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Flex PLI GTR User Manual

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1. 81 Figure ACL PCL upper and lower corridors 81 Diagram of Dynamic Pendulu c L u a usa 82 Exploded view Dynamic Rig part nr 133 8400 84 Check screws with 8 Nm 9 86 Stop cable clearance adjustment using setting tool 87 Recommended method to align knee to remove any twist and shear 87 Attaching Pendulum Ballast 88 Attaching Pendulum Rig Pivot hinge 88 Checking the Impact Block position 89 Examples orrelease esse pavo Cu mast cav Sta 89 Diagram of Dynamic Inverse Certification Test set 92 Paper cloth wrapping of 93 Launch guide with 15 tilt toward guided impactor 95 Optional catch rope bracket 133 5034 98 Impactor guide width setting 113 nennen 98 Humanetics Launch plate Part Nr 133 8200 Aluminum and Carbon Fiber 99 GTR9 6 06
2. 70 4 1 kuupa 70 4 2 General External Damage 70 4 3 SUPPO a 70 4 4 Hed Neoprene COVES runis 2 E a ries 70 4 5 Protective Plastic End Covers Part 133 5516 70 4 6 Els ANG Femy RETE UL ULT 71 4 6 1 Assembly Segment 71 4 6 2 Buffers between 99 71 4 6 3 Shoulder Bolt and Segment Screw Tightness Check 71 4 7 E Uu DU UI LU MEM M UU UM I d UM I 71 eL 71 4 7 2 Knee spring cables and bone stopper 71 4 8 Sensor and Electrical Maintenance meras n ce Pata urea M Seta 72 4 8 1 General Electrical 72 48 2 Bone Su ea erated 72 4 8 3 String Potentiometer Maintenance 72 Section 5 aa uec Uo 7 Section 6 Calibration and certification 3s 74 6 1 Calibration and Certification 74 GTR9 6 06 6 2 Femur and Tibia Bone Assembly
3. 75 EU mE 75 6 2 2 Femur and Tibia assembly 75 6 3 ISe C CHUNG ALON biats 80 Section 7 Pendulum Dynamic 82 7 1 IATMOCUCTION uk T 82 7 2 Pendulum Rig Assembly 83 7 3 Leg Preparation for Pendulum Dynamic Calibration 86 7 4 Pendulum Rid PrepalallOm unana n 88 7 5 BULTIC Ue SL ERR Mm 90 7 6 VOCES SING 91 Section 8 Dynamic Inverse Certification nennen nnne nnne 92 8 1 Ec 92 8 2 Inverse Test 92 8 3 Preparation of the Inverse Test set up 60556 c scaena passed abd 93 8 4 Impactor Friction Stroke Phases and Speed Measuremernt 94 8 5 Leg Preparation of the leg for Dynamic Inverse 94 8 6 RUNING a Dynamic Inverse FesLbuese uo Doe m a Si aa uyum anna 95 8 7 551 MT m n 96 Section 9 Vence ec 97 9 1 46 8
4. ne alus cM A CEP a T er dil 2217 DE Eo Eur 47 riy che gl tae s s oo COSE Qo Figure 75 Leg with outer cover fitted 3 3 6 Leg Disassembly Remove outer cover flesh rubber and remaining covers Unclamp off board wires if fitted and remove side covers from knee Disconnect sensor wires as required Remove front blue covers on knee and remove 8 screws and set screws connecting the femur and tibia to the knee The leg parts can then be pulled out of the knee _ 133 9900 User Manual FLEX PLI GTR Rev E Page 69 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Section 4 Maintenance 4 1 Introduction If the leg is passing pendulum or inverse tests that is the main indicator that the leg is suitable to continue testing If the leg is not passing this would indicate wear or damage has taken place and the problem needs to be investigated and corrected Obviously your first indication of problems would appear with unexpected output of the leg after a vehicle test Severely exceeding injury criteria may also be a first indication of overloading and would indicate further inspection is necessary This section aims to give a systematic checking procedure and guidance on when parts require inspection adjustment replacement reassembly or recalibration The external visual inspections listed below should be carried out at a minimum after every 10 vehic
5. nnne 48 133 8129 base with 133 5514 segment and bone clamps inside 51 133 8129 base with 133 5514 segment bone clamps and bone assembly 52 Fitting and tightening first blue nnne 52 Fitting thin bone spacer with captive nnne 53 Bone exit cable restraint use cable ties ties not shown trimmed or tightened 54 Knee Asseimbly Exploded u POR NR ER 55 Meniscus string pot assembly wire feed 57 Meniscus with all string pots assembled String pots identified 57 M niscus Wire clamp ud E ad bu pa ux dV D E Vd 58 Attachment plate crimp wires in tension ready for knee femur block assembly 59 Cross wire feed through on 59 Tibia Assembly Exploded VIeW ie reed 61 Typical shim arrangement with 05 shim inside captive shim 64 Assembly of last two segments on 65 screws to be tightened to 8 Nm non impact 66 ASSembIVOOL MEST Tes 8 u u
6. 17 Wire routing out of segment for optional sensors Detail A in upper knee 18 Similar arrangement to Detail A but with 2 uniax Kyowa accels Assembly 133 7600 18 Sensor IES 3103 ARS example locations knee lower 19 Kyowa accel 3 axis option for leg top and bottom locations mount 133 7530 19 Optional Instrumentation for 400428400 20 06 Sign Conventi OM usu l als uidet Uo RU 24 Leg manipulations for positive outputl 25 Clamping Arrangement and Position for Off board Wires 26 Off Board wiring left hand side of impact face 27 Board wiring right hand side of impact 27 Wiring Diagram for 12 channel 05 28 M BUS arrangement in knee 12 channels LH side to impact direction 29 M BUS arrangement 12 channels RH side of impact direction 29 Clamping of M BUS Disconnect Connector 8 29 M BUS Terminator housing installation in upper 30 Fixing M BUS Wire to 4 30 Right hand side of knee M BUS
7. ThstUT e at OT t ens qay 15 2 3 ISG COGCS qm c 21 2 3 1 Co ordinate uu nu muyu 24 2 3 2 Signal Polarity Sensor function check 25 2 3 3 CASS EA 25 2 4 Datis Acquisition 29 e eee na ta nus Qa amta ak fetta 26 2 5 CTT OAC ERR 26 2 6 Messring M BUS On Board Data 28 2 6 1 JESION H H 28 2 6 2 24 30 2 7 DTS Onboard SLICE Nano BAS rote ocd 32 SOBGE24Chahtel ODHOD te eat ced tanec seated 36 2 7 2 Electrical Interference 36 2 8 DT Onboard ote ada ER Meroe 37 2 54 c n 37 2 9 E c 39 2 9 1 MICEOD AU DeSCTIDUOED a DUO es a ua qutu N UA
8. 10 6 133 5019 VELCRO BUNDLE TIE 500mm LONG NOT SHOWN Table 6 Flex PLI Parts List 1 1 1 1 1 1 1 1 1 GTR9 6 06 3 1 Femur Exploded View Figure 54 Femur Assembly Exploded View 133 9900 User Manual FLEX PLI GTR Rev E Page 48 of 99 2013 Humanetics Innovative Solutions GTR9 6 06 am 2 1 1835508 BONECLAMP THIN KNEE o Z o 3 1 183 550 THIN FEMUR TIBIA 4 1 183 50 BONECLAMP THICK KNEE 002 5 1 183550 CLAMP THICK FEMUR TIBA 6 5 183550 SPACER BONE CONTACT THICK 8 1 1835500 RUBBER BUFFER FEMUR TIBIAEND 9 5 183 5507 SPACER BONE CONTACT THIN 002 SHIM 0 4 THICK OPTIONAL 16 1 1835108 SEGMENTTOP FEMUR o 7 1 1335102 PLATE TOP 00 18 1 183510 LAUNCHGUDE gt Z 19 4 1835104 WASHER 1210 2600 3 1 10 a 133 5521 WASHER CABLE 4 133 5110 CABLE ASSEMBLY FEMUR O 6 4 I 6 500072 SCREWBHCSMeX1X16 0 00 4 4 2 133 5002 SHIM BONE CLAMP T0 05 OPTIONAL SHOWN 133 5003 SHIM BONE CLAMP T0 5 OPTIONAL NOT SHOWN 0 6 133 5027 TAPE END COVER 10 X 12 133 5004 SHIM BONE CLAMP T0 6 OPTIONAL NOT SHOWN 5 133 5005 SHIM T0 6 OPTIONAL NOT SHOWN 133 5012 SHIM 05 OPTIONAL NOT SHOWN Table 7 Femur Assembly Parts List GTR9 6 06 3 1 1
9. 97 9 2 Leg Loading free 21 u u Pa Du ba 97 9 3 WARNING VIOLENT REBOUNDI nnne nnnnnnn sss n nnns ananas 97 9 4 RODO MEER m m 97 9 5 impactor silio idi Ic UU UU Mc 98 GTR9 6 06 Table of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 TRIACS amp uuu 11 Hox TE uin p NONEM VA MUEVE 12 Ratchet offset wrench with hex bits kit 12 Leg Wire s tliig 1060 1855112 uy m 13 nee spacertool 1993 51 13 3 u u hunukuna 13 Tibia and Femur base tool 133 8114 13 Optional Insirurmeni alti nrior Femuru uu uuu a au aus i 16 Detail A Exploded View upper and lower knee 17 Wire routing for Detail A optional
10. lt Q lt Q lt rr lt rr Hj Hj Q rr 2 Tibia Segment 5 Acceleration Y additional Tibia Segment 6 Acceleration Y additional Tibia Segment 7 Acceleration Y additional Tibia Segment 8 Acceleration Y additional D C 45 rr D rr D rr AC Tibia Segment 4 Acceleration Y additional GTR9 6 06 Tibia Bottom Acceleration additional 42 X Acceleration 43 Y additional HL A Acceleration 44 Z additional TIBI D 0 00 C le WOWIWIISWN IIII OOI Table 4 ISO MME Sensor Code table Wire Label TRIAX Sensor Location Description Code wire label ISOMMECODE code 3 DOKNEELCOOPFDSZC DOKNEEACOOPFDSZC DOKNEEPCOOPFDSZC DOKNEEMCOOPFDSZC 3 DOTIBILOO0PFMOXC AYKB A FT p F css F KL Femur Moment 3 Upper X Femur Moment 2 Middle X Femur Moment 1 Lower X S LCL T T T T F1 Knee LCL Elongation LCL T1 Tibia Moment 3 Middle Lower X T8 Tibia Moment 4 Lower X T4 K AR KU AX KL 3 2 1 1 2 3 4 AR KL Tibia Segment 1 Acceleration Y AY S7 DOTIBIOI00PFACYC Tibia Segment 2 Acceleration Y AY S8 7 D0TIBI0200PFACYC Tibia Segment 3 Acceleration Y AY S9
