HARDWARE USER`S MANUAL
Contents
1. Joo Cs 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 Dummy Y mm os E aa o ao Do pos Bis Figure A3 RibEye measurement range in Y Z plane lower three ribs 42 January 2013 A 2 Power requirements The RibEye can be powered by a high quality DC voltage source from 12 to 36 Volts At idle the RibEye draws 8 Watts When collecting data 1t draws 12 Watts typically and up to 20 Watts maximum If all LEDs were blocked and driven to full power the RibEye could draw up to 40 Watts When the batteries are fully charged the backup battery pack can power the RibEye while collecting data for at least 10 minutes After running the RibEye on batteries for 10 minutes 1t will take about 4 hours to fully recharge the batteries The RibEye controller has a self resetting polymer fuse on 1ts power input If this fuse ever opens 1t can take up to 4 hours to self reset A 3 Data acquisition and storage Data is collected to RAM memory and stored post test in flash memory Sample rate 10 000 samples per second per LED 10 kHz Modes Linear or circular buffer Total acquisition time 25 seconds Data storage 25 seconds in RAM 1 7 seconds in flash non volatile A 4 Ethernet communication Communication between the RibEye and the PC software 1s via 10 100 MBS Ethernet The IP address can be set by the user Factory default 192 168 0 240 Please refer to the RibEye Software Us2. O 2013 Boxboro Systems LLC January 2013 Figure 8 LED snapped into angled mounting block The angled mounting blocks are used on four of the dummy s six ribs the shoulder thoracic 2 thoracic 3 and abdominal 2 ribs On the shoulder and thoracic 3 ribs the LEDs are mounted on the bottom edge of the ribs On the thoracic 2 and abdominal 2 ribs the LEDs are mounted on the top edge of the ribs On the dummy s other two ribs the thoracic 1 and abdominal 1 all three LEDs are mounted flat without a block This becomes more clear 1f you refer back to Figure 2 which shows three LEDs mounted on each rib 10 O 2013 Boxboro Systems LLC January 2013 The center LEDs on the thoracic and abdominal ribs are mounted to inner rib clamp plates shown in Figure 9 e Hole A is for installing the angled blocks which are screwed to the clamp plates using a Ys inch long 2 56 screw that engages in a captive 2 56 nut inside the angled blocks e Recess B is for gluing flat LED assemblies to the clamp plate The clamp plates for the thoracic and abdominal ribs are shipped with the LED assemblies already glued into recess B e The two C holes are for mounting a 7264 type accelerometer on any rib The clamp plate for the shoulder rib also has holes for mounting the LEDs and the accelerometer Figure 9 Inner rib clamp plate for thoracic and abdominal ribs As noted earlier the forward LEDs are closer to the front of the
3. RibEye sensor bases mounted to spine oooooooooooononnnnnnnnnnnnnononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonoss 18 RIDE 6 SCnSOr FONE PISCO E AURAR E A EE EEA 19 RibEye sensor assemblies mounted to spine 00oooconcconononononononon nono nono nono non nn nono no nnnnnnnnos 20 Controller adaptor installed on thoracic 1 r1b ooccccccnncnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnss 22 Controller adaptor installed on abdominal 2 rib ooccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnoss 23 Controller end cover attachment SCreWS micras 24 Controller sensor connector end attached to adaptor at thoracic 1 rib 25 Controller cable connector end attached to adaptor at abdominal 2 rib 26 Dunn exit calera 27 Sensor cables routed to back Of dummy ooccnnnnncnnnnnncncnnnnnnnnnnnnnononnnininnnnnininininininenos 28 Sensor cables tied to outer ribs near spine plate oococcccnnnnncnnnnnnnnnnnnnnnnonnninnnos 29 Sensor cables routed over the top sensor and below the neck assembly 30 Sensor cables Ted 10 COMO eii 31 A A 34 RibEye battery pack Cell Con charger and exit cable charger receptacle 35 Shoulder Toan stop SMA Gan 36 RibEye measurement range in X Y plane all ribS ooooccnccccnnnnnnnnnnnnnononnnnnnos 40 RibEye measurement range in Y Z plane upper three rIbS oooooonnnncnnnnnnnnnnos 41 RibEye measurement range in Y Z plane lower three r
4. This section provides information on the following cable assemblies e Dummy exit cable including battery charger socket e LED cables e Sensor cables e Status cable Molex Microfit 3 0 connectors are used on all of the cable assemblies The drawings call out the crimp terminals used for the Microfit connectors We recommend using a Molex crimp tool designed for the Microfit 3 series The current production hand crimp tool is Molex part number 638190000 The extraction tool 1s Molex part number 11 03 0043 B 1 Dummy exit cable The dummy exit cable connects to a 24 pole Molex Microfit 3 receptacle on the controller This cable provides RibEye power Ethernet communications and a trigger signal to the RibEye The cable can be configured to meet the customer s requirements The RibEye has several spare inputs and outputs that can be programmed for the desired user functionality and for connections to multiple types of DAS systems The configuration described below is for connecting the RibEye to a DTS MDB system connector for power trigger and Ethernet Figure Bl shows the dummy exit cable The cable has a 24 pin Molex Microfit plug on the RibEye end and a 14 pin Lemo 2b connector at the external end The 14 pin Lemo connector plugs into a standard DTS DBX cable to SYSTEM port DDX 5 m DTS part number 10700 00053 Figure Bl shows the dummy exit cable with the details of the Microfit end connections Table B1 lists the pinouts of th
