FlexPLI Preparation before Car Testing
Contents
1. 7 5 Running a test Step 1 Hook up the sensors on the Data Acquisition System DAS and check the Flexing Leg after alignment sensor polarities Section 2 3 2 and Figure 16 by flexing the leg during preparation Step 2 Fit the suit according instruction in section 3 3 5 allowing for the electrical wires to exit at the end of the Pivot Hinge at the top of the upside down leg The leg is now ready to be hung on the rig Step 3 Fit the leg to the pivot block on the rig using the M10 Socket Head Shoulder Screw SHSS Route the disconnect wire as required out of the end of the tibia or below the knee depending on type of DAS and tape up to the rig so that it does not interfere with the free swing motion of the leg when tested If using off board DAS the wires are routed out of the top of the leg e Step 4 With the leg hanging down vertically start up and initiate the DAS and set the DAS such that the sensors are zeroed to zero sensor output in this position Important The leg sensors are zeroed in the vertical impact position before lifting to 15 degree above horizontal Suit fit already described in item 7 3 leg preparation User Manual Page 90 f IG GTR9 Phase 2 8t meeting OICA office Paris 9 GTR9 8 13 Pedestrian Protection yen ML AA FlexPLI Leg Preparation Leg Preparation for Pendulum Dynamic Calibration 7 5 Running a test Step5 The leg is lifted up to the release mech2. Leg Preparation for Pendulum Dynamic Calibration M a T b m obw Figure 72 Assembly of flesh second layer Figure 73 Rubber flesh assembly Velcro positions Figure 74 Rubber flesh tied on with Velcro RS PER Figure 75 Leg with outer cover fitted IG GTR9 Phase 2 8t meeting OICA office Paris 6 FlexPLI Leg Preparation GTR9 8 13 Pedestrian Protection Nor cm ML AA Leg Preparation for Pendulum Dynamic Calibration 7 3 Step 1 e Step 2 e Step 3 e Step 4 Step 5 Step 6 Step 7 Leg Preparation for Pendulum Dynamic Calibration Check the eight M8 set screws shown in Figure 88 are tightened to 8 Nm After 60 vehicle tests remove the knee blue front covers and check the 4x M8 button head screws attaching the legs are tightened to 8 Nm Check the four stop cable clearances passing through the femur are set to 9 1 mm and 10 3 on the tibia See Figure 89 a special tool 133 5112 is used for this Check knee blocks are aligned to ensure knee is not twisted or in a shear condition before the test Using two equal height blocks push down on the back of the knee for y direction and also on one side of the knee for x direction as shown in Figure 90 A straight edge can be used to double check alignment after any adjustment on two sides Check all segment screws and side aluminum shoulder screws are tightened to 3 Nm The impact covers would need removal to check front se
3. Phase 2 8 meeting OICA office Paris 14 GTR9 8 13 Pedestrian Protection Py en FlexPLI Leg Preparation Sy Leg Preparation for Pendulum Dynamic Calibration 3 3 5 Fitting Flesh an Covers Step 1 Place the large outer cover N3 on the bench with lettering face down Lay 6 strips of Velcro tape over with fluffy side down then place the rubber buffer sheet assembly 133 5020 over the strips R1 R2 2sheets R1 The large rubber part goes to the top of the leg this is the side where the hanger for dynamic testing is attached Adjust the tape so that all the Velcro strips line up with the six markers on the rubber see Figure 73 Lay Thigh 2 and Leg 2 covers N2F N2T over with the two knee end inside arrows pointing towards each other allowing a gap for the knee area then do the same with Thigh 1 and leg 1 covers N1F N1T IG GTR9 Phase 2 8 meeting OICA office Paris 15 GTR9 8 13 Pedestrian Protection Py MESE FlexPLI Leg Preparation Say Leg Preparation for Pendulum Dynamic Calibration 3 3 5 Fitting Flesh an Covers Step 2 Place the leg assembly onto the laid out flesh covers with thigh femur section over thigh covers and leg tibia over leg covers with the leg assembly Following position of the rubber and neoprene sheets shall be finally ensured the lower edge of the rubber parts R1 and the femur neoprene parts N1F N2F shall align with the upper end of the knee block e the recess o