11. PCL out Push femur LCL out ACL out PCL out Figure 16 Leg manipulations for positive output 2 3 3 Filter Class The filter class to be used on the Flex PLI is CFC180 for all channels GTR9 6 06 2 4 Data Acquisition Options The FLEX PLI can be used with various options for data acquisition systems The most basic version is a system with connection cables to a static laboratory Data Acquisition System DAS the so called off board DAS option As the FLEX PLI is a tool that is in free flight after launch the off board cables may affect the free flight trajectory accuracy and the cables are susceptible to damage when the tool lands after rebound from the vehicle Therefore the use of off board DAS is not recommended Currently Humanetics can provide onboard DAS systems from Messring DTS SLICE Hentschel DTI Kayser Threde and Kyowa These systems are described in paragraphs 2 6 2 7 2 8 2 9 and 2 10 This section is provided in the manual for information only For detailed and up to date information on DAS systems please refer to the original DAS equipment manufacturer 2 5 Off Board DAS For off board DAS umbilical cables of 10m long exit the leg just below the knee This position is close to the CG of the leg to minimize the mass affect from the cables in free flight The cables are clamped to the leg via the top shoulder link bolts of the tibia to provide restraint protection to the connectors see Figure 1
12. 10 15 20 25 Deflection mm Femur assembly certification corridor moment vs deflection showing typical results 400 350 300 250 200 150 100 90 0 0 10 30 Deflection mm Tibia assembly certification corridor moment vs deflection showing a typical results GTR9 6 06 6 3 Knee Certification This operation requires the use of a materials testing machine with high definition load cell and some parts from calibration fixture 133 8120 see Figure 79 Temperature for this test must be between 20 2 C Locate the femur insert into the femur knee block the femur insert is 3mm longer than the tibia insert so it is important the correct insert is in the correct knee block or results will be wrong Fit 2x M8 x 35 BHCS and tighten then fit the 2x M8 x 30 set screws on the opposite side and torque all screws to 8 Nm Follow the same procedure for the tibia insert Assemble the fixture as shown ensuring the impact side is on the top and the two blue plastic covers have been removed along with the accelerometer if fitted and double sided tape It is important to check that the two knee blocks are aligned before starting the test to remove any shear or twist in the assembly A procedure like that used in figure 90 can be used and double checked with a straight edge Place assembly over the center of the base plate with 3 2 mm thick Teflon sheets fitted with double sided tape as in Figure 77
13. DOTIBIOS3O0PFACYC Tibia Segment 4 Acceleration Y 610 7 DOTIBIO400PFACYC Tibia Segment 5 Acceleration Y AY ST DOTIBIOSO0PFACYC Tibia Segment 6 Acceleration Y DOTIBIOG00PFACYC GTR9 6 06 Tibia Segment 7 Acceleration Y AY S13 DOTIBIO700PFACYC Tibia Segment 8 Acceleration Y 614 DOTIBIO800PFACYC Tibia Bottom Acceleration X AY TB Tibia Bottom Acceleration Y AY TB A TB Tibia Bottom Acceleration Z AZ TB Table 5 Wire label codes for all sensors 2 3 1 Co ordinate System The recommended local co ordinate system for standardization follows the SAE J 211 dummy co ordinate system gt i A Figure 15 Leg Local Sign Convention GTR9 6 06 2 3 2 Signal Polarity Sensor function check The leg can be manipulated manually as shown in Figure 15 below to test polarity and function for positive output A spacer can be placed under the leg to assist in the bending of the leg The positive outputs shown in Figure 16 below are preferred for standardization users can use their own polarity if required For accelerometers signal polarity a blow in the direction of the positive axis should result in a positive acceleration output Figure 15 Example a blow f i with a wooden hammer on the blue impact cover in negative y direction should give a negative y acceleration Impact face down Push femur MX tibia out MX femur out MCL out ACL
14. 35 Optional SLICE unit 24 channel option right side 36 Left side wiring example of 24 channel 36 DTI DAS left hand side of knee showing Di Mod hubs 37 DTI DAS right hand side of knee showing crash recorder on the left and DiMod hub on the 38 General OVOrVIOW s escenas vor det detras tate 38 Exploded view of knee showing Micro Dau integration 39 Showing drawing of Micro Dau part 40 Right hand side of impact face lower covers 40 hand side of impact face Covers 41 Schematic layout of 12 channel Micro 41 Kyowa 12 Channel System Configuration 42 Iowa SIdedb 12 ha m ym iter do cU 43 2 Ih k xu 43 Kyowa Disconnect 44 Kyowa Frontside iti 2011 2254 Eco Eee e e Estee 44 45 Leg assembly Exploded 60 46 Femur Assembly Exploded
15. Table List Table 1 Contents of the tool kit provided with the leg on delivery 14 Table 2 12 Channel Instr meritatlOD secs eee 15 Table 3 Example of Optional Instrumentation Parts 20 Table4 ISOMME Sersor Gode table ose aie ea SR atic ees Datus 23 Table 5 Wire label codes for all nennen nnns 24 Table uuu ukun addicta O 47 Table 7 Femur Assembly des neo hte leaks 49 fables lt Eo 56 Table 9 Tibia Assembly Parte EISE u Dn ass eg rod 62 Table 10 Sa u E A tne SEO 73 Table 11 Sensor Mass bei 73 Table 12 74 Table 13 Parts List for Static fixture 199 9 120 iuo u oen et a oq Su c etus quqa 77 Table 14 Pendulum Dynamic Big Part uuu uuu u uuu u SD 85 Table 15 Pendulum test corridors peak values within 250 ms after 91 Table 16 Inverse test corridors peak values within 50
16. Femur Upper Leg Assembly Before assembly check all rubber buffers are bonded to segments In the unlikely event a buffer should become dislodged damaged or lost it will need re bonding When bonding the segment buffers ensure surfaces of both parts are prepped before bonding prepare plastic with 240 grit paper and rubber with 80 grit degrease then bond with Loctite 401 or similar When handling the bone core it is recommended that gloves are worn to prevent getting splinters in the hand Do not run your hand along the bone without protection Start the assembly from the knee end of the bone The tibia femur base tool 133 5114 will be required for assembly as this will allow the bone to be assembled flush with the end clamps make assembly stable when building and simplify segment assembly The part 133 8129 from the bone static fixture can also be used and is shown in Figure 55 Fit bone clamp 133 5506 inside the tool base with curved end upwards and groove side inwards loosely fix with 2x M8 x 20 screws Fit the inner segment knee 133 5514 over the clamp and attach finger tight with 2x M6 x 16 BHCS See Figure 55 Place 133 5508 over the bone PCB curved end up and insert bone and clamp into the base see Figure 56 The PCB is on the rear of the leg non impact side Fit 2x M8 x 12 SSFP Socket Set Flat Point screw into the fixture base then the 2x M8 x 16 SSFP into 133 5514 segment Tighten all the screws to 3 Nm Lay the PCB exit wire to
17. Figure 2 can be used to access most of the fasteners in the dummy In some cases access to fasteners is easier if a ratchet offset wrench with hex bits is used Figure 3 Figure 1 T Handle Wrenches gt 133 9900 User Manual FLEX PLI GTR Rev E Page 11 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 2 Hex Wrenches Da 100 1RT 4410 Figure 3 Ratchet offset wrench with hex bits kit Eight 4 mm and 1 8 open ended wrenches are required A wire spacer tool 133 5112 is needed see Figure 4 to set bone assembly wire stopper clearance and there is another spacer tool to space the knee string potentiometer attachment part 133 5113 for knee assembly See Figure 5 Two of these are used to hold string potentiometer attachment plate in position on assembly All these tools are provided with the leg as part of the tool box T NNNM 133 9900 User Manual FLEX PLI GTR Rev E Page 12 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 4 Leg wire setting tool 133 5112 Figure 5 Knee spacer tool 133 5113 Figure 6 Tibia and Femur base tool 133 8114 Note Apart from the string potentiometer 2 56 UNC cap head screws and the ARS optional angular rate sensors which use 0 80 cap heads all the leg screws are metric NN 133 9900 User Manual FLEX PLI GTR Rev E Page 13 of 99 2013 Humanetics Innovative Solutions GTR9 6 06 Table 1 Contents of the tool kit
18. GTR9 6 06 Figure 61 Meniscus string pot assembly wire feed OUT OF 2 LIGIMENT BUSHES WIDER NON IMPACT SIDE Figure 62 Meniscus with all string pots assembled String pots identified S mmm 133 9900 User Manual FLEX PLI GTR Rev E Page 57 of 99 2013 Humanetics Innovative Solutions GTR9 6 06 Figure 63 Meniscus wire clamp Pass all four ball crimps through attachment plate 133 5302 and place two spacers below it the pot wires will then be in tension see Figure 64 Two tubular plastic spacers are shown in the photo to show setup clearly there are special spacers in the tool kit for this purpose 133 5113 See Figure 5 Place four of the 12 x 40 long springs 9003159 into the knee block femur and place washer 133 5311 on top of springs insert wires 133 5360 through springs Lower this block assembly carefully over the tibia knee block guiding the wires across to their designated holes and locating over the attachment plate see Figure 65 Double check the knee femur block is the right way round ref exploded view figure 60 and the wires are in their correct aligned holes and not crossed over Carefully turn the whole assembly over and locate the remaining 212 springs over the wires Fit all four washers and Nyloc nuts tighten nuts down until the washers are exactly flush with the Femur block Two wrenches 8mm and 1 8 are required to tighten nuts Humanetics recommends that the Nyloc nuts are only used twice aft
