1 2 3 4 5 Adjacent Door Works Is Adjacent Properly In Is Seat Is Curtain Is Seat Track Window in Good Good Airbag Airbag Movable Condition Condition Deployed Deployed Power Power or Yes No N Position Yes No NA Manual Yes No Manual Yes No NA A Yes No NA Left Front Driver Right Front Passenger Right Rear Passenger Left Rear Passenger If No to Items 1 3 in table above please describe the nature of the damage and if the damage 15 repairable replaceable RECORDED BY DATE APPROVED BY N69 FORM NO 3 LABORATORY NOTICE OF TEST FAILURE FRONTAL IMPACT PROTECTION TEST DATE LABORATORY CONTRACT NO DELV ORDER NO LAB PROJECT ENGINEER S NAME VEH MY MAKE MODEL VEHICLE BODY STYLE BUILD DATE NHTSA NO VIN DUMMY TEST FAILURE DESCRIPTION 214 REQUIREMENT PARAGRAPH NOTIFICATION TO NHTSA COTR DATE BY REMARKS N70 FORM NO 4 MONTHLY VEHICLE STATUS REPORT NCAP DATE OF REPORT
312. s 2 The contractor 15 responsible maintaining test dummies in good working order and shall protect and segregate the data that evolves from conducting Part 572 Subpart O dummy calibration tests before and after each vehicle test usage No information concerning the Part 572 Subpart O dummy calibration data shall be released to anyone except the COTR unless specifically authorized by the COTR or the COTR s Branch or Division Chief NOTE No individuals other than contractor personnel directly involved in the dumny calibration test program shall be allowed to witness dummy calibration tests unless specifically authorized by the COTR GOOD HOUSEKEEPING Contractors shall maintain the entire dummy calibration laboratory test fixtures and instrumentation in a neat clean and painted condition with test instruments arranged in an orderly manner consistent with good test laboratory housekeeping practices TEST SCHEDULING AND MONITORING The Part 572 Subpart O dummies are being calibrated as test tools to be used in NCAP vehicle crash tests The schedule for these performance calibration tests must be correlated with that of the vehicle tests In addition all testing shall be coordinated to allow monitoring by the COTR TEST DATA DISPOSITION The contractor shall make all dummy calibration data available to the COTR for review and analysis as required calibration test data for each particular Part 572 Sub
313. s time follows this sheet Signature Date 038 TORSO TEST SET UP SPECIFICATION VERTICAL INITIAL POSITION OF TORSO ATTACHED LOADING ADAPTER 15 REFERENCE PLANE BRACKET TO MACHINED SPINE MAX 1 CENTERLINE OF BOX WELDMENT 210 8020 DETAIL OCCIPITAL CONDYLE TN 210 3107 WITH 4 8 32 SCREWS i OCCIPITAL CONDYLE LOCATION ALSO AXIS LOCATION OF LOAD APPLICATION FINAL POSITION OF 94 11mm TORSO REF PLANE 45 3 705in COMPLETE DUMMY ASSEMBLY 210 0000 REF LOAD CELL 133 96 5 274in PELVIS LUMBAR JOINING SURFACE HORIZONTAL 1 22225tm PULL CABLE 0 875in ATTACH PELVIS REF DWG 210 3000 TO TABLE MOUNTED m LOADING ADAPTER FIXTURE WITH FOUR 1 4 20 BRACKET TYPICAL BOLTS AT THE LUMBAR LOAD q CELL STRUCT REPLACEMENT 210 4510 Ne NN FLAT RIGID SURFACE NC S FIGURE 13D COMBINED WEIGHT OF LOAD CELL LOADING ADAPTER BRACKET PULL CABLE AND ATTACHMENT HARDWARE lt 0 70kg 1 54 Ib 039 08 PART 572 INSTRUMENTATION CALIBRATION INFORMATION DATE OF LAST DATE OF NEXT MANUFACTURER MODEL NO SERIAL NO CALIBRATION CALIBRATION DUMMY INSTRUMENTATION HEAD ACCELEROMETERS NECK ROTATION TRANSDUCER 1 OPTIONAL NECK ROTATION TRANSDUCER 2 OPTIONAL LABORATORY TECHNICIAN APPENDIX E PART 572R 12 MONTH OLD DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE APPENDIX PART 572 SUBPART R DUMMY PERFORMANCE CALIBRATION TEST
314. sent via e mail to pertinent NHTSA personnel within twenty four 24 hours of test completion N50 FORM NO 1 TEST VEHICLE INFORMATION NCAP Frontal Side MDB and Side Pole Tests Vehicle Model Year and Make Vehicle Model and Body Style 1 SEAT FORE AFT POSITION CUSHION ANGLE AND HEIGHT Provide instructions for positioning the driver front outboard passenger and rear left passenger seat s in their testing positions Since seat positioning procedures differ between the Frontal NCAP 50 male and the Side NCAP 50 male two diagrams are provided below to assist in positioning the seat These diagrams assume that the seat will move forward if the seat cushion is moved upward in height SEAT POSITIONING FOR FRONTAL SEAT POSITIONING FOR ALL NCAP 507 PERCENTILE MALE OTHER NCAP DUMMIES LEFT SIDE VIEW LEFT SIDE VIEW SEAT lt gt PUE E 1 Total range of seat travel B Mid track position For more clarification regarding foremost and rearmost seat positions please refer to FMVSS 208 58 1 2 50 Male Driver FMVSS 208 516 2 10 3 5 Female Front Passenger FMVSS 214 58 3 1 3 50 Male Driver FMVSS 214 S10 3 2 3 5 Female Driver and FMVSS 214 58 3 3 3 5 Female Rear Passenger 11 11 1 1B 1 1C N51 Driver s Seat Seat Fore Aft Positioning Depending on the seat track adjuster type complete one of the tables below
315. sent be sure to provide laboratory with detailed instructions prior to test day OCCUPANT CLASSIFICATION SYSTEMS Are all related airbags activated when a 5 percentile female or 50 percentile male dummy is in the seat Please choose YES or NO for each Frontal YES NO Side MDB YES NO Side Pole YES If NO please provide system bypass information Frontal Side MDB Side Pole 11 12 N61 SHOULDER BELT LOAD CELL POSITIONING Frontal NCAP Can a shoulder belt load cell be mounted on the seat belts YES If YES please provide following Distance from the Driver s side D ring to the load cell centerline mm Distance from the Passenger s side D ring to the load cell centerline mm Can a lap belt load cell be mounted on the seat belts YES If there are specific instructions how best to position lap load cell please provide those here HEIGHT ADJUSTABLE SUSPENSION Does this vehicle have a height adjustable suspension Off road modes that must be manually activated are not applicable YES If YES and the suspension does not automatically adjust to default ride mode comfort ride sport ride etc when the ignition 15 set to but the engine is not running please list and describe the ride mode options available on the vehicle and discuss
316. sh The impact surface is rigidly supported 572 122 c 4 The impact surface is a flat horizontal steel plate 50 8 mm 2 inches thick and 610 mm 24 inches square 572 122 c 4 Record thickness Record width Record length Drop the head assembly from a height of 376 0 1 0 mm 14 8 inches 0 04 inches by a means that ensures a smooth instant release onto the impact surface 572 122 b amp 572 122 c 4 Complete the following table using channel class 1000 data 572 122 b Parameter Specification Result Peak resultant acceleration 245 g lt x lt 300 g Resultant versus time history curve Unimodal Oscillations after the main pulse Less than 10 of the peak resultant acceleration Lateral acceleration y axis acceleration lt 15 g Plots of the x y z and resultant acceleration data follow this sheet Signature Date 23 HEAD COMPLETE 127 1000 B PLANE WITH HEAD PERPENDICULAR ACCELEROMETER ASS Y 127 1550 REF INTER FACE DROP HEIGHT 62810 NN STEEL PLATE 224x24 in ou Qx24x24 in IMPACT SURFACE FINISH 203 to 2032 jzmm mm 8 to 80 RMS pin in CENTERLINE 1 57mm 0 062 in DIA HOLES IN SKULL DISTANCE A DISTANCE 0 0 0 1 mm 040 004 in FIGURE 5C 24 DATA SHEET C4 NECK FLEXION TEST 572 123 6 YEAR OLD Dummy Serial Number Test Date Technician __ Pretest calibration Post test calibration verifi
317. shall at COTR s discretion and shall performed without additional costs to the OC WS FINAL PERFORMANCE CALIBRATION REPOR TS COPIES Copies of the data sheets containing the calibration verification data for each Part 572 Subpart P dummy used in the NCAP test shall be submitted with the final test report for the vehicle Contractors are required to PROOF READ all Final Test Reports before submittal to the COTR The OCWS will not act as a report quality control office for contractors Reports containing a significant number of errors will be returned to the contractor for correction and a hold will be placed on invoice payment for the particular test D13 15 DATA SHEETS DATA SHEET D1 DUMMY DAMAGE CHECKLIST 3 YEAR OLD Dummy Serial Number Test Date Technician This check sheet is completed as part of the calibration verification __ Perform general cleaning Dummy Item Inspect for Comments Damaged OK Outer skin Gashes rips cracks Head Ballast secure General appearance Neck Broken or cracked rubber Upper neck bracket firmly attached to the lower neck bracket Looseness at the condyle joint Nodding blocks cracked or out of position Spine Broken or cracks in rubber Ribs Broken or bent ribs Broken or bent rib supports Damping material separated or cracked Rubber bumpers in place Chest Displacement