5. dummy and the rearward LEDs closer to the dummy s back These rearward and forward LEDs on all ribs are held in place with high strength double sided foam tape and heat shrink tubing The foam tape is 3M 4936 1 inch wide VHB acrylic tape The heat shrink tubing is either 1 or 1 4 inches in diameter For ribs with angled blocks use 1 inch diameter tubing For LEDs mounted flat on the ribs use 1 inch diameter tubing Table 1 summarizes the LED positions and mounting methods for all 18 LEDs 11 O 2013 Boxboro Systems LLC Table 1 Summary of LED positions and mounting methods January 2013 LED position Rib number and type Rearward Center Forward bottom edge of rib snap LED assembly to angled block tape and heat shrink in place 1 inch diameter tubing Rib 1 shoulder center of rib mounted flat tape and heat shrink in place 1 inch diameter tubing Rib 2 thoracic 1 top edge of rib snap LED assembly to angled block tape and heat shrink in place 1 inch diameter tubing Rib 3 thoracic 2 bottom edge of rib snap LED assembly to angled block tape and heat shrink in place 17 inch diameter tubing Rib 4 thoracic 3 center of rib mounted flat tape and heat shrink in place 1 inch diameter tubing Rib 5 abdominal 1 top edge of rib snap LED assembly to angled block tape and heat shrink in place 1 inch diameter tubing Rib 6 abdominal 2 bottom edge of rib
6. reel 43030 0012 bag 26 30 gauge 30 micro inch gold Figure B3 Sensor cables 50 brown blue orange black yellow red green BOXBORO SYSTEMS LLC 369 Sargent Road Boxborough MA 01719 978 257 2219 WorldSID Sensor Cables Oct 24 2012 January 2013 Note Terminal Top faces upwards to top of receptacle to install Female Terminal 43030 0003 reel 43030 0009 bag 20 24 gauge 30 micro inch gold 2 LKT General Cable C1356 21 01 Black Speaker Cable 24 gauge or equivalent 3 A Tinned lead to pin 1 Tinned Lead has grooves on insulation Microfit 3 0 2 circuit 2 row Receptacle 43025 0200 BOXBORO SYSTEMS LLC 369 Sargent Road Boxborough MA 01719 978 257 2219 Status LED Cable December 23 2011 Figure B4 Status cable 51
7. ribs and sensors 1 Mount the LEDs on the ribs 2 Mount the ribs to the spine as follows a Install the outer ribs first b Attach the inner ribs to the outer ribs c Attach the inner ribs and sensor bases to the spine 3 Add nylon zip ties around the inner and outer ribs on either side of the inner rib clamps 4 Attach the sensor front pieces to the bases Note again that each sensor base number must match the rib where it belongs and each sensor front piece must match the rib for which it was calibrated 21 2013 Boxboro Systems LLC January 2013 2 2 Controller installation The RibEye controller is installed on the non struck side of the dummy In existing WorldSID dummies the RibEye controller takes the place of the battery enclosure and tungsten ballast weight which are removed 2 2 1 Mounting the adaptor plates The controller mounts to two adaptor plates that take the place of the rib clamps on the non struck side of the thoracic 1 rib and the abdominal 2 rib Figures 18 and 19 The adaptor plates are installed by removing the four rib clamp bolts M5x10 flat head cap screws removing the rib clamp plates and then installing the adaptors using the same four M5x10 screws A n A Figure 18 Controller adaptor installed on thoracic 1 rib 22 2013 Boxboro Systems LLC January 2013 R pa ae Wi lt o o Fr r no Se do E Figure 19 Co
8. ribs the center of the coordinate system is the center of the inside face of the lens in the sensor mounted on the abdominal 1 rib The X Y and Z axes are the same as for the upper sensor set X parallel to the rib Y perpendicular to the spine plate and Z perpendicular to the rib Table 2 shows the nominal positions of the LEDs with the RibEye mounted on the left side of the dummy The forward and rearward LEDs might vary slightly from these positions as they are mounted with double stick tape and heat shrink tubing The data in Table 2 was collected from a used set of ribs that had passed the thorax impact tests A new set of ribs will have larger Y values typically from 3 mm to 8 mm larger than shown For R amp D testing the LEDs can be placed anywhere within the RibEye s measurement range see Appendix A 1 For example a user could place nine LEDs on a single rib to show the shape of the rib 32 2013 Boxboro Systems LLC January 2013 Table 2 Nominal LED positions with RibEye mounted on dummy left side 1 9 Thoracic 1 Center 13 1080 09 A 35 2 3 2 Status indicator The status light flashes at varying rates to indicate that the RibEye is operating and what it is doing 0 5 Hz idle with data in memory 1 0 Hz idle with memory erased 2 0 Hz acquiring data 5 0 Hz storing data in flash memory 10 Hz erasing flash memory or downloading data 3 3 Ethernet link and activity lights There are