19. The testing machine must be fitted with 100mm D shaped profile part 133 8105 see Figure 79 The center of the profile must be aligned with the top of the meniscus a line is marked on the loading profile for this visual alignment Plug string pots into recording equipment A piece on Neoprene minimum size 85 x 50 x 5mm thick is placed over the loading point to prevent damage to the knee The 85 min dimension is the knee width dimension This Neoprene is the same material used in the covers The loading profile is brought down to contact the Neoprene at the zero load point Then the test loading is started The knee is then loaded to 4 KN speed rate must be between 10 and 100 mm min Calculate the bending moment at knee with Mk F 2 x 0 2 LCL ACL PCL and MCL string pot deflections are recorded The LCL deflection is only checked for function in this test as it would be in compression The results must be inside the corridors given in Figure 84 and 85 If the result does not fit into the corridor the springs may be tightened or loosened Humanetics recommends the nuts are not adjusted more than 1mm from the nominal flush washer position to the knee block to avoid affecting the designed full range of motion of the knee The knee ligament outputs should all be positive the LCL will bottom out between 2 and 4mm Figure 83 Knee Certification Fixture GTR9 6 06 450 400 350 300 250 200 150 moment L 100 i m
20. axis at the time of first contact shall be within a tolerance of 0 2 in relation to the longitudinal vertical plane The yaw angle of the impactor rotation around z axis at the time of first contact shall be within a tolerance of 0 2 Step 1 Suspend the leg on the inverse test rig on the release mechanism with its launch guide Step 2 Make sure the launch guide at the top of the femur is locked tilting 15 towards the impactor Lock the guide in position using the two M6 screws both sides This allows the leg to hang vertically on the spring loaded release mechanism See Figure 97 below Impactor Direction Figure 97 Launch guide with 15 tilt toward guided impactor Step 3 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 WARNING After the impact the leg is thrown violently away from the test rig and can seriously injure anyone standing in the flight area It is highly recommended that a safety barrier is erected in the flight area ensuring no one is inside this danger zone during the test to avoid any injury Step 4 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 min
21. 133 8120 showing knee QTY 1 ws 04 Eu GN 7 e N Table 13 Parts List for static fixture 133 8120 15 _ GTR9 6 06 The femur bone is loaded centrally on the forth plastic impact cover from the knee and on the tibia the fifth plastic impact cover which is the centre of each bone The loading spigot is connected to a high definition load cell on a load frame Connect assembly to recording equipment The loading spigot is at zero load just touching the impact cover Each bone assembly is loaded to 380 Nm Check deflection moment output must be inside corridor see Figure 81 and 82 Temperature for this test must be between 20 2 C Note that the loading path from the machine must have no rubber damping otherwise the load curve will be inaccurate To calculate moment loading centres femur is 330mm and tibia 410mm For femur moment MF F N 2 x0 165 m and for tibia MT F N 2 x0 205 m Loading rate is to be between 10 and 100 mm min Figure 80 Bone Assembly Fixture femur shown under bending 133 9900 User Manual FLEX PLI GTR Rev E Page 78 of 99 02013 Humanetics Innovative Solutions Moment Nm Figure 81 Moment Nm Figure 82 400 350 300 250 200 150 100 90 GTR9 6 06
22. Dd 39 2 10 Kyowa 5554282558422052 055124822421286358 288 ab a ai Au a ab 42 Section 3 ASSEMDIY andibIsasselnbly cod aid ee tad ded sees 46 3 1 Felm rExplodesd VIEW ue nim Eben Ern rebos 48 3 1 1 Femur Upper Leg 50 3 1 2 Femur assembly after static certification 54 Iko Fem rDisassemDy azu 54 3 2 Knee Exploded 55 GTR9 6 06 dd ISACEASSEMDIY aaa a 56 3 2 2 Assembly After Certificato M 2 2 bien a 59 3 23 Knee DISasselnbDly tu Rum cux Rb once meet tenets meets 59 3 9 XDIOUEd ten citis uu icd 61 WADIA 11 5 tuan 63 3 2 Q uuu uuu u ARS 65 3 3 3 LIDIAIDISASSCIMDIY PERPETUUM 65 Si uu uuu yuna uuu e 65 34345 11110 ES e 66 330 Leg Disassembly 69 Section 4
23. SEF 131 5711 FOR DETAILS 5 CONTAINS ITEMS 10 AND 11 SEE 133 5712 FOR DETAILS MODULE CONTAINS ITEM 12 SEE 133 5713 FOR DETAILS DESCRIPTION MIL R OBATTERY ME DUMMY EXIT 1 CONNECTOR 5 t CABLE APPRITXIMATELY 5m LORG 5 ADLEL MALE LATCH Ax ID CONNECTED KISTLER BLS EXTENDER 5 BCREW FACS MA X L 7 X 8 MICROBATTERY 52 ASSEMBLY MICROOA HOUSING ASSEMBLY ASSw TIBIA T POB BONE 3 CHANNEL FEMUR TAC RED L SEE 110 5700 F R ASSEMBLY DETAILS 2 SEE MODULES 1335710 1332 5711 132 5712 AND 133 5711 FOR WIRING AND ASSEMBLY DETAILS FLEX PLI MICRODALI VERSION ET SYSTEM CABLE ASSEMBLY Figure 43 Showing drawing of Micro Dau part numbers The battery module also provides the leg exit cable This cable is configured with a magnetic breakaway connector assembly Magnets are configured such that electrical contact is solidly made while preventing unwanted misalignment The connector is specifically designed for easy and safe disconnect to prevent cable sensor or data acquisition system damage Figure 44 Right hand side of impact face lower covers removed 133 9900
24. Ti 1Ch 6Ch CU C is 4 6 DIC 51A 040 DIC 54A 050 1 d m DIC 52A 220 F1 F2 7 9 DIC 51A 040 DIS 506A D Knee Acc DIC 50A 1 70 LCL 1 010 50 170 PCL TJ DIC 50A 170 7Ch 12Ch Figure 47 Kyowa 12 Channel System Configuration Diagram One logger is installed on the front side of the tibia knee block and the other is on the rear side of the femur knee block This configuration is shown in Figures 48 and 49 GTR9 6 06 Figure 48 Kyowa Side in 12ch Figure 49 Kyowa Rear Side in 12ch Sensor information can be set with the installed software DIS 5A after installing the loggers into the Flex PLI GTR The Kyowa 6 system works with sensor ID and TEDS meeting IEEE 145 1 4 spec and it is possible to shorten the amount of preparation time by using the TEDS For TEDS programmable chips would need to be fitted which are not currently fitted as standard The disconnect connector is routed towards the top of the Flex PLI GTR as shown in Figure 50 a 7 7 7 7 133 9900 User Manual FLEX PLI GTR Rev E Page 43 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 50 Kyowa Disconnect Connector This connector is detached when the Flex impactor is pushed out from a launcher system The launch guide angle needs to be set up as described in section 9 shown here in Figure 50 Data can be downloaded when the system is reconnected through DIS 5A software after the test The internal ba
25. User Manual FLEX PLI GTR Rev E Page 29 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 24 M BUS Terminator housing installation in upper knee Figure 25 shows the M BUS disconnect wire on the launcher and how the coax wire is routed and fixed to the launcher The disconnect design has a low release force however a strong tape is recommended to hold the wire in place Figure 25 Fixing M BUS Wire to Launcher 2 6 2 24 Channel M BUS Four six channel loggers can be fitted to the leg to provide 24 channels of data recording See figures below for typical installation Wire connections can vary according to optional sensors installed 133 9900 User Manual FLEX PLI GTR Rev E Page 30 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 26 Right hand side of knee M BUS 24 channels sensors not connected Figure 27 Top right hand side of knee M BUS 24 channels sensors connected Figure 28 Bottom right hand side of knee M BUS 24 channels sensors connected 133 9900 User Manual FLEX PLI GTR Rev E Page 31 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 29 Top left hand side of knee Messring 24 channels sensors connected Figure 30 Bottom left hand side of knee M BUS 24 channels sensors connected 2 DTS Onboard SLICE Nano DAS For detailed use and specifications please refer to suppliers user instructions The SLICE is a modular system where a 3 channel b
26. be reused if still sticky and if it is not folded over It will also be important to check for any damaged parts that would need replacement see section 4 When removing the segments it would be wise to lay them out in order or number their position so that segments spacers and shims can go back to the same position This is not critical but is recommended by Humanetics 133 9900 User Manual FLEX PLI GTR Rev E Page 54 of 99 2013 Humanetics Innovative Solutions GTR9 6 06 3 2 Knee Exploded View 18 v e E o Figure 60 Knee Assembly Exploded View DESCRIPTION KNEE BLOCK TIBIA FLEX PLI MENISCUS ASSEMBLY SCREW SHCS M5 X 8 X 10 LOWHEAD 900159 SPRING 12 X 40 AMISTAR DB 12 x 40 SPRING 18 X 80 AMISTAR DB 18 x 80 SPRING CAP 183531 CABLE WASHER 8 133 5850 CABLEASSEMBLY KNEEML GTR9 6 06 11 2 9000203 SCREW FHCS M3 X 0 5 X 10 1 12 1 1395315 COVER KNEE FEMUR RIGHT SIDE Table 8 Knee Assembly Parts List 3 2 1 Knee Assembly Make a note of the string pot serial numbers and their ligament positions this is needed for DAS identification for sensitivity input Also see paragraph 4 8 3 for str
