HARDWARE USER`S MANUAL
Contents
1. Figure A1 RibEye measurement range in X Y plane 21 February 2011 RIBS 1 3 4 6 RIBS 2 5 Dummy Z 20 25 30 35 40 45 50 55 60 6 7 75 80 8 90 95 100 Dummy Y Figure A2 RibEye measurement range in Y Z plane X Errors mm Y Errors mm Z Errors mm of I points maximum average maximum average maximum average Shoulder Tnorace2 131 01 058 008 074 00 7238 Thoracic3 1 88 019 086 016 052 006 7236 Abdominal2 082 0o11 os oo 09 007 7236 Table A1 Calibration check data for WorldSID RibEye Model 10000 serial number 0075 Axis Channel Amplitude Class Max Error mm Error as a of CAC CAC a 2 0 83 a a 1 32 80 a 40 i 1 25 Table A2 The SAE J211 Channel Amplitude Class CAC and the maximum error as a percent of the CAC 22 February 2011 A2 Power Requirements The RibEye can be powered by a high quality DC voltage source from 12 to 36 Volts and it is intended to be powered by the Messring MBUS system at 20 VDC At idle the RibEye will draw 8 watts When collecting data it will draw 12 watts typically and 20 watts maximum If all LEDS were blocked and d2. Spare Output Spare Output shield connected to Power Ground shield in controller Ground to turn RibEye power on Trigger Input Trigger Input Pull to power ground to trigger 12 LEMO CONNECTOR MALE 2 PIN EANA OD ZAS I ATEN FGG 2B 302 CLAD52 m BELDEN CABLE 9740 2 COND 18 AWG LEMO CONNECTOR MALE 4 PIN FGG 0B 304 CLAD52 Figure 12 Battery charger cable OLS RIB ie RibEye Controller February 2011 N EI NEAR o UG gt 5 _ Ajy RAD BELDEN CABLE 83348E TRUCK CABLE COND 4 COND A AtA 24 AWG Front Center Rear Front Center Rear Front Center Rear fo Sensor Power Connectors Connectors RIB 6e o Figure 13 LED wiring 13 Front Center Rear Front Center Rear Front Center Rear February 2011 Top Red Sensors Bottom Blue Sensors Figure 15 LED junction box 14 February 2011 3 0 Operation 3 1 Software The WorldSID RibEye is set up operated and data is downloaded via a PC program Refer to the RibEye Software User s Manual for installation and operation of the software For operation of the Messring software that will control the RibEye refer to the Messring documentation The Live Display tab is slightly different for each of the RibEye models so it is described below for the WorldSID RibEye The RibEye reports positions with respect to the center sensors of the
3. BLUE LED CUSTOMER SUPPLIED ACCELEROMETER CUBE 10075 LEFT RIB 6 REAR LED MOUNT ASS Y RED CONNECTOR BLUE LED CUSTOMER SUPPLIED ACCELEROMETER CUBE N S SS H S LIK Vay February 2011 10031 RIB 1 CENTER LED MOUNT ASS Y GREEN CONNECTOR RED LED 1033 LEFT RIB 1 FRONT LED MOUNT ASSY WHITE CONNECTOR RED LED 10041 RIB 2 CENTER LED MOUNT ASSY GREEN CONNECTOR RED LED 9083 LEFT RIB 2 FRONT LED MOUNT ASS Y WHITE CONNECTOR RED LED 10032 RIB 3 CENTER LED MOUNT ASS Y GREEN CONNECTOR RED LED 10063 LEFT RIB 3 FRONT LED MOUNT ASSY WHITE CONNECTOR RED LED 10042 RIB 4 CENTER LED MOUNT ASS Y GREEN CONNECTOR BLUE LED 10072 LEFT RIB 4 FRONT LED MOUNT ASS Y WHITE CONNECTOR BLUE LED 10043 RIB 5 CENTER LED MOUNT ASS Y GREEN CONNECTOR BLUE LED 9145 LEFT RIB 5 FRONT LED MOUNT ASS Y WHITE CONNECTOR BLUE LED 10044 RIB 6 CENTER LED MOUNT ASS GREEN CONNECTOR BLUE LED 10074 LEFT RIB 6 FRONT LED MOUNT ASS Y WHITE CONNECTOR BLUE LED Figure 6 LEDs mounted on the ribs Figure 7 LEDs mounted on a single rib Position data from each sensor set is reported with respect to a coordinate system that has its origin at the center of the center sensor of each set The RibEye coordinate systems are aligned with the ATD coordinate system Table 1 shows the nominal positions of the LEDs with the February 2011 RibEye mounted on the left side of th