9. route the cables As noted earlier the center LEDs are mounted on the inner rib clamp plates which either have the LED glued onto them or have the LED angled block screwed into them Temporarily install the inner rib clamp with LED assembly Then place the double stick tape for the forward LED and route the cables from the center and rearward LEDs as shown in Figure 13 above Note how the LED cables are routed to avoid crossing in front of any LEDs Place the forward LED in position on the double stick tape and slide a piece of heat shrink tubing over the LED The tubing should also cover all three LED cables Heat shrink the tubing over the forward LED in the same way described above for the rearward LED When heat shrinking 1s complete the tubing will hold the LED and the cables in place 16 O 2013 Boxboro Systems LLC January 2013 Later after the rib is assembled into the dummy see Section 2 1 3 below nylon zip ties will be used on both sides of the inner rib clamp to further secure the LED cables preventing them from moving in front of the LEDs The zip ties are shown in Figure 14 Figure 14 Zip ties on both sides of the inner rib clamp securing the LED cables 17 2013 Boxboro Systems LLC January 2013 2 1 2 Installing the sensors on the spine The RibEye s sensor assemblies take the place of the existing rib to spine clamps Each sensor assembly has a front piece that contains the electronics and a base for mounting
10. to the spine It is the sensor bases that act as the rib clamps Figure 15 shows the sensor bases mounted to the spine The sensor bases are installed through the spine s existing rib mounting holes using four M5x10 flat head cap screws The sensor bases have different angles depending on the mounting positions Table 2 Figure 15 RibEye sensor bases mounted to spine ribs not shown 18 O 2013 Boxboro Systems LLC January 2013 Table 2 Sensor base part numbers and angles Rib Sensor Base Part Number Base Angle degrees Shoudr e O mho wonsa 3 10071 20 a Abdominal 1 10071 0 O flat Abdominal 2 10071 20 Ooo d The sensor front piece containing the electronics Figure 16 is attached to the sensor base by two M3x16 flat head cap screws Although the sensor front pieces look identical each piece is marked with the number of the rib that it was calibrated on and the sensor front piece must be installed on that rib Figure 17 shows the spine with the entire sensor assemblies installed bases and front pieces However the sensor front pieces are not mounted to their bases until the ribs are in place inside the dummy see Section 2 1 3 Figure 16 RibEye sensor front piece 19 2013 Boxboro Systems LLC January 2013 at hres A at Figure 17 RibEye sensor assemblies mounted to spine ribs not shown 20 O 2013 Boxboro Systems LLC January 2013 2 1 3 Order of assembly LEDs
11. 00 ms to 1500 ms that is retained after power is turned off If external power is lost the RibEye will operate on internal batteries Communication to the RibEye is via Ethernet Two sets of three sensors monitor the LED positions as shown in Figure 1 The top set of sensors uses red optical filters and monitors the red LEDs mounted on the first three ribs the shoulder rib the thoracic 1 rib and the thoracic 2 rib The bottom set of sensors uses blue optical filters and monitors the blue LEDs mounted on the lower three ribs the thoracic 3 rib the abdominal 1 rib and the abdominal 2 rib Figure 1 RibEye sensors mounted in the dummy view from pelvis upward 2013 Boxboro Systems LLC January 2013 Three RibEye LEDs are mounted on each rib Figure 2 shows the RibEye LEDs installed in the WorldSID dummy The center LEDs are lined up along the dummy s left or right side The forward LEDs are closer to the front of the dummy and the rearward LEDs closer to the dummy s back Figure 2 RibEye LEDs mounted in the dummy view from pelvis upward The RibEye controller mounts on the non struck side of the dummy The controller enclosure also contains the battery pack for the data acquisition system DAS and a second battery pack for the RibEye Figures 3 6 show the following views of the controller e Figure 3 shows the controller as shipped with connector covers installed on the top and at each end Note that the green cabl
12. 2013 Boxboro Systems LLC January 2013 Figure 22 Controller cable connector end attached to adaptor at abdominal 2 rib 2 3 Cable routing 2 3 1 Status cable First plug in the status cable at the 2 pole connector at the bottom end of the controller This cable is routed to the outside of the dummy so you can see that the RibEye is working and what state it 1s in see Section 3 2 2 3 2 Dummy exit cable Next plug in the dummy exit cable at the 24 pole connector This cable provides RibEye power Ethernet communications and a trigger signal to the RibEye The dummy exit cable 1s routed outside the dummy along with the DAS exit cable Note that the dummy exit cable has the RibEye battery charger receptacle bundled with 1t The dummy exit cable 1s shown in Figure 23 The RibEye controller end 1s a 24 pole Molex Microfit 3 connector At the external end is a 14 pole Lemo 2B connector The charger receptacle 1s a 2 5 mm barrel jack Appendix B provides more details on all of the cables including the connector pinouts 26 O 2013 Boxboro Systems LLC January 2013 Figure 23 Dummy exit cable 2 3 3 LED cables Route the rib LED cables between the ribs and over the front of the dummy under the sternum then downward to the bottom end of the controller The LED cables exit from the six ribs as follows e Shoulder rib 1 LED cables exit from the bottom of the rib and goes between the shoulder rib and the thoracic 1 rib to