318. shed to the contract laboratory by the OCWS The dummies shall be stored in a hanging position using the bracket and positioning shown in drawings 1E and 2E 0487 1 25 4 50 1 5 1 4 50 IS THE MINIMUM DIMENSION REQUIRED JRS ARI NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION TO CLEAR THE DUMMIES SHOULDER AND ARM 12 UORT POP EG n0 J C FIGURE IE 4 PLATE STIFFENER AS NEEDED MOUNTING SURFACE PLATE STIFFENER AS NEEDED HANGER PLATE PART DLAB 100 105 MOUNTING SURFACE HYBRID 3 YEAR OLD T 2 7 HANGER PLATE 1 PART 4DLAB1G9 105 12 MONTH OLD UMS ARL ir mm NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION pue GANGER FIGURE 2E E5 These dummies shall be stored in a secured room that is kept between 55 F and 85 F The contractor will check dummy components for damage after each crash test and complete a dummy damage checklist as part of the NCAP procedure which will be included with the dummy calibration if requested The COTR will be kept informed of the dummies condition so that replacement parts can be provided The dummies will be calibrated by the contractor according to the schedule indicated in the NCAP test procedure CALIBRATION AND TEST INSTRUMENTATION Before the contractor initiates the dummy performance calibration test program a test instrume
319. side edges of the outer surface of the windshield and the lower edge of the protected zone previously determined in the plane perpendicular to the edge at that point 4 FMVSS 301 A GENERAL REQUIREMENTS This standard specifies requirements for the integrity of motor vehicle fuel systems It is the contractor s responsibility to follow the most updated FMVSS 301 test procedure when conducting this assessment as part of NCAP testing The latest published versions of all FMVSS test procedures may be found at http www nhtsa gov Vehicle Safety Test Procedures 1 Frontal Impact MAX FLUID SPILLAGE From impact until vehicle motion Lande by weight ceases For 5 minute period after vehicle 5 ounces by weight motion ceases ounce by weight minute For the next 25 minutes 2 Static Rollover 15 MAX FLUID PME SPILLAGE For 5 minute period from onset of saa rotation at each 90 position TUE For 6th minute 1 ounce by weight For 7th minute if required 1 ounce by weight For 8th minute if required 1 ounce by weight B FACILITY AND EQUIPMENT PRE TEST REQUIREMENTS STATIC ROLLOVER MACHINE The rollover machine must be capable of rotating the barrier impacted test vehicle about its longitudinal axis with the axis kept horizontal to each successive increment of 90 180 and 270 at a uniform rate with 90 of rotation taking place in any time interval from 1 to 3 minutes Leakag
320. simultaneously with the driver dummy Adjustments made to the seat to position the driver will over ride any adjustments that would normally be made to position the passenger 516 2 10 3 1 Seat Position 1 1 Position the seat s adjustable lumbar supports so that the lumbar supports are in the lowest retracted or deflated adjustment positions S16 2 10 1 20 1 9 1 520 4 1 522 1 7 1 __ N A No lumbar adjustment 2 Position any adjustable parts of the seat that provide additional support so that they are in the lowest most open adjustment position S16 2 10 2 S20 1 9 2 S20 4 1 522 1 7 1 822 4 2 1 822 4 3 1 524 4 2 1 S26 2 3 S26 3 1 _ N A No additional support adjustment 1 3 Position an adjustable leg support system in its rearmost position 8 27 04 interpretation to Toyota N A No adjustable leg support system 1 4 Mark a point seat cushion reference point on the side of the seat cushion that is between 150 mm and 250 mm from the front edge of the seat cushion 516 3 1 12 1 5 Draw a line seat cushion reference line through the seat cushion reference point S16 3 1 13 1 6 Use only the controls that primarily move the seat in the fore aft direction to move the seat cushion reference point to the rearmost position S16 2 10 3 1 S22 1 7 3 1 7 If the seat cushion adjusts fore aft independent of the seat back use only the controls that primarily move the seat cushion in the fore aft direction to m
321. sing the adjustable seat back Head adjusted using the neck bracket Head Angle degrees _ 18 Measure and set the pelvic angle using the pelvic angle gage TE 2504 The pelvic angle should be 20 0 degrees 2 5 degrees If the pelvic angle cannot be set to the specified range because the head will not be level or because the dummy will have need major repositioning adjust the pelvis as closely as possible to the angle range but keep the head level Pelvic angle set to 20 0 degrees 2 5 degrees Pelvic angle of 20 0 degrees not achieved the angular difference was minimized Record the pelvic angle degrees 19 Check the dummy for contact with the interior after completing adjustments No contact Dummy in contact with interior Seat moved aft mm from the previous position Seatmovedaft X detent positions from the previous position 20 Verify the transverse instrument platform of the dummy head is level 0 5 degrees Use the lower neck bracket adjustment to level the head If a level position cannot be achieved minimize the angle S16 3 3 1 9 16 3 3 1 10 and S16 3 3 1 11 Head Level Achieved Head Angle degrees Head Level NOT Achieved Head Angle degrees 21 Check the dummy to see if additional interior clearance is obtained allowing the seat to be moved forward 516 3 3 1 12 N A Bench Seat N A Seat already at full forward position Clearance unchanged No adjustments
322. sult Initial ref plane angle Angle lt 22 Torso rotation rate 0 5 s lt rate lt 1 5 s Force at 45 0 5 147 N force lt 200 N Final ref plane angle Initial ref plane angle 8 Signature Date C38 TORSO FLEXION TEST SET UP SPECIFICATIONS ATTACH LOADING ADAPTER BRACKET TO MACHINED SURFACE 127 8000 DETAIL IN 127 2022 WITH FOUR 6 32 SCREWS TO MATCH THE POINT OF LOAD APPLICATION WITH THE LEVEL OF THE UNDISTURBED NECK OCCIPITAL CONDYLE PIVOT AXIS INITIAL POSITION VERTICAL P A CENTERLINE OF PIVOT PIN f FINAL POSITION OF ANGLE 20 4mm REF PLANE 45 3 5 p r PIVOT PIN 78051 339 REF 31 8mm 691 125 LOADING ADAPTER BRACKET TYPICAL COMPLETE DUMMY ASSEMBLY 127 0000 ATTACH PELVIS REF 127 3012 CABLE TO TABLE MOUNTED FIXTURE WITH FOUR 14 20 x 1 2 BOLTS COMBINED WEIGHT OF LOAD CELL LOADING ADAPTER BRACKET PULL CABLE AND ATTACHMENT HARDWARE lt 0 77 kg 1 7 Ib PELVIS LUMBAR JOINING SURFACE HORIZONTAL 1 FIGURE 11C C39 DATA SHEET LEFT KNEE IMPACT TEST 572 126 6 YEAR OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive knee impact tests are necessary __1 It has been at least 30 minutes since the last knee impact test 572 127 0 __ N A ONLY one knee impact test performed 2 test
323. t before barrier impact The test vehicle s velocity shall be constant zero acceleration or deceleration for a minimum of the last 5 feet of travel before impact The final velocity shall be measured when the front of the test vehicle is within 1 foot of the barrier face and the reported impact velocity will take into consideration all of the response characteristics of the entire velocity measurement system utilized in its determination Impact velocity will be measured by no less than 2 sets of timing devices and the timing devices shall be accurate to within plus or minus 08 km h 0 05 mph The basis for the speed measurement time and distance shall be calibrated by an instrument traceable to the National Institute of Standards and Technology NIST The impact velocity shall be permanently recorded at a minimum by the photograph taken to satisfy the requirements of this procedure s Appendix N Test Deliverables and Report Requirements The physical locations of the recorded primary and redundant impact velocity readouts should remain the same from test to test for example the laboratory may always choose to display the primary speed on the left hand side etc If the display location of the primary and redundant speeds will change the COTR should be notified prior to the test Another method of permanently documenting the velocities recorded by these timing devices is highly encouraged as is a source of battery power as a backup A t