4. in 3 2 1 RibEye Battery Pack The RibEye battery pack should be charged with the Patco charger A fully charged battery can power the RibEye for at least 10 minutes while acquiring data The charger should be disconnected when operating the RibEye When the charger is plugged in to the RibEye battery the 4 pin Lemo battery connector should be disconnected from the controller The battery pack is diode isolated from the main RibEye power input so the R bEye will continue to operate even if the main power input is shorted out February 2011 3 3 Status Light on the Messring interface panel The status light on the Messring interface panel s powered by the external power from the Messring interface panel If the Messring system 1s powered down and the RibEye is running from battery power the status light will not flash The status light flashes at varying rates to indicate the status of the RibEye e 0 5 Hz idle with data in memory e 1 0 Hz idle with memory erased e 2 0 Hz acquiring data e 5 0 Hz storing data in flash memory e 10 Hz erasing flash memory and downloading data 3 4 Arming the RibEye The RibEye is armed via the RibEye or Messring software 3 5 Trigger Input The WorldSID RibEye receives its trigger from the Messring interface panel through the 19 pin power control cable The trigger setting on the RibEye software Connect Setup tab should be set to Switch Rising Edge 4 0 Data Processing 4
5. in the power communications cable to the power supply ground WARNING Although the RibEye can operate on 12 to 36 VDC input power pins 8 and 9 of the power communication cable if the power supply is above 20 VDC the 0 2 watt series resistors will get overheated if the trigger line is pulled to ground continuously If the power input is above 20VDC limit the width of the external trigger pulse to less than 10 seconds 23 February 2011 1K 0 2 WATT LAN 20 VDC PINS 6 9 PS2805 4 SE 4K 0 2 WATT PS2806 4 TRIGGER PIN 15 i External Trigger eg pun O Figure A3 Trigger input circuit 24
6. the unloaded positions Table 3 shows the pivot to pivot dimensions based on the CAD model of the dummy Actual production ribs can be 3 4 mm different from the CAD model and the ribs can yield slightly during testing while still passing the thorax calibration tests Table 3 IR TRACC pivot to pivot dimension for all ribs Pivot to pivot dimension mm Shoulder 133 78 Thoracic 1 133 50 Thoracic 2 Thoracic 3 Abdominal 1 Abdominal 2 18 Starting LED or IR Tracc attachment point on rib Final LED or IR Tracc Rx February 2011 Ry attachment point IR Tracc Reading X IR Trace Pivot point gt at spine plate Veo Py Figure 18 Calculation of IR TRACC output from RibEye data in X Y plane 19 February 2011 5 0 Maintenance The only maintenance required for the RibEye is to keep the lenses clean A dirty camera lens will create a fuzzy photo and smudged eyeglasses will cause distorted vision The same holds true for RibEye If the lenses are not clean the data will be less accurate Make sure that the lenses are clean before each test If the lenses need to be cleaned 1 Blow dust off the lenses with clean dry air 2 If there is grease or dirt on the lenses clean them with eyeglass or camera lens cleaning solution and lens cleaning paper or a lens cleaning cloth You can also use isopropyl alcohol 3 Make sure there is no residue from the cleane
7. 1 Error codes in the data If the RibEye cannot calculate a LED position it will insert error codes n the data Usually this will occur if the light from a LED 1s blocked to one of the sensors Typically this happens if a loose cable gets between the LED and the sensor Also if the center rib on each set of three ribs compresses significantly more than the upper or lower ribs of the set it can block the light from the upper or lower r b LEDs to one of the sensors Too much ambient light can also cause the RibEye to generate error codes If an error code occurs data from all three axes X Y and Z will be forced to the same error code The error codes for each sensor set are 1 The top sensor is blocked or sees too much ambient light The bottom sensor is blocked or sees too much ambient light Both top and bottom sensors are blocked or see too much ambient light The middle sensor is blocked or sees too much ambient light The middle and top sensors are blocked or see too much ambient light The middle and bottom sensors are blocked or see too much ambient light All three sensors are blocked or see too much ambient light er os ee SE A divide by zero condition occurred in the data processing Note that the error code numbers will be changed if the data is processed to give the relative motion of each LED by subtracting the pre event data from each data sample Also filtering the data can mask error codes that occur for a short time We recom