27. bone and magnesium segments contact surfaces with a soft brush At this point with the bone disassembled also check for wear or damage to electrical components and repair as necessary The timing for gage calibration is stated in Table 12 4 8 3 String Potentiometer Maintenance The timing for sensor recalibration is stated in Table 12 For the string potentiometers check that the pull cables are tight when the knee is assembled and not lose or deformed If this is the case with injury channels ACL PCL and MCL they will need replacing The LCL is not an injury channel but does give information on the test So replacement is advised as well On disassembly of the knee the string crimps should be checked for possible slippage the dimension from the crimp to the pot is 61 5 mm 1 Also check the spring pull by gently pulling on the pot wires they should all feel the same careful not to exceed the 38 mm travel If the pots have not been calibrated for a while it may be worth calibrating while the knee is dismantled Also check for damage and wear of electrical cables and connectors and repair as necessary Figure 76 string potentiometer pull wire length 1mm GTR9 6 06 Section 5 Weight Specification Leg Part Weight kg Weight Tol kg Knee 133 5300 Tibia 133 5500 Table 10 Flex PLI GTR Mass If off board DAS is used knee has 0 1 kg allocated for cables Includes tape and Velcro straps IES
28. bone contact thick to segment 133 5535 blue segment with rubber buffers both sides using 2x M6 x 18 zinc plated BHCS Fit screws diagonally then slide over the bone with the thick spacer on the impact side Take care not to damage the black strain gage cover running down the centre of the bone The difference in thickness between the rear thin curved spacers and the front impact thick curved spacers is 0 5mm 12 25 thin 12 75mm thick The thinner spacer allows for the shim thickness The bone segments should have been laid out in the order they were disassembled this should help reassembly if not the process will still be the same If the leg has seen a number of tests some wear may have taken place and a different shim configuration would be required to ensure the bone is rebuilt with as tight a segment fit as possible This tight fit allows for wear in future testing and will help keep the leg certified Using the previous shim arrangement with its internal flat shims inside the captive shim see figure 67 locate against the spacer bone contact thin 133 5507 see Figure 58 and push this assembly centrally into the gap against the bone When fitting the shim assembly use thumb force only pushing down on the top of the spacer Do not hammer shims into place You should feel high resistance when pushing this assembly in You can check the fit by rotating the segment on the bone Z axis If there is play remove and add a 0 05 mm 133 5012 0 1
29. flight to the target See Figure 17 for an example Users can establish their own wire routing but the important issues to note are that both sides are balanced and there is no restriction at release from the pusher plate when fired 133 9900 User Manual FLEX PLI GTR Rev E Page 27 of 99 w x 11 r3 3 Y Ati rx CA ANALA Tn iT 02013 Humanetics Innovative Solutions GTR9 6 06 2 6 Messring M BUS On Board Data Acquisition 2 6 1 M BUS description An overview of the M BUS system is shown in Figure 20 The M BUS is a 6 channel logger fitted inside an aluminium housing connection is made to the logger via a plug in PCB board Each logger has its own battery For the standard 12 channels there are two M BUS units one either side of the knee in the tibia knee block three M3 FHCS fix the units to the knee The sensor connection is made by either a 7 pin or 16 pin miniature round connector with locking latch For M BUS left hand side of leg see Figure 21 For detailed use and specifications please refer to the suppliers user instructions Sensors Leg Form Launcher 2 1 To Sensors Terminator Quick Disconnect Gateway Coax cable To PC Figure 20 Wiring Diagram for 12 channel M BUS For leg wire routing please ref
30. leg was intended to remain the same to ensure existing test data was still valid The main improvements were centralising the knee ligament deflection sensors to avoid impact direction sensitivity balancing the spring force load in the knee joint to reduce knee joint twist about vertical axis various improvements related to handling and repeatability introduction of full bridge strain gauge configuration additional optional sensors and incorporating on board Data Acquisition Systems DAS to improve free flight stability Humanetics also reviewed the quasi static calibration procedures for internal bones thigh knee and lower leg assemblies The pendulum dynamic calibration rig and procedure were also updated to provide more realistic loading The high speed inverse linear guided impactor test is also a requirement for the GTR9 regulation The standard leg instrumentation has 12 channels this includes 3 full bridge strain gage sensors in the thigh and 4 in the lower leg all measuring leg bending moments an accelerometer and 4 string potentiometers in the knee each one measures specific ligament elongation There are also options for a further 26 linear accelerometer channels and 15 Angular Rate Sensors ARS Flex GIR has symmetric design so can represent a right or left leg GTR9 6 06 1 2 Tools Required Several types of standard tools are used in the assembly and disassembly of the dummy T handle wrenches Figure 1 and hex wrenches
31. mm 133 5029 or 0 2 mm 133 5030 flat shims inside the inner captive area or any combination of these to get a tight fit When the spacer assembly does not fit usually you only need to remove a 0 05 shim and that will be as tight as you can achieve When fit is as tight as possible with thumb pressure ensure screw holes are aligned then fix the shim assembly in the segment with 2x M6 x 18 BHCS fitted diagonally and tighten front and rear screws to 3 Nm You can use the Allan key to align the holes if not aligned by inserting into the hole and levering the inner assembly into position For the next segment assembly attach a spacer bone contact thick to the blue segment part 133 5534 using 2x M6 x 18 zinc plated BHCS fitted diagonally as per the previous segment Slide over the bone rubber buffers on top side and spacer to the front impact side Try fitting the same new shim arrangement as the previous shim assembly Adjust shims if still loose remove a 0 05 shim if the assembly cannot be GTR9 6 06 pushed into the segment Align holes to the segment and fit the two rear M6 x 18 BHCS diagonally and torque all 4 M6 screws front and rear to 3 Nm Repeat for the next 5 segments Check inside 133 5511 Segment bottom tibia that the rubber buffer is still bonded inside the bottom of the part If not this will need to be located and re bonded to prevent bone end play For the last 2 segments fit 133 5502 Bone clamp thick to the last segment and
32. ms after impactl 96 GTR9 6 06 Section 1 Introduction 1 1 Overview Pedestrian Lower Legform Impactors are used to evaluate pedestrian protection afforded by passenger vehicles in case of vehicle collision with a pedestrian The current EEVC WG17 Pedestrian lower legform impactor is known to have certain limitations regarding the biofidelity and the repeatability of the test results Therefore Japan proposed to use a completely new legform the so called Flexible Pedestrian Legform Impactor FlexPLI In the year 2000 the Japan Automobile Manufacturers Association Inc JAMA and the Japan Automobile Research Institute JARI initiated development of the Flexible Pedestrian Leg form Impactor In 2002 an initial design was made available followed by the Flex GT version in 2006 The FLEX PLI features biomechanically based femur tibia and knee design with biofidelic bending characteristics In the knee the ligaments are represented according to human anthropometry A Technical Evaluation Group FLEX TEG consisting of governmental and industrial parties evaluated the possibility to use the leg form impactor for Global Technical Regulation on Pedestrian Safety PS GTR Humanetics was a member of this group as dummy manufacturer and was asked to review the GT design and manufacture the leg This review highlighted a number of improvements and the proposed GTR design was accepted The performance of the
33. point nearest to the leg to the impact S e c V TOCG lt ZKG amp TNTV SWLSL LT 133 9900 User Manual FLEX PLI GTR Rev E Page 88 of 99 2013 Humanetics Innovative Solutions GTR9 6 06 segments of the tibia See Figure 93 Adjust the height of the Impact Block by moving the Impact Bar Weldment Figure 87 item 5 up or down 4 screws that mount tube to frame Adjust the horizontal Impact Block to Leg distance to 13 2 mm Shims can be added to the back of the Impactor Block or the Pivot Clearance Block if necessary 14 M e Pr Figure 93 Checking the Impact Block position adjustment Next step is to make a loop of steel wire rope of the proper length such that the drop angle matches the required suspension angle of 15 1 above horizontal Figure 86 Suspend the leg with the Pivot Hinge to the Pendulum Rig The leg is lifted up to the release mechanism Figure 94 and held in position with the steel wire rope attached to the ballast weight Adjust the loop length to the required suspension angle of 15 12 Check the angle with a digital inclinometer laid on the back of the knee The steel is tied to the ballast weight via an eye bolt which can be used for fine height adjustment The Pendulum Rig is now ready for running a test Manual release button Wire in latch Figure 94 Examples of release latches 133 9900 User Manual F