4. Pendulum Dynamic Calibration Check alignment of upper an lower knee covers 133 5304 133 5305 Check the eight M8 set screws shown in Figure 88 are tightened to 8 Nm After 60 vehicle tests remove the knee blue front covers and check the 4x M8 button head screws attaching the legs are tightened to 8 Nm Check the four stop cable clearances passing through the femur are set to 9 1 mm and 10 3 on the tibia See Figure 89 a special tool 133 5112 is used for this Check knee blocks are aligned to ensure knee is not twisted or in a shear condition before the test Using two equal height blocks push down on the back of the knee for y direction and also on one side of the knee for x direction as shown in Figure 90 A straight edge can be used to double check alignment after any adjustment on two sides Check all segment screws and side aluminum shoulder screws are tightened to 3 Nm The impact covers would need removal to check front segment screws Remove the aluminum launch guide Figure 47 item 18 Part Nr 133 5103 U shaped bracket fitted to the top of the femur along with the black protective cover Figure 54 item 28 Part Nr 133 5516 Attach the ballast weight Part Nr 133 8436 as shown in Figure 91 to the top of the femur using two M8 x 50 long cap head screws IG GTR9 Phase 2 8t meeting OICA office Paris 19 GTR9 8 13 Pedestrian Protection Py MESE FlexPLI Leg Preparation Say Leg Preparation for Pendulum Dynamic Cali
5. 5 Check knee block alignment no twist no shear with straight edge Figure 90 Align if necessary Fit the flesh and skin covers as described in 3 3 5 Check all wires to be in position and restraint Hang assembled Legform in the launch apparatus Initiate DAS and zero sensors with leg hanging down vertically in launch apparatus Conduct test Remove outer Skin and flesh after each test If a test is to be repeated the leg should rest for 30 minutes minimum before repeating If another flesh set is used the test does not need to wait 30 minutes User Manual Page 94 IG GTR9 Phase 2 8 meeting OICA office Paris 26 GTR9 8 13 Pedestrian Protection Eur em FlexPLI Leg Preparation WEE Thank you for your attention On behalf of OICA provided by Winfried Schmitt BMW Jan Wilsman BMW Thomas Kinsky OPEL Klaus Rathje Daimler Leonhard Ferdinand Porsche IG GTR9 Phase 2 8th meeting OICA office Paris 27 Pedestrian Protection FlexPLI Leg Preparation BACK UP IG GTR9 Phase 2 8th meeting OICA office Paris GTR9 8 13 mA OICA Bs sx 28 GTR9 8 13 Pedestrian Protection Py FlexPLI Leg Preparation Sw Push femur MX tibia out MX femur out MCL out ACL out PCL out Push femur LCL out ACL out PCL out Figure 16 Leg manipulations for positive output IG GTR9 Phase 2 8th meeting OICA office Paris 29 GTR9 8 13 Pedestrian Protection P74 DEV amp Fl
6. DAS such that the sensors are zeroed to zero sensor output in this position Important The leg sensors are zeroed in the vertical impact position before lifting to 15 degree above horizontal IG GTR9 Phase 2 8 meeting OICA office Paris 21 GTR9 8 13 Pedestrian Protection DIC MESE FlexPLI Leg Preparation Say Leg Preparation for Pendulum Dynamic Calibration 7 5 Running a test Step 4 The leg is lifted up to the release mechanism and held in position using the steel wire rope loop attached to the ballast weight The rope has been made so that the angle of the leg before release is 15 above the horizontal Check once more the angle with a digital inclinometer on the back of the knee The steel rope is tied to the ballast weight via an eye bolt which can be used for fine height adjustment e Step 5 Arm the DAS system and release the leg The trigger for data collection can be from the accelerometer on the leg started manually or from a speed gate After initial impact the leg will continue to bounce where possible the leg should be caught or stopped to prevent this The springs in the knee and the elastic response from the rubber flesh create a strong rebound If there is any doubt about safety allow the leg to bounce after impact Step 6 Detach leg from rig and remove skin and flesh after each test If a test is to be repeated the leg should rest for 30 minutes minimum before repeating If another flesh set is used