8. 10017 2 RED CENTER SENSOR HEAD GREEN CONNECTOR 10035 RED SENSOR ASSEMBLY 10015 2 RIB 2 LED JUNCTION BOX GREEN CONNECTOR B 10015 3 RIB 3 LED JUNCTION BOX WHITE CONNECTOR 10017 3 RED LOWER SENSOR HEAD WHITE CONNECTOR 10018 1 BLUE UPPER SENSOR HEAD BLACK CONNECTOR are SE 10015 4 RIB 4 LED JUNCTION BOX BLACK CONNECTOR I 10018 2 BLUE CENTER SENSOR HEAD BLUE CONNECTOR 10045 BLUE SENSOR ASSEMBLY 10015 5 RIB 5 LED JUNCTION BOX BLUE CONNECTOR 0015 6 RIB 6 LED JUNCTION BOX YELLOW CONNECTOR SECTION A A 10018 3 BLUE LOWER SENSOR HEAD SCALE 1 2 YELLOW CONNCETOR Figure 1 RibEye sensor sets February 2011 LED wiring junction boxes are mounted between the sensors The junction boxes have a hard wired color coded cable for connecting the junction boxes to the controller The LEDs have color coded plugs that plug into sockets on the junction boxes Figure 2 shows the sensors mounting brackets and sensor cable assemblies The LED junction boxes are not shown in this picture Note that each of the three sensor cables are terminated with 7 p n Lemo OB color coded connectors that plug into color coded sockets on the controller The red top sensors are shown on the right and the blue bottom sensors are shown on the left N ob Figure 2 Sensors on mounting bracket February 2011 The R bEye controller and battery pa
9. 19 PIN LEMO CONNECTOR FOR COMMUNICATION 9965 RIBEYE ELECTRONIC ASSEMBLY LOWER CONNECTOR BLOCK FOR BLUE LED JUNCTION BOXES UPPER CONNECTOR BLOCK FOR RED LED JUNCTION BOXES NR i nik COLOR CODING FOR LED JUNCTION BOXES n ie COLOR CODING FOR mm SENSOR HEADS 7 PIN LEMO CONNECTORS FOR SENSOR HEADS Figure 4 Side view of controller M3 X 0 5 X 16 LG SHCS 4 SCREWS SUPPLIED WITH 734 0800 734 0800 TEMPERATURE SENSOR CUSTOMER TO SUPPLY SHOWN FOR NEW MOUNTING LOCATION ONLY 10079 FLAT BATTERY PACK SUPPLIED WITH 10080 M4 X 0 7 X 25 LG SHCS 4 SCREWS SUPPLIED WITH 10080 M5 X 0 8 X 25 LG SHCS gt 4 SCREWS Re SUPPLIED WITH 9965 ac MOUNTING PATTERN FOR LEFT SIDE TEMP SENSOR PLACEMENT MOUNTING PATTERN FOR RIGHT SIDE TEMP SENSOR PLACEMENT MOUNTING PATTERN FOR MOUNTING PATTERN FOR LEFT SIDE CONTROL BOX RIGHT SIDE CONTROL BOX PLACEMENT PLACEMENT Figure 5 Controller and battery pack mounting 10034 LEFT RIB 1 REAR LED MOUNT ASSY RED CONNECTOR RED LED CUSTOMER SUPPLIED ACCELEROMETER 9143 LEFT RIB 2 REAR LED MOUNT ASS Y RED CONNECTOR RED LED CUSTOMER SUPPLIED ACCELEROMETER CUBE 10064 LEFT RIB 3 REAR LED MOUNT ASS Y RED CONNECTOR RED LED CUSTOMER SUPPLIED ACCELEROMETER CUBE 10073 LEFT RIB 4 REAR LED MOUNT ASS Y RED CONNECTOR BLUE LED CUSTOMER SUPPLIED ACCELEROMETER CUBE 9084 LEFT RIB 5 REAR LED MOUNT ASS Y RED CONNECTOR
10. February 2011 BOXBORO systems HARDWARE USER S MANUAL RibEye Multi Point Deflection Measurement System 3 Axis Version for the WorldSID 50 ATD Model 10000 Boxboro Systems LLC 978 257 2219 www boxborosystems com 1 0 2 0 3 0 4 0 5 0 Table of Contents WorldSID RibEye description Cable assemblies 44004444 no 2 1 Cable routing us44444044e4e nennen Operator eerie 3 1 SOHW re sangen 3 2 RibEye power contro 3 2 1 RibEye Battery Pack 3 3 Status light on Messring interface panel 3 4 Arming the RibEye 3 5 Trigger Input u 4 4404444 Rennen nenn Data processing 4444444444 HH nenn ennn nenne 4 1 Error codes in the data 4 2 Estimating IR TRACC readings Maintenance 422440440040nn nenn nnn een Appendices A RibEye specifications eneen A1 Measurement accuracy and range A2 Power requirements A3 Data acquisition and storage A4 Ethernet Communication A5 Trigger Circuit 00444444444 Rennen February 2011 February 2011 List of Figures and Tables Figure No Page 1 HIDEVE sensor SeS a needs 4 2 Sensors on mo