13. 50 socket head cap screws and two M3x8 socket head cap screws 31 O 2013 Boxboro Systems LLC January 2013 3 0 RibEye Operation This section describes the operation coordinate systems and connections used in the RibEye The RibEye for the WorldSID can be mounted on either side of the dummy to measure left side or right side impacts Please refer to the RibEye Software User s Manual for software details and instructions on how to change the RibEye network s IP address Appendices A C in the software manual The manual is on our website www boxborosystems com 3 1 Data coordinate systems As noted earlier two sets of three sensors monitor the LED positions The top set of sensors monitors the red LEDs mounted on the first three ribs shoulder thoracic 1 and thoracic 2 The bottom set of sensors monitors the blue LEDs mounted on the lower three ribs thoracic 3 abdominal 1 and abdominal 2 Position data from each sensor set is reported with respect to a coordinate system that has its origin in the center middle sensor of each set e For the top three ribs the center of the coordinate system 1s the center of the inside face of the lens in the sensor mounted on the thoracic 1 rib Note that the inside face of the sensor lens is 2 mm from the outside face of the sensor lens The X axis is parallel to the rib the Y axis is perpendicular to the spine plate and the Z axis is perpendicular to the rib e For the lower three
14. 6 Pin Microfit 43025 2400 General Cable C1356 21 01 Black Speaker Cable 24 gauge cut to length see below Cable lengths for Rear LEDs 3 pairs of cables subtract 50 mm for center leds Tinned lead to pin 1 2 3 subtract 100 mm for front LEDs Tinned Lead has grooves on insulation Shoulder 790 mm pins 1 2 3 are led cathodes ground Thorax 780 mm pins 4 5 6 are led anodes Thorax 2 740 mm pin4 is anode 1 rear LED Thorax 3 720 mm pind is anode 2 middle LED Abdomen 540 min pin6 is anode 3 front LED Abdomen 2 530 mm Circuit Numbering view from mating plug side Female Terminal 43030 0003 reel 43030 0009 bag 9 A 3 12 1 20 24 gauge 30 micro inch gold BOXBORO SYSTEMS LLC 369 Sargent Road Boxborough MA 01719 978 257 2219 Circuit Numbering view from Wire side WorldSID LED Cables Figure B2 LED cables 49 rif mm E o 8 Pin Microfit 43025 0800 i i r 7 H 4 a 3 E Circuit Numbering view from mating plug side 8 7 6 5 PH IA 4 3 2 1 Circuit Numbering view from Wire side mg sensor 7 conductor 30 gauge cable 9 amp To WorldSID Sensor Assembly January 2013 Microfit 8 Sensor Board Wire Color Name lt nocomeet 2 oa com 4 wB _ AS ed 6 control 2 8 sv ant Note Shield not connected at microfit connector Female Terminal 43030 0006
15. IbsS cccnnnnnnnnooononnnnns 42 Ea AAA RA Oi a 44 Trigger input configured for DTS MDB supplied trigger occccccnnnononononnonononononons 45 Dummy exit cable Microfit connector end detallS oooooooonnoooocncnnnnnnnnnnnnnnnoss 47 LE Dec O 49 SENSO cal 50 Sta bus CA DO anuidade o 51 3 O 2013 Boxboro Systems LLC Table No l 2 3 4 Bl January 2013 List of Tables Page Summary of LED positions and mounting methods 12 Sensor base part numbers and a a 19 Nominal LED positions with RibEye mounted on dummy left side 33 CAMEO NA ModS caiser ea tac trois E E 34 Dummy exit cable Lemo connector pins ooooooooooooonnnnnnnnnononnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnos 48 4 2013 Boxboro Systems LLC January 2013 HARDWARE USER S MANUAL RibEye Multi Point Deflection Measurement System 3 Axis Version for the WorldSID 50th ATD 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 six ribs The RibEye for the WorldSID can be mounted on either side of the dummy to measure left side or right side impacts Appendix A provides the RibEye measurement range and other specifications Up to 25 seconds of data can be collected at a 10 kHz sample rate Flash memory stores 1 7 seconds of data from 2
16. January 2013 BOXBORO systems HARDWARE USER S MANUAL RibEye Multi Point Deflection Measurement System 3 Axis Version for the WorldSID 50 ATD Boxboro Systems LLC 978 257 2219 www boxborosystems com O 2013 Boxboro Systems LLC January 2013 Table of Contents Page 1 0 WorldSID RibEye Description cias 5 20 Rib ve Installation seen A ee 9 21 LCEDonds nsormsiallalo Meannan E A E 9 2 kl Mo ntine the LEDS on he DSaren DERA al a 9 24152 Installino the Sensors On LhiGISPIN sagas a 18 2 1 3 Order of assembly LEDs ribs and sensors ocoonnnnnnnnnnnooononooononooonnn non nnnnnnos 21 2 2 Controller installation erinan aA lios 22 DA Mountino the adaptor plates ai 22 2 2 2 Removing the controller end covers onssa a non nnnnnnnnnos 24 22 5 O A do o e Ana ad 25 pie MADISON ee ee eae INNTA 26 A Status AAA eee ee 26 Deed DUI A O ada 26 SAS ata ia a pa a E 21 O See a ee est Ua aCe ee ea cee aE 28 30 RIDE Ve Operatii tar cda 32 SL Dia Ca dol ai 32 DZ O O 33 33 Ethernet link and activity MUSAS 33 E Bateries and Charo eiS sido E EEE E 33 32 Shoulder to ansiosa 36 o A E A ia a aa 36 40 RibEye Maintenance saias iss n o i bi 38 Appendices AG RIDEye PEA ill 39 A I Measurement accuracy and Tan Oe sa e nau E 39 A 2 POWEE FEQUINCIMENTS ra a aaa 43 Az Data acquisition and OA a io 43 A A ELN CAMA O an eins a a SS 43 A CE CLRCUIL varias me eee cee a doa te 43 Br RDEV aD SS it 46 Bel Dunn asas E NE ae eae S