34. to 133 5511 Segment bottom tibia using 2x M6 x 18 BHCS for the blue segment and 2x M6 x 16 BHCS for the aluminium segment Ensure the bone clamp thick is on the impact side Replace the previous large shim shim bone clamp and any other thinner shims that went over the clamp 133 5503 Bone clamp thin and place this assembly inside the two segment assembly fix to the aluminium segment using 2x M6 x 16 BHCS and 2x M6 x 18 BHCS to the blue segment See figure 68 Slide or push these two segments over the top of the bone Check there is no gap between the bone and the rubber buffer by looking through the holes in the side of the end aluminium segment If there is this should be packed so that there is no bone end play If the fit is loose over either of the segments add a 0 05 shim until the fit is tight on both segments A higher push force will probably be needed for this fit as the inner dimension of the two segments may not be identical placing the leg on the ground with assembly base 133 8114 and pushing with two hands down on the two segments Once fit is tight tighten all eight screws to 3 Nm Figure 67 Typical shim arrangement with 05 shim inside captive shim Pass the connector through a link 133 5515 then assemble all the links and washers from the knee end with shoulder screws as shown in exploded view both sides The segments may need adjusting slightly to align holes for shoulder bolts If off board DAS or Messring DAS is being used
35. to allow fitting to the calibration fixture Keep all parts together ready for final assembly 3 3 2 After Calibration Fit removed links and side shoulder bolts The end cover 133 5516 should be fitted after pendulum calibration with M5 button head cap screws Also fit any optional instrumentation 3 3 3 Tibia Disassembly Disassembly is the reverse of assembly starting at the bottom of the tibia Care must be observed when removing bone spaces and shims not to damage bone wires and gages down the center of the bone The double sided tape can be reused if still sticky and is not folded over It will also be important to check for any damaged parts that would need replacement see section 4 When removing the segments it would be wise to lay them out in order or number their position so that segments spacers and shims can go back to the same position This is not critical but is recommended by Humanetics 3 3 4 Leg Assembly When the leg is not being used or shipped the tight fitting flesh system should be removed to prevent stretching and long term indentation from the leg components To access the screws in the knee first step is to carefully prize away the two blue front plastic covers if assembled Use a screw driver inside one of the cover lightening holes and gently lever away from the double sided tape attaching it to the knee Insert the Femur into the knee block femur 133 5320 Fit two M8x35 BHCS into the knee block front coun
36. with the honeycomb at time of first contact and the upper edge of the honeycomb must be in line with the knee joint top of blue tibia knee block 2 mm On impact the leg is to be released from the hanging bracket within 10 ms to ensure free flight condition Honeycomb How to fold the paper cover Qutlook Back side Front Impact side Paper cover Figure 96 Paper cloth wrapping of honeycomb GTR9 6 06 8 4 Impactor Friction Stroke Phases and Speed Measurement The impactor free travel and travel through impact are important to obtain good results The linear guided impactor dynamic friction during free travel should be less than 100 N to avoid speed reduction To measure this an accelerometer mounted to the impactor would be required to measure acceleration in the free stroke phase Refer to document GTR9 5 15 for measurement information It is advised all inverse rigs carry out this test Humanetics recommends a free travel of 70mm before impact and 190 to 220 mm after first contact to ensure all kinetic energy from the impactor is transferred The speed must be measured in the free travel phase ideally at a sample rate around 100 KHz due to the high speed and as close to the impact point as possible 8 5 Leg Preparation of the leg for Dynamic Inverse Test Step 1 Check the eight M8 set screws shown in Figure 88 are tightened to 8 Nm Step 2 After 60 vehicle tests remove the knee front covers and check the 4x M8 button
37. 24 channels sensors not connected 31 Top right hand side of knee M BUS 24 channels sensors connected 31 Bottom right hand side of knee M BUS 24 channels sensors connected 31 Top left hand side of knee Messring 24 channels sensors connected 32 Bottom left hand side of knee M BUS 24 channels sensors connected 32 Wing diagram or 12 chanel SEI uy tona rto pite oap Red 33 Typical 12 channel Slice wiring to nnn 33 34 LH of leg with knee covers fitted 12 channels Leg wires are not shown secured 34 SLICE Right hand side of knee 12 channels showing connectors 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 right Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Figure 67 Figure 68 Figure 69 Figure 70 Figure 71 Figure 72 GTR9 6 06 Leg with disconnect wire TDAS interface and power supply
38. 3103 three axis gyro sensor Model 64 Measurement Specialties optional Table 11 Sensor Mass Breakdown Model im vm opecialties optional GTR9 6 06 Section 6 Calibration and certification testing 6 1 Calibration and Certification Overview Certification of the FLEX PLI GTR requires nine different procedures to ensure certified performance of all components All steps that may be performed by the users are discussed in this section Calibration of string potentiometers accelerometer and bending moment strain gauges are not presented in this user manual as this requires operations only to be carried out by experienced and trained lab personnel All certification tests shall be conducted in a temperature controlled test environment with a stabilized temperature of 20 2 C and the temperature shall be recorded The subsequent steps of certifying the FLEX PLI GTR is given in Table 12 Table 12 FLEX PLI GTR certification steps Step Description When Required 7 Pass FailRequirement en 1 Annually recommended 1 1 0 linearity full scale Calibration 2 After exceeding injury thresholds 10 2 2 0 hysteresis full w m for FLEX GTR in an application test Calibration scale recommended otring all gauges 1 Annually 1 096 100 Potentiometer Calibration 5 peewee Calibration 1 Annually recommended 1 Femur centre bending Bending Test 2 After exceeding injury thresholds momen
39. 33 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 GTR9 6 06 Figure 70 Assembly of first flesh layer Figure 71 Zipper locations alternating on the sides schematic cross section 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 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 Wrap the rubber buffer assembly tightly around the leg using the six Velcro straps The thick wider part of the rubber system fits just abov
40. 4 5000814 SCREW 08 8 3 4 5000393 SCREW SHCSM3X 5X6 0 2 5000769 SCREW MSSFP M8X16 002 8 133 5025 TAPE IMPACT SEGMENT gt Z S 1 133 5028 COVER 12X24 22 4 133 5027 COVER 10X12 2 2 133 5026 COVER 12X16 24 1 133 5519 COVER END IMPACT KNEE END 8 183 5517 IMPACT SEGMENT 00 1 133 5518 COVER END IMPACT gt 7 133 5001 SHIM 0 5 OPTIONAL NOT SHOWN 2 183 5002 SHIM BONE CLAMP 10 05 OPTIONAL NOT SHOWN 35 2 133 5003 SHIM BONE CLAMP 0 5 OPTIONAL NOT SHOWN 2 133 5004 SHIM BONE CLAMP T0 6 OPTIONAL NOT SHOWN 7 133 5005 SHIM 0 6 OPTIONAL NOT SHOWN SHIM 05 OPTIONAL NOT SHOWN 6 5000072 SCREW BHCSM6X16 gt 1 1 1 0 2 133 5522 WIRE EXIT BASE gt Z 2 133 5523 WIRE EXIT CLAMP 0 00 2 5000654 SCREW M5X 8X12 0024 N 1 1 1818 0240104 PO PO PO NO PM N O O01 NI PO PO N N NO N PO AJAJIA IIUJ OO I O Table 9 Tibia Assembly Parts List GTR9 6 06 3 3 1 Tibia Assembly Before assembly check all rubber buffers are bonded to segments If for any reason a buffer should become dislodged lost or damaged it will need
41. 7 If off board cables are not used the clamps should be replaced with washer 133 5105 item 16 in Figure 66 See Figure 18 for left hand side wiring arrangement The connectors at the off board DAS side are specified by the customer and fitted by Humanetics as all users have different systems Figure 17 Clamping Arrangement and Position for Off board Wires GTR9 6 06 Figure 18 Off Board wiring left hand side of impact face Most of the wiring for the off board configuration is in the tibia block Only the femur bone wire passes over the knee joint see Figure 19 for wiring on right hand side All the sensors use miniature round connectors with locking latch either a 7 pin or 16 pin is used The 16 pin connectors are for the 3 femur strain gages and for 3 of the 4 tibia strain gages 16 pin connectors are also used for optional triaxial accelerometers All the sensor wires are identified to ensure correct connection Figure 19 Off Board wiring right hand side of impact face The leg wires must be balanced to ensure good free flight after launch with 6 channels each side On the right side are 2 single channel string pots 1 single channel accelerometer and 1 three channel wire for the three femur bone gages On the left side there are 2 single channel string pots 1 single channel tibia bone gage and 1 three channel wire for the other tibia bone gages It is important to route the off board cables out of the knee to ensure good free