11. ck are mounted on the non struck side of the ATD as shown in Figures 3 4 and 5 NEW MOUNTING LOCATION FOR TEMPERATURE SENSOR 10076 BATTERY MOUNTING BRACKET ALTER CUSTOMER PART W50 37001 10080 BATTERY BOX ASSEMBLY a 10049 SHOULDER FOAM SHIELD WITH 10079 BATTERY PACK Figure 3 Controller top view The 4 pin Lemo connector 1s used to connect the controller to the battery pack The 19 pin connector s used for external power Ethernet communications and control signals The mating cable connects the controller to the Messring interface box Figure 4 shows a side view of the controller with the connections for the battery power and control cable LED junction box connections and sensor connections Note that the sensor connection and LED junction box connections are color coded and the mating cables have matching colors on them Figure 5 shows details of the controller attachment to the battery assembly the battery assembly to the battery bracket and the battery bracket to the spine assembly Figure 6 shows the LEDs mounted on the ribs The center LEDs are built into the accelerometer mounting blocks The rearward and forward LEDs on each rib are attached with double sided tape and held in place with heat shrink tubing The figure shows the connector color codes for each LED Figure 7 shows a single rib with the LEDs mounted February 2011 4 PIN LEMO CONNECTOR FOR POWER INPUT
12. e ATD The front and back LEDs may vary slightly from these positions as they are mounted with double sided tape and heat shrink tubing Table 1 Nominal LED positions with the RibEye on the ATD left side LED Figure 8 is a picture of the controller and battery pack Figure 9 is a picture of the controller and battery pack with all cables connected The battery pack s used to provide power for the RibEye if the power and communications cable is disconnected or damaged during a test The RibEye batteries each consist of nine AA 1 2 volt 2 7 amp hour batteries A fully charged battery can run the RibEye for over 10 minutes while collecting data Figure 10 shows the Patco model 8050 battery charger provided to charge the NIMH battery pack The charger has lights to indicate that it is charging ready to charge and when the charge s complete While the Patco charger s connected to the battery pack the 4 pin Lemo battery connector that plugs into the controller should be disconnected at the controller February 2011 TE ars SA 7 im a Figure 9 Controller and battery pack with all cables installed 10 February 2011 Figure 10 Patco Model 8050 battery charger 2 0 Cable Assemblies Figure 11 shows the cable 9096 for power and communications This cable connects from the RibEye controller to the Messring interface panel The connector pin details are shown in Table 2 Figure 12 show
13. mend that all data be reviewed 17 February 2011 unfiltered and as absolute position data to make sure that there are no error codes If an error code does occur the data a few milliseconds before and after the error condition should be discounted because something partially blocking a LED can cause reflections that corrupt the position measurement 4 2 Kstimating IR TRACC readings The IR TRACC does not give true Y compression if there is X and Z motion of the ribs The RibEye reports the LED positions with respect to the center of the center sensor for the top and bottom sensor sets and LEDs If the pre trigger data is used to remove the initial offsets from the data the zeroed data 1s the change in the LED positions in the X Y and Z directions The 3D RibEye data from the center LED can be used to calculate what the output would be for an IR TRACC giving only the compression of the IR TRACC Figure 18 shows the relationship between the RibEye zeroed data and the IR TRACC in the X Y plane To calculate the IR TRACC output from the RibEye data use the following formula IR TRACC reading Py sqrt Py IRyD Rx RZ Where Py is the IR TRACC pivot to pivot dimension for an unloaded rib see Table 2 Ry is the RibEye change in the Y direction Rx is the RibEye change in the X direction Rz is the RibEye change in the Z direction Table 3 has the IR TRACC pivot to pivot dimensions in millimeters for the WorldSID ribs in