324. t ensures a smooth instant release onto the impact surface 572 152 b amp 572 152 c 4 Complete the following table 572 152 b Parameter Specification Result Peak resultant acceleration 100 g lt x lt 120g Resultant versus time history curve Unimodal Oscillations after the main pulse Less than 17 of the peak resultant acceleration Lateral acceleration y axis acceleration lt 15 g Plots of the x y z and resultant acceleration data follow this sheet Signature Date 22 FRONTAL HEAD DROP TEST SET UP SPECIFICATIONS NECK HEAD ASSEMBLY I 1 921022 001 STRUCTURAL REPLACEMENT 910420 003 REF T 376 mm 14 8 in IMPACT SURFACE FIGURE E23 DATA SHEET 4 REAR HEAD DROP TEST 572 152 12 MONTH OLD Dummy Serial Number Test Date Technician Pretest calibration Post test calibration verification Test attempt no when successive head drops are necessary 1 It has been at least 2 hours since the last rear head drop and at least 30 minutes since the last frontal head drop 572 152 c 5 N A ONLY one head drop performed 2 The head assembly consists of the head 921022 001 triaxial accelerometer mounting block SA572 S80 and three 3 accelerometers SA572 S4 572 152 a 3 Accelerometers and their respective mounts are smooth and clean 4 data acquisition system including transducers co
325. t is at least 12 5 mm 0 5 in long The probe s end opposite to the impact face must have provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe The impact probe shall have a free air resonant frequency of not less than 1000 Hz in the direction of the longitudinal direction of the impactor FIGURE 12C 44 DATA SHEET C10 PART 572 INSTRUMENTATION CALIBRATION INFORMATION DATE OF LAST DATE OF NEXT MANUFACTURER MODEL NO SERIAL NO CALIBRATION CALIBRATION DUMMY INSTRUMENTATION HEAD ACCELEROMETERS NECK ROTATION TRANSDUCER 1 OPTIONAL NECK ROTATION TRANSDUCER 2 OPTIONAL LABORATORY TECHNICIAN APPENDIX D PART 572P 3 YEAR OLD DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE APPENDIX D PART 572 SUBPART P DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE PURPOSE AND APPLICATION aiiu Od e 1 2 GENERAL REQUIREMENTS sarte NE et ei 1 S eiae EE SA RE ERE 1 4 GOOD HOUSEKEEPING ar 2 5 TEST SCHEDULING AND 12 4 4 1 1110 2 FT DATA DISPOSITION 222022724 D EM 2 7 GOVERNMENT FURNISHED PROPERTY GFP ettet 2 8 CALIBRATION AND TEST INSTRUMENTATION eene 5 9 PHOTOGRAPHIC DOCUMENTATION terret
326. t to rear of vehicle including footage of vehicle s front end damage Passenger dummy post test positioning close up with door closed Frontal view looking through windshield at both dummies Left side view of vehicle interior and driver dummy as technician opens vehicle 9 9 NCAP 22 door g Right side view of vehicle interior and passenger dummy as technician opens vehicle door E Rotating Fixture Coverage a minimum 10 seconds burst during 0 to 90 degree roll a View of Rollover 0 degrees b View of Rollover 90 degrees c View of Rollover 180 degrees d View of Rollover 270 degrees e View of Rollover 360 degrees F If applicable any fuel system windshield seat back or other vehicle failures or testing G anomalies If the Contractor has concerns about whether a test issue should be included please contact the COTR The End STILL PHOTOGRAPHS Clear and properly focused digital still photographs in jpg format with a minimum dots per inch DPI of 180 shall be taken to document the test A target vehicle information placard identifying the test vehicle model as well as the NHTSA number along with an indication of whether the photo was taken pre test or post test shall appear in each photograph and be legible A time date stamp on each photo is also highly recommended Each photograph shall also be labeled when transferred to the FTP site as part of the QuickLook data In addition
327. tal Impact 50 Male Side Impact 50 Male Side Impact 5 Female For the 50 percentile male is the seat back angle measured with the dummy in the seat Frontal YES Side YES NO Describe any references used for measuring the seat back angle e g door sill Include photograph s If possible include measurement from bottom front of head rest post to outboard sun visor anchor or from bottom back of head rest post to middle of rear door striker Frontal Side MDB Side Pole Front Outboard Passenger Seat 5 percentile female in frontal impact only With the seat in the test seat track position what is the angle of the seat back when it is in the forward most locked position Dummy Angle Frontal Impact 5 Female With the seat in the test seat track position what is the angle of the seat back when it is set to the test position Note The seat back angle will be determined by the related dummy seating procedure for the frontal impact test Dummy Angle t Frontal Impact 5 Female Describe any references used for measuring the seat back angle e g door sill Include photograph s If possible include measurement from bottom front of head rest post to outboard sun visor anchor or from bottom back of head rest post to middle of rear door striker Frontal 2 3 2 4 N56 Side MDB Side
328. te If the damage resulted from the vehicle crash test in which the dummy was an occupant the damaged area is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions 9 Clean the impact surface of the skin and the impact surface of the fixture with isopropyl alcohol trichloroethane or equivalent prior to the test 572 132 c 2 210 Ns _12 48 14 215 16 17 B22 Suspend and orient the head assembly as shown in Figure 5B The lowest point on the forehead is 376 0 1 0 mm 14 80 04 inch from the impact surface 572 132 c 3 Record the actual distance NOTE The masses of the suspension device and the accelerometer cables are to be kept as lightweight as possible to minimize their effect on the test results The 1 57 mm 0 062 inch diameter holes located on either side of the dummy s head are equidistance within 2 mm from the impact surface A typical test setup is shown in Figure 6B 572 132 c 3 Record the right side distance Record the left side distance The impact surface is clean and dry and has a micro finish in the range of 203 2x10 mm 8 micro inches to 2032 0 10 mm 80 micro inches RMS 572 132 c 4 Record actual micro finish The impact surface is rigidly supported 572 132 c 4 The impact surface is a flat horizontal steel plate 50 8 mm 2 inches thick an
329. ter of gravity CG of the head assembly NECK The neck force moment transducer shall have the dimensions response characteristics and sensitive axis locations specified in drawing SA572 S23 and shall be mounted as shown in drawing 921022 000 572 155 c E7 CHEST The chest accelerometers shall have the dimensions response characteristics and sensitive mass locations specified in drawing SA572 S4 and be mounted in the torso assembly in triaxial configuration at the T4 location as shown drawing 921022 000 The chest accelerometers are not required for dummy calibration testing but are required for NCAP testing 572 155 e TEST FIXTURE The neck pendulum and thorax accelerometers shall have the dimensions and characteristics of drawing SA572 S4 1 2 OTHER TRANSDUCER CONDITIONS A TRANSDUCER MOUNTS The mountings for sensing devices shall have no resonance frequency less than 3 times the frequency range of the applicable channel class 572 155 k TRANSDUCER SIGN CONVENTION The sign convention for outputs of transducers mounted within the dummy that measure head and chest accelerations chest deflection and neck loads are located in Figure 3E For other transducers see SAE J1733DEC94 572 155 1 TRANSDUCER OUTPUT FILTERING The outputs of acceleration and force sensing devices installed in the dummy and in the test apparatus specified by this part are recorded with individual data channels Each data channel will be co