17. LED assembly already glued to angled block screw angled block into clamp plate center of rib mounted flat LED assembly already glued to clamp plate top edge of rib LED assembly already glued to angled block screw angled block into clamp plate bottom edge of rib LED assembly already glued to angled block screw angled block into clamp plate center of rib mounted flat LED assembly already glued to clamp plate top edge of rib LED assembly already glued to angled block screw angled block into clamp plate bottom edge of rib snap LED assembly to angled block tape and heat shrink in place 1 inch diameter tubing center of rib mounted flat tape and heat shrink in place 1 inch diameter tubing top edge of rib snap LED assembly to angled block tape and heat shrink in place 1 inch diameter tubing bottom edge of rib snap LED assembly to angled block tape and heat shrink in place 1 inch diameter tubing center of rib mounted flat tape and heat shrink in place 1 inch diameter tubing top edge of rib snap LED assembly to angled block tape and heat shrink in place 1 inch diameter tubing NOTE After rib assembly nylon zip ties are added around the center LED clamp plates to secure the cables 2013 Boxboro Systems LLC 12 January 2013 The rearward and forward LEDs are typically mounted 50 mm from the center of the rib as shown in Figure 10 The 50 mm dimension is the strai
18. d 46 BZ EDADES A o A N ne 46 Br Sensor caleta ad alas 46 TBA SAWS CAG 255 ts os soe is ache es ac Se cst iced eae estat ses 46 2 2013 Boxboro Systems LLC Figure No pj Soe maArIDNBWN HY EN EU io Do DI NN NN NN NW NN INN NY MR Be Ba ee eS Ee O AR re O a E oe tes ae og ton ES January 2013 List of Figures Page RibEye sensors mounted in the dUMINY ccccccccnnnnnnnononononnnnononnnnnnnnnnnnonananannnononnnnnnos 5 RIbE ye LEDs mounted ain tiie UAM ia 6 RibEye controller with connector covers in place cccesssssceccceeeeeeeeeeeeeseeeeeeesaees 7 RibEye controller with connector covers reMOVEe ccessssseceeeeceeeeesseeeeeeessstaaees 7 Controller Sensor CONNCELOrS iii ll iio oia 8 Controller connectors for LED cables status cable and dummy exit cable 8 EED andaneled mounting block 9 LED snapped into angled mounting block rrenan 10 Inner rib clamp plate for thoracic and abdominal ribS oooccccccnnnnnnnnnnonnnonnnonoss 11 Rearyard and forward LE DIOC ONS ii 13 Rearward LED placed on double stick tape oooooononnnnooooooonoonnnnnnnnnnonononnnnnnnnnnnnos 14 Heat shrink tubing placed over rearward LED cccccceesessessssesseesssssssesssseeseeeens 15 Cable routing for rearward and center LEDS ooooononnnononnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 16 Zip ties on both sides of inner rib clamp securing the LED cables 17
19. e ISO 6487 2000 specifications Figure Al shows the RibEye measurement range in the X Y plane for all six ribs The plot also shows the LED positions reported by the RibEye for a used set of ribs Note that a new set of ribs will have slightly larger Y positions as noted in Section 3 1 Figure A2 shows the RibEye measurement range in the Y Z plane for the upper set of three ribs shoulder thoracic 1 and thoracic 2 The plot also shows the LED positions for all of the upper three rib LEDs Figure A2 shows the RibEye measurement range in the Y Z plane for the lower set of three ribs thoracic 2 abdominal 1 and abdominal 2 The plot also shows the LED positions for each of the lower three rib LEDs The maximum error for the Y and Z data is less than 1 mm and the maximum X error 1s less than 1 5 mm 39 O 2013 Boxboro Systems LLC PLEATED MN CH AY IAH YT MULTA 140 120 100 WorldSID 50th XY range All Ribs front rear and center LED positions a g E g g g p A el MH HA IN aa ae EA O a A OOO T IO IO ISO T E ee T APLI AMIA AAA RA Mena E a a oo E e RS E Do o ES a MEA Do E Py yop poo ppp a 29 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 Dummy Y mm Figure A1 RibEye measurement range in X Y plane all ribs January 2013 range Shoulder Thoracic 1 Thoracic 2 Thoracic 3 A Abdom 1 Abdom 2 Dummy Z mm WorldSID 50
20. e Lemo connector with the DTS signal names B 2 LED cables Figure B2 shows the LED cables The three LEDs for each rib go to a single 6 pole connector The cables are marked with the rib number and the letters R rear C center or F forward B 3 Sensor cables The sensor cables are detailed in Figure B3 B4 Status cable The status cable is shown in Figure B4 46 January 2013 24 Pin Microfit 43025 2400 Lemo FGG 2B 314CLADS2 a 4 FEET Belden 9507 7 pair 839 1146 ND Digi 2 5 mm jack and cable mfg p n 10 01095 3 feet long for charger Female Terminal 43030 0003 reel 43030 0009 bag 20 24 gauge 30 micro inch gold DODODPDDIDOS GS DPO Popup Circuit Numbering view from mating plug side 18 17 16 15 14 13 BOXBORO SYSTEMS LLC 369 Sargent Road Boxborough MA 01719 978 257 2219 Power Comm Cable Assembly Microfit End as built for pmg s n112 feo eua Figure B1 Dummy exit cable Microfit connector end details Circuit Numbering view from Wire side 47 January 2013 Table B1 Dummy exit cable Lemo connector pins Moo op vio lack red oa MAINPWR OO OO o O O o O O oo O O O Ooo O Ce O Sa GND black bowy S MAN PWR GND D pe O rene Mo ET black green 6 ETHERNEITE l Ri _ ome ETHERNET Bt _ AO GND brown DS E sir BE e CS ooo meo a black yellow 48 January 2013 3 pieces of