7. GTR9 8 13 5 Te OICA SEs 4e FlexPLI Manual FlexPLI Preparation before Car Testing 04 09 2013 GTR9 8 13 Pedestrian Protection eee m FlexPLI Leg Preparation Sw Introduction Fitting Flesh B current language Leg Preparation for Pendulum Dynamic Calibration Leg Preparation for Dynamic Inverse Test Fitting Flesh and Covers C Leg Preparation for Pendulum Dynamic Calibration Proposal Leg Preparation for Dynamic Inverse Test Leg Preparation for Car Test IG GTR9 Phase 2 8t meeting OICA office Paris 2 GTR9 8 13 Pedestrian Protection Pym FlexPLI Leg Preparation Sey e To ensure repeatability and reproducibility of FlexPLI test results certification and testing shall be carried out always under the same conditions Preparation of FlexPLI is only defined in User Manual for Pendulum Testing Item 7 3 and for Inverse Testing Item 8 5 Also for car testing the setup of FlexPLI must always be in the same standardized testing conditions e Preparation for vehicle testing may not invalidate FlexPLI verification Additional proposal for step by step procedure for fitting flesh and covers to FlexPLI IG GTR9 Phase 2 8t meeting OICA office Paris 3 GTR9 8 13 Pedestrian Protection Pym 5A Aan FlexPLI Leg Preparation Leg Preparation for Pendulum Dynamic Calibration 3 3 5 Fitting flesh On the day of the test or for certification the flesh covers are fitted ov
8. Velcro To get a tight fit with the Velcro it is easier to get someone to pull the rubber sheet around the leg while you are locking the Velcro Step 7 Finally pass any off board wires or disconnect through any holes in the outer cover if applicable For Pendulum testing allowing for the electrical wires to exit at the end of the Pivot Hinge at the top of the upside down leg For Inverse testing and car testing check all wires are correctly positioned to avoid damage and any exit wires are restrained IG GTR9 Phase 2 8t meeting OICA office Paris 17 GTR9 8 13 Pedestrian Protection OCA See FlexPLI Leg Preparation Sew Leg Preparation for Pendulum Dynamic Calibration 3 3 5 Fitting Flesh an Covers Step 8 Wrap the outer cover around the leg The outer cover is zipped up from the bottom of the leg to make zipper fitting easier If Messring onboard DAS is being used just one wire will exit the leg just below the knee if that position is used It may be necessary to cut a hole for this wire Once the zipper is completely zipped up lay the zipper Velcro tag over to protect zipper and to prevent zipper coming undone IG GTR9 Phase 2 8 meeting OICA office Paris 18 GTR9 8 13 ESE Pedestrian Protection Errem FlexPLI Leg Preparation S Leg Preparation for Pendulum Dynamic Calibration 7 3 Step1 e Step 2 e Step 3 e Step 4 Step 5 Step 6 Step 7 Step 8 Leg Preparation for
9. anism and held in position using the steel wire rope loop attached to the ballast weight The rope has been made so that the angle of the leg before release is 15 above the horizontal Check once more the angle with a digital inclinometer on the back of the knee The steel rope is tied to the ballast weight via an eye bolt which can be used for fine height adjustment Step 6 Arm the DAS system and release the leg The trigger for data collection can be from the accelerometer on the leg started manually or from a speed gate After initial impact the leg will continue to bounce where possible the leg should be caught or stopped to prevent this The springs in the knee and the elastic response from the rubber flesh create a strong rebound If there is any doubt about safety allow the leg to bounce after impact If a test is to be repeated the leg should rest for 45 minutes minimum before repeating If another flesh set is used the test does not need to wait 45 minutes User Manual Page 90 f IG GTR9 Phase 2 8t meeting OICA office Paris 10 FlexPLI Leg Preparation GTR9 8 13 Pedestrian Protection Nor cm ML See Leg Preparation for Dynamic Inverse Test 8 5 Step 1 e Step 2 Step 3 e Step 4 e Step 5 Step 6 Leg Preparation for Dynamic Inverse Test Check the eight M8 set screws shown in Figure 88 are tightened to 8 Nm after 60 vehicle tests remove the knee front covers and check the 4x M8 b