330. test the Contractor may dispose of it upon notification from the COTR that the test report has been accepted RETEST CONDITIONS FAILURE OF THE CONTRACTOR TO OBTAIN THE SPECIFIED DATA AND TO MAINTAIN ACCEPTABLE LIMITS OF TEST PARAMETERS IN THE MANNER OUTLINED IN THIS TEST PROCEDURE SHALL REQUIRE A RETEST AT THE EXPENSE OF THE CONTRACTOR AND SHALL INCLUDE THE COST OF THE VEHICLE REPLACEMENT AND RETEST AT THE CONTRACTOR S EXPENSE THE PROVISIONS OF THIS PARAGRAPH APPLY BUT ARE NOT LIMITED TO THE CONTRACTOR MAINTAINING PROPER SPEED TOLERANCE VEHICLE SEAT CUSHION AND BACK POSITIONING DUMMY POSITIONING CORRECT LAP AND SHOULDER BELT POSITIONING AND TEST DATA ACQUISITION REDUCTION AND PROCESSING THE CONTRACTOR SHALL ALSO BE RESPONSIBLE FOR OBTAINING USABLE DATA FROM ALL PRIMARY CHANNELS FROM EACH OF THE TWO PART 572 TEST DUMMIES PLACED IN EACH VEHICLE FRONT OUTBOARD DESIGNATED SEATING POSITION DSP FAILURE TO PRODUCE SUCH DATA SHALL ALSO BE AT THE EXPENSE OF THE CONTRACTOR AND SHALL INCLUDE VEHICLE REPLACEMENT AND RETEST SHOULD IT BECOME NECESSARY FOR THE CONTRACTOR TO PROCURE ANOTHER TEST VEHICLE IT MUST HAVE IDENTICAL EQUIPMENT AND OPTIONS AS THE ORIGINAL VEHICLE THE ORIGINAL VEHICLE REMAINS THE PROPERTY OF NHTSA THE RETESTED VEHICLE BECOMES THE PROPERTY OF THE CONTRACTOR THE RETESTED VEHICLE SHALL BE RETAINED WITHOUT FEE BY THE TESTING FACILITY UNTIL ITS DISPOSAL IS AUTHORIZED BY THE COTR F TEST REPORT No test report is re
331. test Passenger s Side Knee Bolster glove compartment without dummy present show passenger knee contact 1f occurred Pre test Passenger s Side Floorpan Post test Passenger s Side Floorpan Post test Passenger Dummy Face Post test Passenger Dummy Contact with Airbag Post test Passenger Dummy Contact with Headrest Photograph of ballast installed in vehicle Post test Stoddard solvent spillage location view if required Post test Speed Trap Read out Vehicle at 0 on Static Rollover Device Vehicle at 90 on Static Rollover Device Vehicle at 180 on Static Rollover Device Vehicle at 270 on Static Rollover Device Vehicle at 360 on Static Rollover Device Model Year gt lt Make gt lt Model gt Frontal Impact Event Monroney Label Photograph N18 INOTE The underbody views should include the following vehicle components fuel pump fuel lines sender unit fuel tank filler pipe and any other visible fuel system components NOTE The numbering convention filenames shown above must be maintained It is deliberate and intended to keep the photos in a specific order when sorting photos electronically N19 REPORT AREA 4 DUMMY RESPONSE DATA TRACES The following data traces should be included as Appendix B of the Final Test Report Fig List of Data Plots Provided In The Test Report Page No No 1 Driver Head X Acceleration vs Time Primary X Driver Head Y Acceleration vs Time Primary Driver Head Z Acceleration vs Time Primar
332. the Contractor shall have a temperature controlled building constructed which is large enough to house the test vehicle and allow for government vehicle manufacturer and laboratory personnel to move around the test vehicle The building climate control must be capable of maintaining the ambient air temperature between 20 6 C and 22 2 C 69 F and 72 F TOW AND GUIDANCE SYSTEMS A guidance system is required to assure that the test vehicle impacts the barrier at the proper angle At most laboratories a monorail running down the center of the tow road is used to guide a dolly to which the vehicle is connected NO HARD POINT CONNECTIONS BETWEEN THE MONORAIL AND TEST VEHICLE WILL BE ALLOWED NCAP 5 B A soft lateral guidance system is required to assure that test vehicle will impact the barrier face at the designated 90 angle straight perpendicular impact It is suggested that the Contractor s lateral guidance system include steel cables or chains extending from the vehicle lower A arms or front frame rails to the monorail dolly or shoe The dolly will ride on the monorail and may engage the tow cable through a set of gripper jaws The dolly will be stopped at the end of the tow road monorail or at the head of the photographic pit releasing the vehicle cables or chains at the same time allowing the vehicle to proceed to the barrier face for impact C A soft connection seat belt webbing steel cables chains etc between the
333. the damaged area is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions Inspect the nodding blocks 78051 351 for any deterioration but when replacement is necessary ONLY replace during pre test calibration Using a Shore A type Durometer verify the hardness of nodding blocks is between 80 and 90 Ensure the nodding blocks are installed correctly 78051 90 Record findings and actions Pre test calibration neck cable torque Torque the jam nut 78051 64 on the neck cable 78051 301 to 1 0 0 2 Ib ft by loosening the jam nut and relaxing the neck cable before torquing 572 33 c 2 The data acquisition system including transducers conforms to the requirements of SAE Recommended Practice J211 1 MAR95 572 36 1 11 212 28 The test fixture pendulum conforms to specifications in Figure 8A 572 33 c 3 The head neck assembly is mounted on the pendulum so the midsagittal plane of the head is vertical and coincides with the plane of motion of the pendulum longitudinal centerline as shown in Figure 9A for the flexion test 572 33 c 3 Install the transducers or other devices for measuring the D plane rotation with respect to the pendulum longitudinal centerline Note Plane D is the bottom horizontal surface of the skull These measurement devices should be designed to
334. their accuracy and stability B All measuring instruments and standards shall be calibrated by the contractor or a commercial facility against a higher order standard at periodic intervals not exceeding 12 months for instruments and 12 months for calibration standards Records showing the calibration traceability to the National Institute of Standards and Technology NIST shall be maintained for all measuring and test equipment C measuring and test equipment and measuring standards shall be labeled with the following information 1 Date of calibration 2 Date of next scheduled calibration 3 Name of the technician who calibrated the equipment D The contractor shall provide a written calibration procedure that includes as a minimum the following information for all measurement and test equipment 1 Type of equipment manufacturer model number etc 2 Measurement range 3 Accuracy 4 Calibration interval 10 1 D6 5 Type of standard used to calibrate the equipment calibration traceability of the standard must be evident 6 The actual procedures and forms used to perform calibrations The contractor shall keep records of calibrations for all test instrumentation in a manner that assures the maintenance of established calibration schedules such records shall be readily available for inspection when requested by the COTR The calibration system will need the written acceptance of the COTR before tes
335. tial contact between the test probe and chest skin Force impactor mass x acceleration 572 134 b 3 Area under loading curve minus the area under the unloading curve divided by the area under the loading curve Figure 12B 17 Plots of chest compression pendulum acceleration pendulum force and pendulum force versus chest compression follow this sheet Signature Date B36 THORAX IMPACT TEST SETUP SPECIFICATIONS IMPACT PROBE SUPPORT 0 INDEX MARKS ALIGNED CABLES REF DWG 880105 207 ACCELEROMETER MOUNTED AND 880105 208 WITH SENSITIVE AXIS IN LINE WITH CENTERLINE OF TEST PROBE LONGITUDINAL AXIS REF SA572 S4 CENTERLINE OR ARMS ORIZONTAL 2 TEST PROBE CENTERLINE NO 3 RIB CENTERLINE HORIZONTAL 20 5 HORIZONTAL 40 5 PELVIC ANGLE MEASUREMENT REFERENCE SURFACE 7 2 IMPACT PROBE WEIGHT INCLUDING ALL INSTRUMENTATION AND 1 3 OF SUPPORT CABLE WEIGHT 13 97 40 023 kg 30 8 4 0 05 Ib a lt lt lt PELVIC ADAPTER BLOCK P N 880105 1094 COMPLETE DUMMY ASSEMBLY 880105 000 FLAT SMOOTH RIGID CLEAN DRY SEATING SURFACE HORIZONTAL 0 5 1 3 CABLE WEIGHT NOT TO EXCEED 5 OF THE TOTAL IMPACT PROBE WEIGHT Probe specifications 1 2 Rigid metallic construction concentric about its longitudinal axis A mass of 13 97 0 023 kg 30 8 0 05 lbs 1 3 of the weight of the suspension cables and their attachments to t