21. e comes from the DAS battery pack e Figure 4 shows the controller with the two end covers removed e Figure 5 shows the connectors for the sensors at one end of the controller e Figure 6 shows the connectors for the LED cables status cable and dummy exit cable at the other end of the controller 2013 Boxboro Systems LLC January 2013 RibEye TM BOX BORO WorldSID 0 Serial No 112 ara baaberosystemms cow Figure 3 RibEye controller with connector covers in place green cable exiting from DAS battery pack Figure 4 RibEye controller with connector covers removed 2013 Boxboro Systems LLC January 2013 Figure 6 Controller connectors for LED cables status cable and dummy exit cable O 2013 Boxboro Systems LLC January 2013 2 0 RibEye Installation This section explains how to mount the RibEye components into the WorldSID 50 Male ATD The instructions cover the installation of the LEDs sensors and controller as well as the cable routing Some components are mounted before the ribs are assembled in the dummy and others during or after rib assembly 2 1 LED and sensor installation 2 1 1 Mounting the LEDs on the ribs Figure 7 shows a LED assembly with its lead cable attached and an angled mounting block The LED is soldered onto a metal clad printed circuit board MCPCB Figure 8 shows the LED assembly snapped into the angled mounting block Figure 7 LED and angled mounting block
22. er s Manual for software details and instructions on how to change the RibEye network s IP address Appendices A C in the software manual The manual 1s on our website www boxborosystems com 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 RibEye Communications Protocol document on our website for more information A 5 Trigger circuit The trigger circuit can be configured for a variety of options including a high impedance input or a lower impedance optically isolated input Please contact Boxboro Systems for your requirements The generic trigger circuit inside the RibEye controller is shown in Figure A4 Figure AS shows the trigger input configured for connection to a DTS Mini Distributor MDB system connector 43 January 2013 0355 MWEE R111 MMOZIC a om ee low impedance trigger in x Lo Trig In Hi Trig In R118 MMIZISVE high impedance trigger in Hi _ Trig_In Figure A4 Generic trigger input circuit 44 January 2013 Vin from DTS MDB 0805 AAA VVV EE 15V Pullup to DTS MDB Event tk y MM3Z15VC it 3 34 I GND 10K Vin from OTS MDB 10k uw GHD 52K i lt Hi_ Trig In from DTS MDB Event MM3Z15WC No gt 75 GND Figure A5 Trigger input configured for DTS MDB supplied trigger 45 January 2013 Appendix B RibEye Cables
23. er at the end of the controller The cover screw locations were shown previously in Figure 20 2 3 4 Sensor cables Route the sensor cables between the ribs toward back of dummy as shown in Figure 24 Then route the cables along the inside of the outer ribs toward the dummy s head as shown in Figure 25 Zip tie the cables to the inside of the outer rib as close to the spine plate as possible Figure 24 Sensor cables routed to back of dummy 28 O 2013 Boxboro Systems LLC January 2013 Figure 25 Sensor cables tied to outer ribs near spine plate 29 O 2013 Boxboro Systems LLC January 2013 The bundle of sensor cables should go above the top sensor and below the bottom of the neck assembly as shown in Figure 26 On the non struck side zip tie the sensor cables to the shoulder rib as shown in Figure 27 Figure 26 Sensor cables routed over the top sensor and below the neck assembly 30 O 2013 Boxboro Systems LLC January 2013 Figure 27 Sensor cables tied to controller Plug the sensor cables into the sensor sockets at the top end of the controller Plug in the cables in the following order 1 Abdominal 2 rib cable 6 2 Abdominal 1 rib cable 5 3 Thoracic 3 rib cable 4 4 Thoracic 2 rib cable 3 5 Thoracic 1 rib cable 42 6 Shoulder rib cable 1 Zip tie the cables to the cable tie downs on the end of the controller Then re install the cover on the top end of the controller using two M3x
24. er the error condition should be discounted because something partially blocking a LED can cause reflections that corrupt the position measurement 37 O 2013 Boxboro Systems LLC January 2013 4 0 RibEye Maintenance The only maintenance required for the RibEye 1s to keep the sensor lenses clean A dirty camera lens will create a fuzzy photo and smudged eyeglasses will distort 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 and every test If the lenses need to be cleaned follow this procedure 1 Blow dust off the lenses with clean dry air 2 Ifthere 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 70 vol 3 Make sure there 1s no residue from the cleaning solution remaining 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 38 O 2013 Boxboro Systems LLC January 2013 Appendix A RibEye Specifications A 1 Measurement accuracy and range The RibEye meets the requirements of SAE J211 1 July 2007 as a combined sensor and data acquisition system It also meets th