14. r on the lens WARNING DO NOT USE cotton tipped swabs like Q Tips They leave fibers on the lens Note If you can t get enough light into the thorax to see the lenses well you can arm the RibEye to turn on the LEDs DANGER Do not look directly at the LEDs as they are very bright 20 February 2011 Appendix A RibEye Specifications A1 Measurement Accuracy and Range The RibEye meets the requirements of SAE J211 1 July 2007 as a combined sensor and data acquisition system Figure Al shows the RibEye measurement range in the RibEye X Y plane Figure A2 shows the RibEye measurement range in the RibEye Y Z plane The maximum error for the Y and Z data is less than 1 mm and the maximum X error 1s less than 2 mm The maximum and average errors for each rib for each axis are shown in Table Al for WorldSID RibEye Model 10000 serial number 0075 For each rib the total number of points tested in the measurement range is shown in the last column The maximum error is the maximum of the absolute value of the calculated errors The average error is taken by summing the absolute value of all errors and dividing by the number of points collected for the rib Table A2 shows the SAE J211 Channel Amplitude Class CAC for each axis and the maximum error as a percentage of the CAC 110 100 90 80 ro 60 50 40 30 20 10 0 120 100 80 60 40 20 0 20 40 60 80 100 120 Dummy X mm Dummy Y mm
15. red and blue sets However for the live display screen when set to show the LED positions in the Y Z plane the LED Z positions are reported with respect to the midpoint of the thorax approximately half way between ribs 3 thoracic 2 and rib 4 thoracic 3 Examples of the live display are shown in Figure 16 for the Y Z plane and Figure 17 for the X Y plane The live display plots shown are zoomed around the LED positions See the software manual or press on the Help button for instructions on zooming plots t JRibEye Ver 1 06 2 o x MEREEREE SEE gt a Connect Setup Plot Live Display Export Coordinate System KY si 161 140 420 100 60 40 20 20 40 80 100 120 140 161 HELP Figure 16 Live Display tab with data shown in the Y Z plane 15 February 2011 JRibEye Ver 1 06 O x Connect Setup Piot Live Display Export Coordinate System Figure 17 Live Display tab with data shown in the X Y plane 3 2 RibEye Power Control A locking toggle switch on the Messring interface panel is used to turn the RibEye power on and off The power switch indirectly controls the RibEye power and if the R bEye is busy acquiring or storing data or communicating with the PC program it will not shut down immediately The RibEye must be idle for 10 minutes to shut down The purpose of the power switch is to prevent the RibEye from draining the battery pack 1f it is left plugged
16. riven to full power the RibEye could draw 40 watts The backup battery pack can power the RibEye while collecting data for over 10 minutes when the batteries are fully charged After running the RibEye for 10 minutes it will take about 4 hours to fully recharge the batteries The RibEye controller has a self resetting polymer fuse on its power input If this fuse ever opens it can take up to 4 hours to self reset A3 Data Acquisition and Storage Sample rate 10 000 samples per second per LED Modes Linear or circular buffer Total acquisition time 25 seconds Data storage 25 seconds in RAM 1 7 seconds in flash non volatile Data is collected to RAM memory and stored post test in flash memory A4 Ethernet Communication Communication between the RibEye and the PC software is via 10 100 MBS Ethernet The IP address can be set by the user Factory default 192 168 0 240 Refer to the RibEye Software User s Manual for information on changing the RibEye IP address The RibEye communicates with the PC software using port 3000 An open protocol is used to send commands to the RibEye and to receive data See the Boxboro Systems web page www boxborosystems com Manuals tab for the protocol document A5 Trigger Circuit The Trigger circuit inside the RibEye Controller is shown in Figure A3 The external trigger source is shown as a switch in the figure but it can be any type of circuit that will pull the trigger line pin 15