336. tible with and recordable in a J211 channel The channel by definition includes all the instrumentation from the transducer to the data acquisition system output The channels therefore include the accelerometers mounted in the dummy connected to a data acquisition system using connectors wiring data acquisition software and hardware The polarity of a data channel for any given dummy may therefore be affected by changing the manufacturer of the accelerometer positive and negative pins from the accelerometer to the wiring in a connector the polarity assigned in software and by changing the way it is mounted in the dummy Since there are many ways to influence the polarity of a data channel it is appropriate to document the polarity of the assembled channel just before testing to assure the accelerometer is not exchanged with that of another manufacturer s and that no changes are made to the way 15 mounted in the dummy the connector pin arrangement and polarity assigned in software before testing When a test dummy is delivered for a test and connected to the data acquisition system the polarity of the internal accelerometers can be established using the following approach The procedure requires the user to think of the data channel as a black box The procedure requires manipulating the dummy head to determine the polarity of the black box with respect to the sign convention If the polarity is wrong then steps must be taken to correct it prior
337. ting begins Test equipment shall receive a calibration check immediately prior to and after each test This check shall be recorded by the test technician s and submitted with the final report Anthropomorphic test devices shall be calibrated as indicated in NCAP test procedure These calibrations shall be submitted with the final report PHOTOGRAPHIC DOCUMENTATION Provide still photographs color prints properly focused for clear images no more than two 2 per 8 5 x11 sheet of post test damage resulting from the vehicle crash test DEFINITIONS PADI Procedures for Assembly Disassembly and Inspection PRETEST REQUIREMENTS TRANSDUCER REQUIREMENTS The contractor shall provide and install the following instrumentation to the GFP dummies excluding the chest deflection transducer A HEAD The head accelerometers shall have dimensions response characteristics and sensitive mass locations specified in drawing SA572 S4 and be mounted in the head as shown in drawing 210 0000 572 146 b Three accelerometers shall be mounted in the head cavity to measure orthogonal accelerations Ax Ay Az at the center of gravity CG of the head assembly NECK The upper neck force transducer shall have the dimensions response characteristics and sensitive axis locations specified in drawing SA572 S19 and shall be mounted at the upper neck transducer location as shown in drawing 210 0000 572 146 c D7 CHEST The chest
338. tments other than vertical adjust them as recommended by the manufacturer N A No head restraint adjustment 13 Place any adjustable seat belt anchorages at the vehicle manufacturer s nominal design position for a 50th percentile adult male occupant S8 1 3 N A No adjustable upper seat belt anchorage Manufacturer s specified anchorage position Tested anchorage position 14 Place adjustable pedals in the full forward position N A the pedals not adjustable 15 Is the steering wheel adjustable up and down and or in and out Yes go to 16 No go to 19 16 Find and mark each up and down position Label three of the positions with the following H for highest M for mid position if there is no mid position label the next lowest adjustment position and L for lowest N A steering wheel is not adjustable up and down _ 17 Find and mark each in and out position Label three of the positions with the following for foremost M for mid position if there is no mid position label the next rearmost adjustment position and R for rearmost N A steering wheel is not adjustable in and out 18 Set the steering wheel hub at the geometric center of the full range of driving positions including any telescoping positions _ 19 Place the dummy in the seat such that the midsagittal plane is coincident with the longitudinal seat cushion markings as determined in item 10 or 11 and the upper torso
339. to determine compliance with the requirements of NCAP The schedule for these performance calibration tests must be correlated with that of the vehicle tests All testing shall be coordinated to allow monitoring by the COTR TEST DATA DISPOSITION The contractor shall make all dummy calibration data available to the COTR for review and analysis as required calibration test data for each particular Part 572 Subpart E dummy will be sent to the COTR with each test report 4 backup data sheets strip charts recordings plots technicians notes etc shall be either sent to the COTR or destroyed at the conclusion of each delivery order purchase order etc GOVERNMENT FURNISHED PROPERTY GFP P572 test dummies will be furnished to the contract laboratory by the OCWS The dummies shall be stored in an upright sitting position with the weight supported by the internal structure of the pelvis The dummies head shall be held upright without supporting the weight of the dummy by using an eyebolt that can be secured in the top of the head These dummies shall be stored in a secured room that is kept between 55 F and 85 F The contractor will check dummy components for damage after each crash test and complete a dummy damage checklist Section 15 Data Sheets that will be included with the posttest dummy calibration The COTR will be kept informed of the dummies condition in order that replacement parts can be provided The contractor s
340. to setting the front seating positions consult Appendix F of this document for a check list pertaining to the proper procedure NOTE If a seat track latching verification procedure is included with the Form 1 provided by the COTR ensure that procedure is followed ADJUSTABLE HEAD RESTRAINTS Prior to adjusting the head restraints consult Appendix F of this document for a check list pertaining to the proper procedure STEERING WHEEL ADJUSTMENT Consult Appendix F of this document for a check list pertaining to the proper procedure for adjusting the steering wheel ADJUSTABLE ARMRESTS Place any adjustable armrest in the retracted position NCAP 31 S ADJUSTABLE BELT ANCHORAGES 1 50 Male Dummy Place adjustable anchorages in the nominal adjustment position in accordance with the manufacturer s data supplied by the COTR 2 5 Female Dummy Place adjustable anchorages in the nominal adjustment position in accordance with the manufacturer s data supplied by the COTR T WINDOWS 1 Place driver and passenger front windows in the fully open position Place all other windows and vents in the fully closed position unless otherwise specified by the COTR 2 The windshield mounting material and all vehicle components in direct contact with the mounting material must be at a temperature between 15 F and 110 F This temperature measurement must be made within 15 minutes of the impact test event 3 Adjustable cowl tops or othe
341. to submitting data to NHTSA so that data is in accordance with the sign convention However it is M2 recommended to correct and document the channel polarity at the test site so no further modifications to the data are required If difficulty is experienced in determining the polarity when these procedures are being properly followed it may indicate that the accelerometer has not been mounted in accordance with the dummy instrumentation assembly drawings contained in the appropriate Nine Array Head with Redundant C G Accelerometers User s Manual SAE J211 Procedure The body coordinate system used for reference is attached to the dummy and is x positive pointing forward y positive pointing to the right and z positive pointing down For NHTSA tests the accelerometers referred to are those meeting NHTSA 5 572 54 specifications The SAE J1733 explains that for any dummy component oriented in its standard position blows to the back side left side and top will produce positive accelerations relative to its x y and z directions respectfully As an example to document the polarity of the dummy s head x axis accelerometer data channel in a plot similar to Figure 1 apply a blow to the back of the head with a rubber mallet and record the data channel output The polarity of Figure 1 dummy channel is positive and no changes are needed to conform to the sign convention Similarly to document the polarity of the dummy s y and z axis accelerometer