10. bration 7 3 Leg Preparation for Pendulum Dynamic Calibration Step 9 Remove the black protective cover Part Nr 133 5516 from the tibia bottom and attach the Pivot Hinge Part Nr 133 8418 as shown in Figure 92 using four M6 x 18 long screws Step 10 See next step in section 7 4 for rig preparation The checking and adjustment of the pendulum Impact lock Part 133 8423 must be done with a bare leg without the suit Check the Impact block is adjusted to the specification Step 11 Fit the flesh and skin covers as described in 3 3 5 allowing for the electrical wires to exit at the end of the Pivot Hinge at the top of the upside down leg The leg is now ready to be hung on the rig IG GTR9 Phase 2 8 meeting OICA office Paris 20 GTR9 8 13 AES Pedestrian Protection Errem FlexPLI Leg Preparation wy Leg Preparation for Pendulum Dynamic Calibration 7 5 Step 1 Step 2 Step 3 Running a test Hook up the sensors on the Data Acquisition System DAS Fit the leg to the pivot block on the rig using the M10 Socket Head Shoulder Screw SHSS Route the disconnect wire as required out of the end of the tibia or below the knee depending on type of DAS and tape up to the rig so that it does not interfere with the free swing motion of the leg when tested If using off board DAS the wires are routed out of the top of the leg With the leg hanging down vertically start up and initiate the DAS and set the
11. eck all wires are correctly positioned to avoid damage and any exit wires are restrained Step 8 Hook up the sensors on the Data Acquisition System DAS as applicable IG GTR9 Phase 2 8 meeting OICA office Paris 24 GTR9 8 13 AI Pedestrian Protection Errem FlexPLI Leg Preparation WEE Leg Preparation for Dynamic Inverse Test 8 6 Step 1 e Step 2 Step 3 Step 4 Step 5 Step 6 Running a Dynamic Inverse Test With the leg hanging down vertically start up and initiate the DAS and set the DAS such that the sensors are zeroed to zero sensor output in this position Important The leg sensors are zeroed in the vertical impact position Arm the DAS system and release the linear guided impactor The trigger for data collection can be from the accelerometer on the leg contact switch or from a speed gate Conduct test Remove outer skin cover and inner flesh system after each test If a test is to be repeated the leg should rest for 30 minutes minimum before repeating If another flesh set is used the test does not need to wait 30 minutes IG GTR9 Phase 2 8t meeting OICA office Paris 25 GTR9 8 13 BESIEN Pedestrian Protection Errem FlexPLI Leg Preparation Sew Leg Preparation for Car testing 9 2 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Leg Preparation for Car testing Check alignment of upper an lower knee covers 133 5304 133 530
12. er the leg To simplify the fitting of the flesh system all the covers should be laid on the bench in reverse order of assembly Place the large outer cover on the bench with lettering face down Lay 6 strips of Velcro tape over with fluffy side down then place the rubber buffer sheet assembly 133 5020 over the strips The large rubber part goes to the top of the leg this is the opposite end to where the zipper on the outer cover starts Adjust the tape so that all the Velcro strips line up with the six markers on the rubber see Figure 73 Lay Thigh 2 and Leg 2 covers over with the two knee end inside arrows pointing towards each other allowing a gap for the knee area then do the same with Thigh 1 and leg 1 covers Place the leg assembly onto the laid out flesh covers with thigh femur section over thigh covers and leg tibia over leg covers with the leg assembly on its side Fit the black plastic protective end covers to the ends of the leg with 4x M5 BHCS Figure 70 Assembly of first flesh layer Figure 71 Zipper locations alternating on the sides schematic cross section IG GTR9 Phase 2 8t meeting OICA office Paris 4 GTR9 8 13 Pedestrian Protection Nor cm ML AA FlexPLI Leg Preparation Leg Preparation for Pendulum Dynamic Calibration 3 3 5 Fitting flesh Do up the zippers on Thigh 1 and Leg 1 making sure each zipper is positioned on the side of the leg in the area of the shoulder bolts Turn the leg ove
13. exPLI Leg Preparation Sew Check alignment of upper an lower knee covers 133 5304 133 5305 3 2 Knee Exploded View IG GTR9 Phase 2 8th meeting OICA office Paris 30 GTR9 8 13 Pedestrian Protection Pay FlexPLI Leg Preparation Say Figure 88 Check screws with 8 Nm torque IG GTR9 Phase 2 8th meeting OICA office Paris 31 GTR9 8 13 Pedestrian Protection Pye FlexPLI Leg Preparation Sw push l J push Figure 90 Recommended method to align knee to remove any twist and shear IG GTR9 Phase 2 8th meeting OICA office Paris 32