42. GTR9 6 06 Flex PLI GTR User Manual _ ll C L P 133 9900 User Manual FLEX PLI GTR Rev E Page 1 of 99 2013 Humanetics Innovative Solutions GTR9 6 06 AN IN wim For information on Humanetics products please visit our web site at www humaneticsatd com or contact Humanetics Innovative Solutions 47460 Galleon Drive Plymouth MI 48170 USA Telephone 1 734 451 7878 Fax 1 734 451 9549 No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic photocopying recording mechanical or otherwise without the express written consent of Humanetics Innovative Solutions Copyright 2013 Humanetics Innovative Solutions All rights reserved The information in this manual is furnished for informational use only and is subject to change without notice Humanetics Innovative Solutions assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual GTR9 6 06 Table of Contents Section 1 TOM 255545 1 25515428 CHE 10 1 1 OV SRV IG WW desi leger Hed NA 10 1 2 UU UU T 11 Section 2 EE 15 2 1 Standard 12 Channel instrumentation r 15 2 2
43. LEX PLI GTR Rev E Page 89 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 7 5 Running a test The test facility used for the certification must have a stabilized temperature of 20 2 C during the certification and the temperature is to be recorded Step 1 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 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 5 55 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 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 Step 5 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 th
44. Leg Form Launcher PC Figure 31 Wiring diagram for 12 channel SLICE Typical Slice wiring to knee with SLICE units on the right in tibia knee block and super cap on the left in femur knee block Figure 32 Figure 32 Typical 12 channel Slice wiring to knee S __ _ 133 9900 User Manual FLEX PLI GTR Rev E Page 33 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 eer Figure 33 SLICE disconnect connector To assemble the SLICE fit the SLICE unit with the higher stack part closest to the knee joint as shown in Figure 32 using four M3 Pozi type screws two 25mm and two 20mm long Then fit the super capacitor with the disconnect wire pointing downward towards the tibia using four M3 x 16 long screws All the connectors are identified so connect like for like MCL to MCL etc For the two string pot wires that pass across the knee tie wrap mounts are provided both sides to anchor the wires see Figure 35 showing connectors on the right hand side of the knee Route the wires as shown to provide adequate slack in the knee joint to prevent any disconnection or damage to the wires when the knee flexes The disconnect bracket is fixed to the launch guide as shown in Figure 33 using M2 5 screws and the 12 pin connector is mated with the connector coming out of the bottom of the base SLICE Most of the wires and connectors are behind the knee covers but the gage wires coming out of the leg must be properly restrained There should be t
45. User Manual FLEX PLI GTR Rev E Page 40 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 45 Left hand side of impact face covers fitted 133 5710 Flex PLI Leg Assembly 133 5711 MicraHub MicroDa ST KM3861 Battery And MicroHub JabMab Magnetic Connector K3872 8 Stationary nxt Controller K3BBDO08D Bus Extender Figure 46 Schematic layout of 12 channel Micro Dau 133 9900 User Manual FLEX PLI GTR Rev E 02013 Humanetics Innovative Solutions U D g 5 cO cO GTR9 6 06 2 10 Kyowa 6 Das System Four six channel data logger units can be mounted in Flex PLI GTR Each logger has its own re useable battery inside with a run time of three minutes Sensors are connected to the loggers with either 7 pin or 16 pin small circular connectors The Kyowa 6 logger is fixed to the side of Flex PLI GTR knee block with three low head SHCS screws Please refer to the kyowa 6 user s manual regarding detailed use and specifications The standard Kyowa 6 12 channel system is shown in Figure 47 DIC 57A 7 DIP S0A Trigger DIC 56A 33 S KB USB R205 U2C BF10BK 4 3 5 P s 1 00 60 a EI DIC 58A 580 DIC 52A 050 74 IL PDI1C 50A 040 ACL 2 DIC 50A 100 010 50 100 oiei i
46. WG 2 CONDUCTOR NOT SHOWN Table 14 Pendulum Dynamic Rig Part List N N GTR9 6 06 7 3 Leg Preparation for Pendulum Dynamic Calibration Step 1 Check the eight M8 set screws shown in Figure 88 are tightened to 8 Nm Figure 88 Check screws with 8 Nm torque Step 2 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 Step 3 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 L mmm 133 9900 User Manual FLEX PLI GTR Rev E Page 86 of 99 2013 Humanetics Innovative Solutions GTR9 6 06 Figure 89 Stop cable clearance adjustment using setting tool Step 4 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 push 1 1 Figure 90 Recommended method to align knee to remove any twist and shear Step 5 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 Step 6 Remove the aluminum lau
47. d must be recorded The leg assembly is tested with the flesh cover parts fitted and the leg is upside down so that the leg pivots from the bottom of the tibia This is to increase the amount of test energy to a similar loading level of a vehicle impact an additional 5 0kg mass is also added to the femur end GTR9 6 06 7 2 Pendulum Rig Assembly Instruction If the assembly has been stripped down use the following steps to assemble the rig Otherwise skip this and go to the next section Stand the Left and Right support weldments 133 8401 amp 133 8402 opposite each other and about 400mm apart ensure the tapped hole flanges are facing inwards Fit the cross bars 133 8412 and tighten this will bring the side supports together Now loosen the screws on the cross bars and fit Impact Bar 133 8420 and pivot cross bar 133 8415 tighten the screws this will pull the support weldments square with the Impact and pivot cross bars The Cross Bar screws can now be tightened The top A frame assembly can be assembled on the ground and lifted on to the base or assembled directly on to the base Note it will be important to keep all the screws loose while the parts are being fitted Fit the two A Frames 133 8424 then fit two side supports making sure diagonals go in the opposite direction Do up all the bolts so there is no slack but the parts can still move Fit the top cross member 133 8431 and then tighten all the screws ensuring the top cr
48. dard KNEE Elongation standard KNEE Loa Elongation standard KNEE Pu 1 Upper X standard TIBI Tibia Moment Upper X standard TIBI Tibia Moment 1 3 Middle 0 Lower X standard TIBI 4 Lower X standard TIBI Knee Bottom standard KNEE emus Top additional FEMR TIT Top additional FEMR Filter Class N N PUB additional FEMR Segment 1 Acceleration Y additional FEMR Femur Segment 2 Acceleration Y additional FEMR Femur Segment 3 Acceleration Y additional FEMR Femur Segment 4 Acceleration Y additional FEMR 22 Segment 5 Acceleration Y additional FEMR O gt GTR9 6 06 Femur Segment 6 t additional D Knee Upper EE additional Knee Upper additional rr D Q FEMR 06 KNEE UP PF A KNEE UP AC Knee Upper additional KNEE AC rr lt Knee Upper ae Rate additional Knee Upper Angular Rate 26 additional au Rate 27 additional rem Lower 8 additional A Lower S rM 9 additional Knee Lower 0 additional i Rate 31 additional Rate 32 additional Kuss Lower Angular Rate additional Tibia Segment 1 Acceleration Y additional Tibia Segment 2 Acceleration Y additional Tibia Segment 3 Acceleration Y additional tU rr D lt Q rg rr D td 45 td td 45 td 45 JD D D JD JD D JD D JD D D
49. e LED shows the status of the DAS using numerous color signals an overview of the status signals can be found in the recorder manual The quick release is achieved through a modified Lemosa 2F connector Depending on the channel configuration one hub may be removed if not needed Figure 39 DTI DAS left hand side of knee showing Di Mod hubs The hubs contain the DiMods Digitized Modules for each of the sensors each hub is engraved with a letter A B C The DiMods store individual sensor data then it is transferred to the recorder at a slower rate to ensure data quality The DiMods for the attached sensors are located within the hub it is therefore imperative that the correct sensor is connected to the corresponding port To achieve this both the connector sensor side and the port have been labeled uniquely Each hub has 9 ports 7 x 7 pin and 2 x 16 Pin The six 7 pin ports that are positioned away from the centre of the knee are sensor ports as are the two 16 pins ports The 7 pin ports that are closest to the middle of the knee Nr 7 16 25 are for the data recorder bus line 0 e 0gz C tCC P 133 9900 User Manual FLEX PLI GTR Rev E Page 37 of 99 2013 Humanetics Innovative Solutions GTR9 6 06 Figure 40 DTI DAS right hand side of knee showing crash recorder on the left and DiMod hub on the right There is no standard configuration for the DTI leg The configuration of the leg is set by the customer and