342. to the longitudinal centerline of the vehicle 4 5 Camera 6 7 Camera 8 Camera 9 Camera 10 NCAP 15 Filename Camera No 4 LEFT ANGLE High speed left side view camera positioned adjacent to the vehicle s B post or center post at an angle to document the movement of the driver dummy during the impact event Filename Camera No 5 STEERING COLUMN TOP High speed left side view camera positioned adjacent to the vehicle s B post to document the movement of the vehicle s steering column wheel assembly relative to the roof targets and the rear sill target during the impact event This camera is also used for steering column displacement analysis The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle Filename Camera No 6 STEERING COLUMN BOTTOM High speed left side view camera positioned adjacent to the vehicle s left front door and underneath to document the movement of the vehicle s steering column wheel assembly relative to the roof target and the rear sill targets during the impact event This camera is also used for steering column displacement analysis The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle Filename Camera No 7 RIGHT OVERALL High speed right side view camera to cover the entire right side of the test vehicle during the impact event The centerline of the came
343. tric center of the locus it describes when it is moved through its full range of positions Test detent is taken with respect to the upper most detent which is defined as 0 SEATING REFERENCE POINT SgRP Please give the location of the Seating Reference Point SgRP for each vehicle seating position Coordinates mm X forward Y right Z down Seating Position Left Front Driver Right Front Front Passenger Left Second Row Rear Passenger Describe any references used for measuring the SgRP e g center of the front door striker Include photograph s DUMMY MEASUREMENTS FOR THE 5018 MALE AND 5 FEMALE See the attached instructions and diagram and provide measurements for the following seat configurations NR CS KDL KDR SH SHY HS N59 Driver Manual Seat Driver Power Seat Passenger Manual Seat Passenger Power Seat 2nd Row Occupant Side only 8 FUEL TANK CAPACITY DATA VEHICLE FUEL TANK ASSEMBLY Usable capacity of standard equipment fuel tank gal Usable capacity of optional equipment fuel tank gal Capacity used when lt 1 lt certification testing to eters CAPACITY requirements of FMVSS No 301 gal UNUSABLE CAPACITY Operational instructions VAPOR VOLUME FILLER PIPE VOLUME FILLER CAP US
344. ts and or specifications of the NCAP Laboratory Test Procedure and Statement of Work applicable to the test INVALID TEST NOTIFICATION The Contractor shall notify NHTSA of any test not meeting all requirements and specifications of the NCAP Laboratory Test Procedure and Statement of Work applicable to the test by telephone within 24 hours of the test and send written notice to the COTR within 48 hours of the test completion RETEST NOTIFICATION The COTR is the only NHTSA official authorized to notify the Contractor that a retest is required The retest shall be completed within 2 weeks after receipt of notification by the COTR that a retest 15 required WAIVER OF RETEST NHTSA in its sole discretion reserves the right to waive the retest requirement This provision shall not constitute a basis for dispute over the NHTSA s waiving or not waiving any requirement TEST VEHICLE NHTSA shall furnish only one vehicle for each test ordered The Contractor shall furnish the test vehicle required for the retest if it is determined that the Contractor is at fault The retest vehicle shall be equipped as the original vehicle The original vehicle used in the invalid test shall remain the property of NHSTA and the retest vehicle shall remain the property of the Contractor The Contractor shall retain the retest vehicle for a period NCAP 51 not exceeding 180 days if it fails any of test criteria If retest vehicle passes
345. ually inspect the head skin for cracks cuts abrasions etc Repair or replace the head skin if the damaged area is more than superficial Note If the damage resulted from the vehicle crash test in which the dummy was an occupant the damaged area is to be documented with photography and the post test calibration verification testing completed before any replacement or repairs are made Record findings and actions Clean the impact surface of the skin and the impact surface of the fixture with isopropyl alcohol trichloroethane or equivalent prior to the test 572 122 c 2 210 m _12 48 14 215 16 17 C22 Suspend and orient the head assembly as shown in Figure 5C The lowest point on the forehead is 376 0 1 0 mm 14 8 0 04 inch from the impact surface 572 122 c 3 Record the actual distance NOTE The masses of the suspension device and the accelerometer cables are to be kept as lightweight as possible to minimize their effect on the test results The 1 57 mm 0 062 inch diameter holes located on either side of the dummy s head are equidistance within 2 mm from the impact surface A typical test setup is shown in Figure 5C 572 122 c 3 Record the right side distance Record the left side distance The impact surface is clean and dry and has a micro finish in the range of 203 2 10 mm 8 micro inches to 2032 0 10 mm 80 micro inches RMS 572 122 c 4 Record actual micro fini
346. uel Spillage The fall flow or run of fuel from the vehicle but does not include wetness resulting from capillary action 571 301 S3 Gross axle weight rating or GAWR The value specified by the vehicle manufacturer as the load carrying capacity of a single axle system as measured at the tire ground interfaces 571 3 Gross vehicle weight rating or GVWR The value specified by the manufacturer as the loaded weight of a single vehicle 571 3 H Point The mechanically hinged hip point of a manikin which simulates the actual pivot center of the human torso and thigh described in SAE Recommended Practice J826 Manikins for Use in Defining Vehicle Seating Accommodations November 1962 571 3 Longitudinal or longitudinally Parallel to the longitudinal centerline of the vehicle 571 3 Outboard designated seating position A designated seating position where a longitudinal vertical plane tangent to the outboard side of the seat cushion is less than 12 inches from the innermost point on the inside surface of the vehicle at a height between the design H point and the shoulder reference point as shown in fig 1 of Federal Motor Vehicle Safety Standard No 210 and longitudinally between the front and rear edges of the seat cushion 571 3 Overall vehicle width The nominal design dimension of the widest part of the vehicle exclusive of signal lamps marker lamps outside rearview mirrors flexible fender extensions and mud flaps dete
347. up and maintained as follows A Standards for calibrating the measuring and test equipment shall be stored and used under appropriate environmental conditions to assure their accuracy and stability B measuring instruments and standards shall be calibrated by the contractor or a commercial facility against a higher order standard at periodic intervals not exceeding 12 months for instruments and 12 months for calibration standards Records showing the calibration traceability to the National Institute of Standards and Technology NIST shall be maintained for all measuring and test equipment C measuring and test equipment and measuring standards shall be labeled with the following information 1 Date of calibration 2 Date of next scheduled calibration 3 Name of the technician who calibrated the equipment D The contractor shall provide a written calibration procedure that includes as a minimum the following information for all measurement and test equipment 1 Type of equipment manufacturer model number etc 10 4 2 Measurement range 3 Accuracy 4 Calibration interval 5 Type of standard used to calibrate the equipment calibration traceability of the standard must be evident 6 The actual procedures and forms used to perform calibrations E The contractor shall keep records of calibrations for all test instrumentation in a manner that assures the maintenance of established calibration schedu