14. f the rubber parts R2 shall align with the upper end of the knee block The upper edge of the tibia neoprene parts N1T N2T shall align with the lower end of the knee block Theouter cover N3 shall be centered to the leg assembly without hangers and ballast weights Step 3 Fit the black plastic protective end covers to the ends of the leg with 4x M5 BHCS for inverse and car testing Step 4 Do up the zippers on Thigh 1 and Leg 1 making sure each zipper is positioned on the side of the leg in the area of the shoulder bolts IG GTR9 Phase 2 8t meeting OICA office Paris 16 GTR9 8 13 Pedestrian Protection Errem FlexPLI Leg Preparation Sey Leg Preparation for Pendulum Dynamic Calibration 3 3 5 Fitting Flesh an Covers Step 5 Turn the leg over and do up the Thigh 2 and Leg 2 zippers making sure these zippers are on the opposite side to the first No zipper should be at the back or the front of the leg or it will interfere with the flat surface of the launcher plate or sustain damage due the impact Step 6 Wrap the rubber buffer assembly tightly around the leg using the six Velcro straps The thick wider part of the rubber system fits just above the top of the femur knee block See Figure 74 there are markers on the rubber showing the exact position for the Velcro It is important that the fluffy side of the Velcro is to the outside otherwise the outer cover cannot be stretched over due to grip from the eye side of the
15. gment screws Remove the aluminum launch guide Figure 47 item 18 Part Nr 133 5103 U shaped bracket fitted to the top of the femur along with the black protective cover Figure 54 item 28 Part Nr 133 5516 Attach the ballast weight Part Nr 133 8436 as shown in Figure 91 to the top of the femur using two M8 x 50 long cap head screws User Manual Page 26f IG GTR9 Phase 2 8t meeting OICA office Paris 7 GTR9 8 13 Pedestrian Protection Nor cm FlexPLI Leg Preparation Say Leg Preparation for Pendulum Dynamic Calibration 7 3 Leg Preparation for Pendulum Dynamic Calibration Step 8 Remove the black protective cover Part Nr 133 5516 from the tibia bottom and attach the Pivot Hinge Part Nr 133 8418 as shown in Figure 92 using four M6 x 18 long screws Step 9 See next step in section 7 4 for rig preparation The checking and adjustment of the pendulum Impact lock Part 133 8423 must be done with a bare leg without the suit Check the Impact block is adjusted to the specification fit the suit according to the instructions in section 3 3 5 allowing for the electrical wires to exit at the end of the Pivot Hinge at the top of the upside down leg The leg is now ready to be hung on the rig User Manual Page 86 f IG GTR9 Phase 2 8 meeting OICA office Paris 8 GTR9 8 13 Pedestrian Protection Py en 5A TAA FlexPLI Leg Preparation Leg Preparation for Pendulum Dynamic Calibration
16. r and do up the Thigh 2 and Leg 2 zippers making sure these zippers are on the opposite side to the first No zipper should be at the back or the front of the leg or it will interfere with the flat surface of the launcher plate or sustain damage due the impact Wrap the rubber buffer assembly tightly around the leg using the six Velcro straps The thick wider part of the rubber system fits just above the top of the femur knee block See Figure 74 there are markers on the rubber showing the exact position for the Velcro It is important that the fluffy side of the Velcro is to the outside otherwise the outer cover cannot be stretched over due to grip from the eye side of the Velcro To get a tight fit with the Velcro it is easier to get someone to pull the rubber sheet around the leg while you are locking the Velcro Finally pass any off board wires or disconnect through any holes in the outer cover if applicable and wrap the outer cover around the leg The outer cover is zipped up from the bottom of the leg to make zipper fitting easier If Messring onboard DAS is being used just one wire will exit the leg just below the knee if that position is used It may be necessary to cut a hole for this wire Once the zipper is completely zipped up lay the zipper Velcro tag over to protect zipper and to prevent zipper coming undone IG GTR9 Phase 2 8t meeting OICA office Paris 5 GTR9 8 13 Pedestrian Protection Ner cm FlexPLI Leg Preparation Sw