17. s the cable 9095 that connects the battery to the RibEye controller and the battery charger The two pin Lemo goes to the charger the four pin Lemo goes to the RibEye controller and the four pin Molex goes to the battery pack An overview of the LED and sensor wiring is shown in Figure 13 Note that the LED cables that plug into the controller and into the junction boxes are color coded The cables from the junction boxes to the controller are also color coded Figure 14 shows where the LED junction boxes are mounted on the sensor brackets The mounting of the LED junction boxes and the color codes are also shown in Figure 14 Figure 15 is a picture of a LED junction box with the attached cable and connector for plugging into the controller 2 1 Cable Routing To prevent noise in the RibEye data the LED cables must be kept as far away from the sensor cables as possible Do not bundle the LED cables with the sensor cables The sensor cables should also be separated from the DTS G5 power and communications cables Where the sensor cables cross the LED or Messring cables they should cross at 90 degree angles 11 February 2011 r LEMO CONNECTOR ae An dese y LEMO CONNECTOR j MALE 19 PIN JT BELDEN CABLE 9507 KG FI 4 ALAR f FGA 2B 319 CLADZ2 14 COND 24 AWG Figure 11 Power and communications cable Table 2 Power and communication cable connector pins RibEye Controller At end of Power and Communication Cable Receptacle
18. the RibEye on the ATD left side 9 2 Power and communication cable connector pins 12 3 IR TRACC pivot to pivot dimension for all ribs 18 Al Calibration check data for WorldSID RibEye 22 A2 The SAE J211 Channel Amplitude Class CAC and the maximum error as a percent of the CAC nun 22 February 2011 HARDWARE USER S MANUAL RibEye Multi Point Deflection Measurement System 3 Axis Version for the WorldSID 50th ATD Model 10000 1 0 WorldSID RibEye Description The RibEye for the WorldSID anthropomorphic test device ATD provides X Y and Z position data for 18 light emitting diodes LEDs mounted on the WorldSID ribs Three LEDs are mounted on each of the 6 ribs Up to 25 seconds of data can be collected at a 10 kHz sample rate Flash memory is used to store 1 7 seconds 200 ms to 1500 ms of data that is retained after power is turned off Two sets of three sensors are used to monitor the LED positions as shown in Figure 1 The top set of sensors uses red optical filters and monitors red LEDs mounted on the first three ribs shoulder thoracic 1 and thoracic 2 The bottom set of sensors uses blue optical filters and monitors blue LEDs mounted on the lower three ribs thoracic 3 abdominal 1 and abdominal 2 10017 1 RED UPPER SENSOR HEAD RED CONNECTOR 10015 1 RIB 1 LED JUNCTION BOX RED CONNECTOR
19. unting bracket ee ee ee Re ee ee ee ee ee nenne nnenne nennen 5 3 Controller top VIEW s rete Rike PR Pek A a 6 4 Side VIEW OF Controller 7 5 Controller and battery pack mounting sele a Re ee ee ee ee e ere nennen 7 6 LEDs mounted on the ribs 444444044400 Henne nnnnnnnnnn nenn nennen 8 7 LEDs mounted on a single rib 4444404444RRnnn nennen nennen 8 8 Controller and battery pack 2us040440000nne nenne nennn nenn ee aaa ee 10 9 Controller and battery pack with all cables installed 10 10 Patco Model 8050 battery Charger ee a ee Re Rak eko ee ee ee ee reke nene 11 11 Power and communications cable u0444444440 Rennen nennen 12 12 Ba tlerV charger Cable u ee 13 13 LEDWINNGsn ee 13 14 LED junction box locations on sensor brackets 14 15 LEB JUNEUON DON ee 14 16 Live Display tab with data shown in the Y Z plane 15 17 Live Display tab with data shown in the X Y plane 16 18 Calculation of IR TRACC output from RibEye data in X Y plane 19 A1 RibEye measurement range in X Y plane u4 4u044s nennen nennen 21 A2 RibEye measurement range in Y Z plane u4444 Henne nennen 22 A3 TIGGER INDUL CIrEUN a ee heel 24 Table No Page 1 Nominal LED positions with
Download Pdf Manuals
Related Search