348. ure Record the maximum humidity Record the minimum humidity Seat the dummy without back support on the test fixture surface as shown in Figure 10 The legs are extended forward parallel to the midsagittal plane The surface must be long enough to support the pelvis and outstretched legs 572 154 c 3 The midsagittal plane of the dummy is vertical within 1 572 154 c 3 The posterior surface of the upper spine box is 90 1 from the horizontal Shim material may be used under the upper legs to maintain the dummy s specified spine box surface alignment 572 154 c 3 Place the upper arms parallel to the torso Place the lower arms 0 to 5 forward of vertical 572 154 c 3 The longitudinal centerline of the test probe is centered within 2 5 mm of the midsagittal plane 196 2 5 mm vertically from the plane of the seating surface and is within 40 5 of a horizontal line in the dummy s midsagittal plane 572 154 c 4 The data acquisition system including transducers must conform to the requirements of SAE Recommended Practice J211 1 MAR95 572 146 1 Impact the anterior surface of the thorax with the test probe so the longitudinal centerline of the probe is within 2 of a horizontal line in the dummy s midsagittal plane at the moment of impact 572 154 c 5 The velocity of the test probe at the time of impact 1s between 4 9 m s and 5 1 m s 572 154 b The probe is guided so there is no significant lateral vertical or r
349. urface of the head to fixture s rear vertical 482 584 surface Reference HYBRID III SUBPART P EXTERNAL DIMENSIONS continued 017 ASSEMBLY ACTUAL DIMENSION DESCRIPTION DETAILS du MEASUREMENT CHEST DEPTH WITH JACKET Measured 254 0 5 1 mm above seat surface 138 5 153 7 FOOT LENGTH Tip of toe to rear of heal 137 6 147 8 Lay the dummy out on a flat surface with the rear surfaces of the head upper torso buttocks and heels touching the surface STATURE and with the bottom of the feet perpendicular to that surface 932 2 957 6 Measure the distance from the bottom of the feet to the top of the head TORNER ENOL Knee pivot bolt to the fixture s rear vertical surface 251 4 261 6 Distance across widest of head its widest point 128 3 143 5 Distance from the forward most surface of the head to the HEAD DEPTH rearmost surface of the head in line with midsgittal plane SE HIP BREADTH across width of hip at widest point of the 200 7 215 9 SHOULDER BREADTH Distance between the outside edges of the shoulder flesh in line 236 5 251 7 with the shoulder pivot bolts FOOT BREADTH The widest part of the foot 53 6 63 8 HEAD CIRCUMFERENCE At the largest location 500 4 515 6 CHEST CIRCUMFERENCE ree WITH JACKET Distance around chest at reference location AA with jacket 527 1 552 5 WAIST CIRCUMFERENCE Distance around chest at reference location BB with jac
350. usted so that the seat cushion angle can be at the angle used in the certification test describe the height used during certification testing and how to measure it Include any reference points and photographs Dummy Angle Used Additional Description Frontal Impact 5 Female Provide any other instructions for positioning the front passenger seat at the required test position Frontal In addition please indicate the manufacturer of the 5th percentile dummy used for FMVSS 208 crash test certification Rear Seats 5 percentile dummy in MDB side impact only Seat Fore Aft Positioning Depending on the seat track adjuster type complete one of tables below Manual Seat Track Adjuster Total number of detents Side impact test detent 5 percentile female For manual seat track adjustments test detent is measured from foremost detent which is defined as 0 Power Seat Track Adjuster Complete range of travel mm Side impact test distance from the foremost position 5 percentile female 1 38 1 3C 1 3D 2 1 N54 Seat Cushion Angle If the seat cushion angle is adjustable while maintaining test fore aft seat track position describe the angle used during certification testing and how to measure it Include any reference points and photographs Dummy Angle Used Additional Description Side Impact 5 Fema
351. vots HEAD BACK TO BACKLINE Back of Skull cap skin to seat rear vertical surface Reference 1 6 1 8 Measure from the highest point on top of the shoulder clevis to the lowest part of the flesh on the elbow in line with the elbow 13 0 13 6 pivot bolt ELBOW REST HEIGHT 2 from flesh below the elbow pivot bolt to seat 75 83 BUTTOCK TO KNEE The forward most part of the knee flesh to the rear vertical 22 8 23 8 LENGTH surface of the fixture POPLITEAL HEIGHT 1 to plane of horizontal plane of the bottom of 16 9 17 9 KNEE PIVOT HEIGHT Centerline of knee pivot bolt to the horizontal plane of the 19 1 19 7 bottom of the feet BUTTOCK POPLITEAL The rearmost surface of the lower leg to the same point on the 17 8 18 8 LENGTH rear surface of the buttocks used for dim K SHOULDER TO ELBOW LENGTH 19 HYBRID III SUBPART E EXTERIOR DIMENSIONS continued DIMENSION DESCRIPTION DETAILS MEASUREMENT CHEST DEPTH WITHOUT JACKET Measured 16 9 17 1 in above seat surface P LENGTH Tip of toe to rear of heal SHOULDER BREADTH Outside edges of right and left shoulder clevises FOOT BREADTH The widest part of the foot 6 4 CHEST CIRCUMFERENCE Measured 16 9 17 1 in above seat surface 38 2 39 4 WAISTCIRCUMFERENCE CIRCUMFERENCE Mer 8 9 9 1 in above seat surface 32 9 34 1 REFERENCE LOCATION FOR MEASUREMENT OF Reference 16 9 17
352. wing information 1 Date of calibration 2 Date of next scheduled calibration 3 Name of the technician who calibrated the equipment D A written calibration procedure shall be provided by the Contractor which includes as a minimum the following information for all measurement and test equipment Type of equipment manufacturer model number etc Measurement range Accuracy Calibration interval Type of standard used to calibrate the equipment calibration traceability of the standard must be evident 6 The actual procedures and forms used to perform the calibrations hoe npa NCAP 11 Records of calibration for all test instrumentation shall be kept by the Contractor in a manner that assures the maintenance of established calibration schedules such records shall be readily available for inspection when requested by the COTR The history of the record shall be updated in an electronic file The calibration system will need the acceptance of the COTR before NCAP testing commences Test equipment shall receive a system functional check out using a known test input before and after the test This check shall be recorded by the test technician s and submitted with the final report Anthropomorphic test devices ATDs shall be calibrated before and after every NCAP test The calibrations and calibration checks shall be submitted with both the Quality Control Package see Appendix N and the final report The suite of p
353. with its sensitive axis collinear with the longitudinal axis of the probe de The impact probe shall have a free air resonant frequency of not less than 1000 Hz FIGURE 14B 46 DATA SHEET 10 PART 572 INSTRUMENTATION CALIBRATION INFORMATION DATE OF LAST DATE OF NEXT MANUFACTURER MODEL NO SERIAL NO CALIBRATION CALIBRATION DUMMY INSTRUMENTATION HEAD ACCELEROMETERS NECK ROTATION TRANSDUCER 1 OPTIONAL NECK ROTATION TRANSDUCER 2 OPTIONAL LABORATORY TECHNICIAN APPENDIX PART 572 6 OLD DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE APPENDIX PART 572 SUBPART N DUMMY PERFORMANCE CALIBRATION TEST PROCEDURE PURPOSE AND APPLICATION nebst teet dto iub Po tet 1 27 GENERALREQUIREMENTIS entsteht etai aea Pis t 1 EE Je d uum Sua E LL MAE EE 1 JGOOLD HOUSEREEPING x u patam et latere 2 5 TEST SCHEDULING AND 1 24 4 0 10 2 TESTDATA DISPOSTI ION p 7 GOVERNMENT FURNISHED PROPERTY GFPP ettet 3 8 CALIBRATION AND TEST INSTRUMENTATION ettet 3 9 PHOTOGRAPHIC DOCUMENTATION mama nasa andere 4 DENN Y pun NS LEE u SDD 4 PRESTON tani S s LM AE end aen 5 11 1 TRANSDUCER REQUIREMENTS ccscsscsccsssesscssessscsssecsssssseesssssesessuseecsrssesessnevesssseses 5 11