50. e 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 WARNING After the impact the leg swings back violently and can seriously injure anyone standing in the rebound area Releasing the leg must be done from the side of the rig under no circumstances should anyone be behind the leg or in its swing plane during testing It is highly recommended that a safety barrier is erected in the swing rebound area ensuring no one is inside the drop zone during release to avoid any injury The release can be switched through a safety system and a control box that can only be operated with the barrier closed ensuring that no one is in close range of the rebounding leg 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 and can be carried
51. e noticed that the four knees cross ligament cables will become kinked due to their fixed position This is normal and as long as the wire filaments are not cut or worn down the end fittings not pulled away from the cable and threads are undamaged they are suitable for reuse This also applies to the other eight ligament cables in the knee and the four bone stopper cables GTR9 6 06 4 8 Sensor and Electrical Maintenance 4 8 1 General Electrical Maintenance Check electrical cables and connectors for damage and wear Particularly pay attention to the routing and fixation of the cables in areas with large motion e g around the knee and the point of exit of the cables Also check that cables have sufficient slack to allow the full range of motion in the knee joint when flexed in testing Repair broken cables or connectors as necessary 4 9 2 Bone Maintenance Warning There may be tiny glass fibers on the outer surface of the bone that could be irritating to the skin It is advised to protect the hands with gloves when handling the bone and not to run your hand along the length of the bone The bone will likely see localized small cracks at the curved interface of the segments after some use This is normal and may not greatly affect the performance of the bone If this cracking is severe the bone should be replaced however if the leg is still passing dynamic certification this would be at the discretion of the user On reassembly dust off the
52. e 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 GTR9 6 06 m J 24 D M K ATTE Figure 72 Assembly of flesh second layer Figure 73 Rubber flesh assembly Velcro positions d og x lt 1 EM s E Figure 74 Rubber flesh tied on with Velcro 133 9900 User Manual FLEX PLI GTR Rev E Page 68 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 V mire 5 uo a Wr Lr rue P TER FIN 2
53. er first disassembly after that new nuts should be fitted Fix the attachment plate with 2x M3x8 countersunk screws and remove the spacer blocks Place eight 218 springs into the femur block counter bores and place washer 133 5310 on top feed through the 8 wires 133 5350 Turn knee over and fit remaining 8 springs into their counter bores fit washers 133 5311 and M5 Nyloc nuts tighten until all washers are flush with Tibia block this can be checked with a flat edge As a double check the spring protrusion on the Femur block should be 3mm In this condition the knee is now ready for certification Keep remaining parts together for final assembly DU 133 9900 User Manual FLEX PLI GTR Rev E Page 58 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 64 Attachment plate crimp wires in tension ready for knee femur block assembly 52 ws rl 27 Zoe 3 Ex i s PE 2362 Er Figure 65 Cross wire feed through on knee 3 2 2 Assembly After Certification The remaining parts are fitted at the final leg assembly stage see 3 3 4 These are the single channel accelerometer to impact side of tibia block the front tape blue impact covers and the side covers 3 2 3 Knee Disassembly Remove aluminum side and front blue plastic covers if these have not already been removed to disassemble leg bones See section 3 3 4 for details Take off the accelerometer if not already removed t
54. er to Figure 21 below this is typical for both sides The disconnect wire is a blue coax cable the brass end fitting can be clamped to one of the off board cable clamps just below the knee see Figure 22 This direct clamping avoids any damage to the connector Be careful not to crush the connector when clamping Only one cable clamp requires fitting for Messring installation A hole also has to be cut in the outer red cover to allow exit of the cable if this exit location is used Users can also route the disconnect out of the top of the leg to avoid cutting the outer red cover a longer disconnect wire would be needed for this After the test the disconnect is reconnected and data can be downloaded to a PC installed with the Messring Crashsoft software Inside the femur block there is a terminator housing to complete the coax wiring see Figure 24 two M3 SHCS retain the part The terminator can only be accessed when the knee is disassembled If the knee is stripped down for access it is recommended the knee is recertified GTR9 6 06 The loggers are programmed to specific sensors for sensitivity range and software recognition Loggers cannot change location and connector labels must match to ensure connection to the sensor Figure 21 M BUS arrangement in knee 12 channels LH side to impact direction Figure 22 M BUS arrangement 12 channels RH side of impact direction Figure 23 Clamping of M BUS Disconnect Connector 133 9900
55. etween segments must be in place central to the axis and bonded to the outer edge of the blue polymer segment If one should become dislodged or damaged the bone must be disassembled and a new rubber buffer added See beginning of femur or tibia assembly section 3 for bonding On reassembly segment shim fit must be as tight as possible 4 6 3 Shoulder Bolt and Segment Screw Tightness Check Shoulder bolts and segment screws should be tightened to 3 Nm This includes the M6 button head segment screws behind the bone front polymer covers as well as the rear M6 screws 4 7 Knee 4 7 1 Knee Meniscus The knee meniscus is the blue polymer plate screwed on top of the knee tibia block This can become worn with use due to contact with the femur knee block If this wear has created a significant groove in the plastic this could affect free shear motion in the knee and should be replaced Also if wear has reached the meniscus attachment screws the meniscus must be replaced The bronze cross cable bushes will also wear this is normal after a large number of tests It will be more likely the meniscus will wear before these bushes become a problem These bushes will be new when the meniscus assembly is replaced All the bronze bushes are pressed in if one should become lose it must be bonded in or the meniscus replaced See section 3 of this manual for disassembly and assembly 4 7 2 Knee spring cables and bone stopper cables On disassembly it will b
56. fit the wire clamps as required 133 5522 amp 133 5523 under the shoulder bolts closest to the knee see Figure 17 The two washers 133 5104 will have to be removed to fit these clamps The wire clamps are generally only used for off board wires or Messring DAS disconnect To fit stopper cables first remove the assembly fixture part number 133 8129 or 133 8114 Place washer 133 5521 over each stainless steel cable 133 5530 and feed through the 4 corner holes in all the leg segments from the knee end Place another 133 5521 washer over threaded fitting end and fit four M5 Nyloc nuts Set the gap between nut and washer to 10 3 mm using 4 and 8mm wrenches Check gap with spacer tool 133 5112 If the Nyloc nuts are removed Humanetics recommends they are only used twice GTR9 6 06 ur Figure 68 Assembly of last two segments on tibia If fitting new double sided tape unpeel cover material from the tape on one side 133 5025 and fit over each segment as shown in exploded view Figure 66 Fit an impact segment 133 5517 locating over two BHCS and press down onto the tape Reusing existing tape on segments is OK as long as the tape is flat and still very sticky Where the bone wire comes out through the link tightly tie on two cable ties as shown in Figure 59 to provide restraint to the wire The assembly is now ready for calibration Note When recalibrating a few of the links washers and shoulder screws will need to be removed and replaced
57. gure 38 Left side wiring example of 24 channel SLICE 2 7 2 Electrical Interference The SLICE system has been designed with protective circuitry for EMI Electro Magnetic Interference Radio Frequency Interference and ESD Electro Static Discharge up to 8000 V Since Flex PLI can generate ESD due to its Nylon covered suit and parts the following best practices should be considered 1 Use of anti static spray inside the red skin covers These sprays work by making it more difficult for static charge to build up on non metallic surfaces 2 Ground all test fixtures test articles and even Flex PLI A ground wire could be a small expendable wire off board Although an inconvenience on a wireless device this would be a simple way to prevent ESD and maintain data quality GTR9 6 06 3 Any metal parts with mounted sensors should have good continuity back to the knee blocks where the DAS is mounted An earthing kit for 12 or additional channels can be provided 4 If possible keep laboratory humidity at a level sufficient to prevent dry conditions as dry conditions promote static build up 2 8 DTI Hentschel Onboard DAS 2 8 1 DTI Description The DTI Digitized Transducer Interface DAS consists of three hubs Figure 39 amp 40 a 48 channel Hentschel data recorder X3 from type 327 04 and an LED quick release unit Figure 40 Th