17. the test does not need to wait 30 minutes IG GTR9 Phase 2 8t meeting OICA office Paris 22 GTR9 8 13 Pedestrian Protection Py en FlexPLI Leg Preparation Sy Leg Preparation for Dynamic Inverse Test 8 5 Leg Preparation for Dynamic Inverse Test Step 1 Check alignment of upper and lower knee covers 133 5304 133 5305 e Step 2 Check the eight M8 set screws shown in Figure 88 are tightened to 8 Nm Step 3 after 60 vehicle tests remove the knee front covers and check the 4x M8 button head screws attaching the legs are tightened to 8 Nm e Step 4 Check the four stop cable clearances passing through the femur are set to 9 1 mm and 10 3 on the tibia See figure 89 a special tool 133 5112 is used for this Stepb Check knee blocks are aligned to ensure knee is not twisted or in a shear condition before the test Using two equal height blocks push down on the back of the knee for y direction and also on one side of the knee for x direction as shown in Figure 90 A straight edge can be used to double check alignment after any adjustment Step6 Check all segment screws and side aluminum shoulder screws are tightened to 3 Nm IG GTR9 Phase 2 8t meeting OICA office Paris 23 GTR9 8 13 Pedestrian Protection Pye FlexPLI Leg Preparation wy Leg Preparation for Dynamic Inverse Test 8 5 Leg Preparation for Dynamic Inverse Test Step 7 Fit the flesh and skin covers as described in 3 3 5 Ch
18. utton head screws attaching the legs are tightened to 8 Nm Check the four stop cable clearances passing through the femur are set to 9 1 mm and 10 3 on the tibia See figure 89 a special tool 133 5112 is used for this Check knee blocks are aligned to ensure knee is not twisted or in a shear condition before the test Using two equal height blocks push down on the back of the knee for y direction and also on one side of the knee for x direction as shown in Figure 90 A straight edge can be used to double check alignment after any adjustment Check all segment screws and side aluminum shoulder screws are tightened to 3 Nm Hook up the sensors on the Data Acquisition System DAS and check the sensor polarities Section 2 3 2 and figure 16 by flexing the leg Polarity check must not be done User Manual Page 94 repeatedly before each test IG GTR9 Phase 2 8t meeting OICA office Paris 11 GTR9 8 13 Pedestrian Protection Nor cm FlexPLI Leg Preparation Say Leg Preparation for Dynamic Inverse Test 8 5 Leg Preparation for Dynamic Inverse Test Step 7 Fit inner flesh system as described in 3 3 5 Step 8 Check all wires are correctly positioned to avoid damage and any exit wires are restrained Step 9 Fit the outer skin cover User Manual Page 94 IG GTR9 Phase 2 8 meeting OICA office Paris 12 GTR9 8 13 mme Pedestrian Protection E room FlexPLI Leg Preparation E Leg Preparation for Dynamic In
19. verse Test 8 6 Step 1 Step 2 Step 3 Step 4 Running a Dynamic Inverse Test With the leg hanging down vertically start up and initiate the DAS and set the DAS such that the sensors are zeroed to zero sensor output in this position Important The leg sensors are zeroed in the vertical impact position Arm the DAS system and release the linear guided impactor The trigger for data collection can be from the accelerometer on the leg contact switch or from a speed gate If a test is to be repeated the leg should rest for 45 minutes minimum before repeating If another flesh set is used the test does not need to wait 45 minutes User Manual Page 95 IG GTR9 Phase 2 8t meeting OICA office Paris 13 GTR9 8 13 Pedestrian Protection Py en FlexPLI Leg Preparation Sy Leg Preparation for Pendulum Dynamic Calibration 3 3 5 Fitting Flesh an Covers On the day of the test or for certification the flesh covers are fitted over the leg To simplify the fitting of the flesh system all the covers should be laid on the bench in reverse order of assembly N3 Neoprene outer cover N2 Neoprene second layer N1 Neoprene first layer R2 Rubber second layer R1 Rubber first layer suffix F femur part suffix T tibia part Tolerance of size for NI c T Unit mm N2 F T and N3 10 mi z5m UI Section 11 3 99 of Blue Book Attachment 99 tolerance 54 0 IG GTR9
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