354. ximum temperature Record the minimum temperature Record the maximum humidity Record the minimum humidity __5 Mount the test specimen and secure it to the rigid test fixture 572 126 c 2 6 No parts of the foot or tibia contact any exterior surface 572 126 c 2 7 Align the test probe so that throughout its stroke and at contact with the knee it is within 2 degrees of horizontal and collinear with the longitudinal centerline of the femur 572 126 c 3 8 probe is guided so there is no significant lateral vertical or rotational movement during the impact with the knee 572 136 c 4 9 The data acquisition system including transducers must conform to the requirements of SAE Recommended Practice 1211 1 MAR95 572 136 m Class 600 10 Contact the knee with the test probe at a speed between 2 07 m s and 2 13 m s 572 126 c 5 Neither the suspension hardware suspension cables nor other attachments to the probe including the velocity vane make contact with the dummy 572 126 c 6 42 11 Complete following table Knee Impact Results 572 126 b 1 and 572 126 c 5 Parameter Specification Result Probe speed 2 07 m s lt speed lt 2 13 m s Peak resistance force 2000 N lt force lt 3000 N Force impactor mass x deceleration 572 126 b 2 Plots of acceleration versus time and force versus time follow this sheet Signature Date C43 KNEE IMPACT TEST
355. y Moment in Nm measured by the transducer Force in N measured by the transducer Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material 572 123 b 3 2214 Plots of acceleration velocity y axis moment and x axis force and y axis moment about the occipital condyle follow this sheet Signature Date C28 PENDULUM SPECIFICATIONS 101 6 mm t ini STRUCTURAL STEEL TUBE boo mm 4 8 mm 10 1875 in p 31 8 mm PIVOT 50 8 mm 2 in DIA 11 25 in INERTIAL PROPERTIES OF PENDULUM MOUNTING PLATE AND MOUNTING HARDWARE WITHOUT TEST SPECIMEN T PENDULUM X 7 ACCELEROMETER CENTERLINE WEIGHT 29 57 165 21 156 198 1 mm MOMENT OF INERTIA 33 2 kg m roy 8 294 in Ib sec ABOUT PIVOT AXIS P 7 4 8 mm GE 188 in mm 38 1 mm 8 28 mm f 7 F 11 5 in 132 6m3 A i f i ON 886 2 mm 188 6 mm CG OF PENDULUM SES 9225 in 7 75 in APPARATUS WITHOUT 7 Eu 463 6 NE RADIOS HEXCEL 28 8 kg m zw 1 8 1b ft REF ACCELEROMETER BEFORE TESTING RECRUSH THE HONEYCOMB w MATFRIAL WITH THE PENDULUM TO ASSURE THAT 90 TO 100 OF THE HONEYCOMB SURFACE 15 CONTACTING THE PENDULUM STRIKER PLATE 4 ft 38 1 mm REF 1 5 in MOUNTING PLATE PENDULUM STRIKER PLATE SHARP EDGES 76 2 x 152 4 x 9 5
356. y Driver Head Resultant Acceleration vs Time Primary Driver Chest X Deflection vs Time 2 3 4 5 6 Driver Chest X Acceleration vs Time Primary 7 Driver Chest Y Acceleration vs Time Primary 8 Driver Chest Z Acceleration vs Time Primary 9 Driver Chest Resultant Acceleration vs Time Primary 10 Driver Upper Neck Force X vs Time Primary 11 Driver Upper Neck Force Z vs Time Primary 12 Driver Upper Neck Moment Y vs Time Primary 13 Driver Nij vs Time Primary 14 Driver Left Femur Force vs Time 15 Driver Right Femur Force vs Time 16 Passenger Head X Acceleration vs Time Primary 17 Passenger Head Y Acceleration vs Time Primary 18 Passenger Head Z Acceleration vs Time Primary 19 Passenger Head Resultant Acceleration vs Time Primary 20 Passenger Chest X Deflection vs Time 2 Passenger Chest X Acceleration vs Time Primary 22 Passenger Chest Y Acceleration vs Time Primary 23 Passenger Chest Z Acceleration vs Time Primary 24 Passenger Chest Resultant Acceleration vs Time Primary 25 Passenger Upper Neck Force X vs Time Primary 26 Passenger Upper Neck Force Z vs Time Primary W X x 27 Passenger Upper Neck Moment Y vs Time Primary N20 28 Passenger Nij vs Time Primary X 29 Passenger Left Femur Force vs Time X 30 Passenger Right Femur Force vs Time X The following additional dummy and vehicle response data ca
357. y D 20 P uu Cu annus uvm iom Ec D D 23 DATA SHBET ES de tia eae 26 DATA SHEET EE RE Duka kuwanae dde 28 DAT ASI DE uu te I u SE la ap TN dE E a MEN 33 DATA STEELE Ero tede e NSS SSS e adis eise e dun 36 El PURPOSE AND APPLICATION The purpose of this laboratory procedure is to provide dummy users independent testing laboratories under contract with the Office of Crashworthiness Standards with standard test procedures for performing receiving inspection and performance calibration tests on the Part 572 Subpart R dummy so that repetitive and correlative test results can be obtained The following tests have been developed to establish a uniform calibration procedure for all users as the means of verifying the performance of the dummy A EXTERNAL DIMENSIONS PADI B HEAD DROP TEST 572 152 C NECK FLEXION TEST 572 153 b 1 D NECK EXTENSION TEST 572 153 b 2 E THORAX IMPACT TEST 572 154 National Highway Traffic Safety Administration NHTSA contract laboratories performing NCAP testing for the Office of Crashworthiness Standards OCWS must use this laboratory procedure for the calibration of Part 572 Subpart R dummies GENERAL REQUIREMENTS The Code of Federal Regulations 49CFR Parts 571 and 572 was amended to adopt the Hybrid CRABI 12 Month Old Dummy as the means of determining a vehicle s conforman
358. y as Government Furnished Property GFP will be stored in a safe and secure area such as a dummy calibration laboratory The contractor is financially responsible for any acts of theft and or vandalism which occur during the storage of GFP Any security problems shall be reported by telephone to the Industrial Property Manager IPM Office of Contracts and Procurement within two working days after the incident A letter containing specific details of the security problem will be sent to the IPM with copy to the COTR within 48 hours C2 The contractor is responsible for maintaining the NHTSA test dummies in good working order and shall protect and segregate the data that evolves from conducting Part 572 Subpart N dummy calibration tests before and after each vehicle crash usage No Information concerning the Part 572 Subpart N dummy calibration data shall be released to anyone except the COTR unless specifically authorized by the COTR or the COTR s Branch or Division Chief NOTE No individuals other than contractor personnel directly involved in the dummy calibration test program shall be allowed to witness dummy calibration tests unless specifically authorized by the COTR GOOD HOUSEKEEPING Contractors shall maintain the entire dummy calibration laboratory test fixtures and instrumentation in a neat clean and painted condition with test instruments arranged in an orderly manner consistent with good test laboratory housekeeping
359. zation purposes Section Page No 1 Purpose and Summary of Test X 2 Occupant and Vehicle Information Data Sheets X Data Sheet No Page No 1 General Test and Vehicle Parameter Data x 2 Seat Adjustment Fuel System and Steering Wheel Data X 3 Dummy Longitudinal Clearance Dimensions X 4 Dummy Lateral Clearance Dimensions X 5 Seat Belt Positioning Data x 6 High Speed Camera Locations and Data X 7 Vehicle Accelerometer Locations X 8 Photographic Reference Target Locations X 9 Load Cell Locations on Fixed Barrier X 10 Test Vehicle Summary of Results X 11 Post Test Observations X 12 Vehicle Profile Measurements X 13 Accident Investigation Division Data X 14 Vehicle Intrusion Measurements X 15 Summary of FMVSS 212 FMVSS 219 Partial Data and X 301 Data 16 FMVSS 301 Static Rollover Results X 17 Dummy Vehicle Temperature Stabilization Chart x Appendix Page No A Photographs AX B Dummy Response Data Traces BX Dummy Calibration and Performance Verification Data CX REPORT AREA 1 PURPOSE AND SUMMARY OF TEST PURPOSE This area briefly outlines the purpose for conducting the frontal impact test and states the appropriate test procedure followed during the test The following is provided as an example This Speed km h frontal barrier impact test is part of the Vehicle Barrier Impact Testing Program sponsored by the National Highway Traffic Safety Administration NHTSA under Contract N

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