25. ght line distance This equates to 60 mm along the curve of the rib 50 mm Figure 10 Rearward and forward LED locations As noted earlier the LEDs must be mounted to the ribs before the ribs are installed in the dummy The 18 LED cables are marked with the rib number 1 6 and one of three LED positions as follows Rib 2 thoracic F C R C Thus for example the LED with the cable marked 4 R should be mounted on the thoracic 3 rib in the rearward position 13 2013 Boxboro Systems LLC January 2013 On each rib the rearward LEDs should be mounted first then the center LEDs and finally the forward LEDs The LEDs should be mounted according to the following procedure 1 Rearward LEDs Place a strip of double stick tape on the rib at the rearward LED mounting location Add a second piece of tape that will hold the LED cable in position Place the LED on the first piece of tape and arrange the cable on the second piece of tape so that the cable avoids the spot where the center LED will be mounted see Figure 11 Figure 11 Rearward LED placed on double stick tape 14 O 2013 Boxboro Systems LLC January 2013 Cut a piece of heat shrink tubing 1 to 2 inches long and punch a hole in the tubing where the center of the LED will be this can be done using a standard paper hole punch or similar tool Slide the tubing over the rib and LED as shown in Figure 12 Center the hole directly over the red do
26. ly this results when a loose cable gets between the LED and the sensor Also if the center rib on either 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 rib LEDs to one of the sensors Too much ambient light can also cause the RibEye to generate error codes 36 2013 Boxboro Systems LLC January 2013 The error codes for each sensor set are as follows l 2 3 4 gt 6 7 8 9 The top sensor 1s 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 1s 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 A divide by zero condition occurred in the data processing Out of range error Note that the error code numbers will be changed 1f the data 1s 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 recommend that all data be reviewed unfiltered and as absolute position data to make sure that the data contains no error codes If an error code does occur the data a few milliseconds before and aft
27. ntroller adaptor installed on abdominal 2 rib 23 2013 Boxboro Systems LLC January 2013 2 2 2 Removing the controller end covers The controller is shipped with two covers screwed in place one at each end shown previously in Figure 3 The covers protect the connectors for the RibEye sensors on one end Figure 5 and the connectors for the LED cables status cable and dummy exit cable at the other end Figure 6 To install the controller the two covers must be removed by unscrewing two M3x50 socket head cap screws from the top of each cover and two M3x8 socket head cap screws from the end of each cover Figure 20 shows the locations of three of the four cover attachment screws on one of the covers the fourth screw 1s not visible in the photo Figure 20 Controller end cover attachment screws 24 O 2013 Boxboro Systems LLC January 2013 2 2 3 Attaching the controller When the covers have been removed slide the controller into the non struck side of the ribs from the pelvis end of the dummy The sensor connector panel should be facing toward the dummy s head and the cable connector panel connections for LED status and dummy exit cables should be facing toward the pelvis The controller is attached to the two adaptor plates on the ribs using two M5x16 flat head cap Screws one at each end as shown in Figures 21 and 22 Figure 21 Controller sensor connector end attached to adaptor at thoracic 1 rib 25
28. r indicates its current mode as shown in Table 3 Figure 29 shows the charger and the exit cable charger receptacle Please refer to the Cell Con Manual which is supplied with the charger for information on safety operation maintenance etc Table 3 Cell Con charger modes LED Color o Mode gt gt gt Battery not connected Battery initialization and analysis 7 seconds Fast charge Green with intermittent orange flash Top off charge Green Trickle charge Alternating Red Green Error 34 O 2013 Boxboro Systems LLC January 2013 Figure 29 RibEye battery pack Cell Con charger and exit cable charger receptacle 35 O 2013 Boxboro Systems LLC January 2013 3 5 Shoulder foam stop strap An elastic strap prevents the dummy s shoulder foam from dropping into the shoulder rib and blocking the LEDs mounted on the rib The strap which is 18 inches long and 1 inch wide has a D ring sewn into it The strap is looped through the slot on the shoulder rib clamp goes around the neck and secures to itself with Velcro Figure 30 shows the strap mounted on the dummy Figure 30 Shoulder foam stop strap 3 6 Error codes If the RibEye cannot calculate a LED position the software will insert error codes in the data If an error code occurs data from all three axes X Y and Z will be forced to the same error code Usually error codes occur when the light from a LED is blocked and cannot reach one of the sensors Typical
29. t in the center of the LED NOTE Do not use any glue lined heat shrink tubing because the glue can bubble out of the LED hole and cover the LED blocking its light un o L Ad PJ e LJ LI MAIL Figure 12 Heat shrink tubing placed over rearward LED Carefully begin shrinking the tubing using a heat gun while holding the hole over the LED Start with the areas that are farthest away from the LED then turn the rib over and shrink the back side tightly eliminating bubbles Return to the inner side and apply heat gently around the edges of the LED hole keeping the LED fully exposed but do not apply too much heat directly to the LED You might need to stretch the round hole with your finger so that 1t fits around the square edge ofthe LED However do not touch the soft silicone face ofthe LED with sharp objects Figure 13 right hand side shows a rearward LED after the tubing has been heated and is in place Be careful not to burn yourself It helps to wear a welding glove or other temperature proof glove so that you can hold the heat shrink tubing in place while using the heat gun NOTE It takes a little practice to master the technique of mounting LEDs with heat shrink tubing You can always cut off the tubing and try again 15 2013 Boxboro Systems LLC January 2013 Figure 13 Cable routing for rearward and center LEDs 2 Center and Forward LEDs The next step 1s to install the center LED and
30. th RibEye YZ Range Upper Ribs front rear and center LED positions ao op pop 409 _ _ HT tt Ct o ee pap ee ee ee eee go toe TT CC lp opm 69 L_L ft gg U UUO A A A A AA AA AA AAA AA E AN A A A sj pp pb pp CO C ee O O O ee ee ee eee eee op pop o gt ee JO O A A ee ee ee ee ee eee ee SSA o ft of ff 40 LA A O O A A S S S S gt AA O A e0 _ io pop 4 IA op pp ee ee ee ee ee eee eee go AA of of of of ffl LA Essas 100 EE EE Ee eee ee eee eee eee eee E IESO A eee ee ee ee ee ee eee ee eee eee E SE SE SE MMMM A SAS Sass 120 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 Dummy Y mm Figure A2 RibEye measurement range in Y Z plane upper three ribs 41 January 2013 range E Shoulder O Thoracic 1 Thoracic 2 Dummy Z mm January 2013 WorldSID 50th RibEye YZ Range Lower Ribs 120 front rear and center LED positions 100 LLL AAA IS IS A O O IS e O IS IS AO O eo EA er AAA AAA AAA oL Ie TT T O E IS IS IS AAA OOO A O O IS IS A O PS IO IS IS A O A A AO AAA A Ea A II IE O l range E Thoracic 3 AAA ROR A OO CT OET COO O e E E O BO IO IS IS IS IO E IS O E IS O IO O E O 40 Foo spa E O O O IS E E O E E IO IS IO IS O O IS O IS E O E 60 a IH OS ISO OO OOO IO OO IO O ee ee eee ee epa e lp pp po ppp 1 gt
31. the non struck side e Thoracic 1 rib 2 LED cables exit from the top of the rib and goes between the shoulder rib and the thoracic 1 rib to the non struck side e Thoracic 2 rib 3 LED cables exit from the top of the rib and goes between the thoracic 1 rib and the thoracic 2 rib to the non struck side e Thoracic 3 rib 4 LED cables exit from the bottom of the rib and goes between the thoracic 2 rib and the thoracic 3 rib to the non struck side e Abdominal 1 rib 5 LED cables exit from the bottom of the rib and goes between the abdominal 1 rib and the abdominal 2 rib to the non struck side e Abdominal 2 rib 6 LED cables exit from the top of the rib and goes between the abdominal 1 rib and the abdominal 2 rib to the non struck side Tie the LED cables together on the non struck side and tie the cable bundle to the inside of the ribs along the side of the controller Then plug the connectors into the LED sockets on the bottom end of the controller and zip tie the bundle to one of the cable tie downs on the end of the 2l 2013 Boxboro Systems LLC January 2013 controller Zip tie the dummy exit cable and the status cable to the other cable tie down at the end of the controller After all the LED cables and the dummy exit cable are connected the cover on the bottom end of the controller can be re installed Two M3x50 socket head cap screws attach the cover top to the base Two M3x8 socket head cap screws attach the cov
32. two lights on the side of the controller below the green DAS battery cable shown previously in Figure 4 The green light 1s the Ethernet link light and the orange light 1s the Ethernet activity light 3 4 Batteries and chargers There are two battery packs in the RibEye controller enclosure They can be accessed by removing the top cover of the controller Figure 28 shows the controller with the top cover removed and end covers also removed The RibEye battery pack is on the left in Figure 28 and the DAS battery pack is on the right The DAS battery pack consists of nine AA nickel metal hydride NiMH batteries The DAS battery cables exit the controller green cable to the standard DAS battery connector Refer to your DAS documentation for connector and charging information 33 O 2013 Boxboro Systems LLC January 2013 Figure 28 Battery packs The RibEye battery pack consists of 12 AAA NiMH batteries It is plugged directly into the controller with a connector under the white nylon spacer The RibEye batteries are turned on only when the RibEye 1s armed or storing collected data to flash memory They will provide a minimum of 10 minutes of run time Whenever the charger is plugged in the RibEye will automatically disconnect the batteries from the RibEye circuits to allow the charger to function properly even if the RibEye is armed The charger for the RibEye battery pack is a Cell Con Model 452115 01071 3311 A LED on the charge
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