58. head screws attaching the legs are tightened to 8 Nm Step 3 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 Step 4 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 Step 5 Check all segment screws and side aluminum shoulder screws are tightened to 3 Nm Step 6 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 Step 7 Fit the 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 The leg is now ready for suspension on the test rig GTR9 6 06 8 6 Running a Dynamic Inverse Test The test facility used for the certification must have a stabilized temperature of 20 2 C during the certification and the temperature is to be recorded The pitch angle of the impactor rotation around y axis at the time of first contact shall be within a tolerance of 0 2 relation to the lateral vertical plane The roll angle of the impactor rotation around x
59. hen remove the 8 large springs from each end by unscrewing the eight M5 Nyloc nuts on one end of the wires Hold the wire on its end with a 1 8 open ended wrench to allow this Before removing the small cross ligament springs the attachment plate holding the string pot wires must be unscrewed otherwise string pots could be damaged when the two knee blocks are pulled apart Remove the two M3 flat head screws fixing the attachment plate to the femur block Now unscrew the four M5 Nyloc nuts holding the central cross wires and remove the four smaller springs from the tibia block Lift the femur block away from the tibia block The fitting on the end of the cross wire can catch on the hole in the counter bore so the cables may require some realignment to free them Remove the wires and 133 9900 User Manual FLEX PLI GTR Rev E Page 59 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 smaller springs from the femur block On the tibia block disconnect the crimped ends of the spring pots from the attachment plate and remove attachment plate To remove the meniscus for access to spring pots remove the four M5 low head cap screws and pull it away from the tibia block These should have been loctited in so may be stiff If the string pots need servicing remove wire retaining clamps and unscrew the 42 56 cap screws fixing the pots Check all parts for damage and replace if necessary Take note to check there has been no slippage on the crimps on
60. imum before repeating If another flesh set is used the test does not need to wait 45 minutes GTR9 6 06 8 7 Data Processing All data shall be filtered CFC180 The Inverse Certification corridors of all the GTR9 injury channels given in Table 16 Peak values shall be within 50 ms after impact Peak Moment Tibia Peak Moment Tibia Peak Moment Tibia Peak Moment Tibia Peak MCL Elongation gt e 2 gt Cc Calibration Results Peak ACL Elongation Peak PCL Elongation Units mm Table 16 Inverse test corridors peak values within 50 ms after impact For further details of the test requirements refer to document ECE TRANS WP 2 9 GSRP 2009 21 GTR9 6 06 Section 9 Vehicle Test 9 1 Introduction For the vehicle test a special launch plate or pusher is required which is attached to a firing ram or launch system for an example see Figure 101 The design of the pusher and stroke length is important to maintain stable release conditions when the leg leaves the launcher The leg is fired at the vehicle at 40 kph or 11 1 m s 0 2 For the specifications and requirements of the test refer to ECE TRANS WP 2 9 GSRP 2009 21 9 2 Leg Loading limits in free flight The loading level of the impactor during free flight for tibia bending moments are recommended to be less than 10 Nm and for knee ligaments MCL ACL PCL elongations are recommended to be less than 1mm If there are
61. ing pot check Referring to Meniscus assembly 133 5313 feed the connector of one of the right hand RH pull string pots through the inner side of one of the central holes see Figure 61 The RH and the LH string pots can be identified from the serial number the RH has an R at the end of the number and the LH an L The two RH pull string pots are positioned closest to the main flange of the meniscus one is shown fitted in Figure 61 Attach the string pot with the 42 56 1 4 long cap head screws making sure the pull wire is directed towards the furthest away outer bronze bush Fit the other RH pull string pot in the same way on the opposite side Pass the pull wires through their designated bushes Carry out the same procedure with the Left hand pull string pots the pull wires are directly in line with the two inner bushes Feed the pull wires through the bushes Make sure electrical wires are inside the cavity as much as possible then run cables through channels both sides and clamp with retaining plate see Figure 63 Fit assembly to knee block bottom ensuring pot wires are in their grooves The threads of the four M5x10 low head cap screws used to retain the meniscus will need to have low strength thread lock applied e g loctite 222 This will prevent the screws coming lose when in service If the Messring on board DAS system is to be installed a terminator has to be fitted at this stage For details of onboard DAS installation see Section 2
62. it either side See Figure 12 A special impact cover is required to accommodate the Sensor Figure 12 Sensor IES 3103 ARS example locations knee lower Figure 13 Kyowa accel 3 axis option for leg top and bottom locations mount 133 7530 133 9900 User Manual FLEX PLI GTR Rev E Page 19 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 14 Optional Instrumentation for Tibia DESCRIPTION ACCEL INSTRUMENTED OPTION LEG TOP amp BOTTOM 133 7514 IMPACT SEGMENT INSTRUMENTED ASSEMBLY FEMUR 133 7514 IMPACT SEGMENT INSTRUMENTED ASSEMBLY TIBIA 3 133 7507 ACCEL amp ARS INSTRUMENTED OPTION FOR KNEE 5 3 6 2003103 SCREW SHCS 0 80X 5 16 j ACCELEROMETER LINEAR TRIAXIAL MEASUREMENT SPECIALTIES MS 68 133 7506 SPECIAL M2 ACCEL FIXING Table 3 Example of Optional Instrumentation Parts List 6 o 3f 1 KNEE END ACCEL MOUNT s E GTR9 6 06 2 3 Codes For the identification of sensor channels and for computer processing of signals the following codes have been established for ISO MME Transd Fine Fine Fine Location Physical Femur Moment 3 Upper X standard FEMR Femur Moment 2 Middle X standard FEMR Femur Moment 1 Lower X standard FEMR Le Elongation standard KNEE a o Elongation stan
63. its life It the tape loses its stickiness or gets folded over replace with new Fit the 4x M3 x 8 SHCS if not already fitted to the front of the two end aluminium end segments Degrease the front of the segments and fit the small double sided tape parts if not already fitted as shown in exploded view Figure 54 Fit the two end impact covers 133 5518 and 133 5519 Where the bone wire comes out through the link tie on two cable ties one on the link and one on wire attached to each other as shown in Figure 59 to provide restraint to the wire The femur must be certified before full leg assembly Remove the base 133 8129 if not being directly calibrated after build Note a few of the links washers and shoulder screws will need to be removed and replaced to fit onto the static certification fixture 133 8120 Keep parts together ready for final assembly GTR9 6 06 Figure 59 Bone exit cable restraint use cable ties ties not shown trimmed or tightened 3 1 2 Femur assembly after static certification Fit removed links and shoulder bolts After pendulum test fit launch guide and roller as shown in exploded view Fit end cover 133 5516 with 4x M5 x 8 screws Also fit any optional sensors and mounts if not already fitted 3 1 3 Femur Disassembly Disassembly is the reverse of the assembly starting from the top of the femur Care must be observed when removing bone spaces and shims not to damage bone wires and gages The double sided tape can
64. k A schematic of the test set up is given in Figure 95 Hanging System Z axis release the FlexPLI within 10 ms after the moving ram impact Y axis X axis Hanging Bracket tilted 15 towards FlexPLI with Flesh cross sectional image Moving ram Total mass 8 15 40 1 Kg incl honeycomb Impact speed 11 1 0 2 m s Impact face Moving ram guide Honeycomb Width 200 5mm Depth 160 5 mm Crash strength 75 10 psi Figure 95 Diagram of Dynamic Inverse Certification Test set up GTR9 6 06 8 3 Preparation of the Inverse Test set up The linear guide impactor face is covered with 5052 Aluminum honeycomb with a crush strength of 75 PSI 10 The size of the honeycomb is width 200 5mm length 160 5mm and depth 60 2mm To ensure a consistent and good level of repeatability the honeycomb should either have a 3 16 inch cell size or a 1 4 inch cell size The honeycomb should have a density of 2 0 pcf in combination with a 3 16 inch cell size or a density of 2 3 pcf in combination with a 1 4 inch cell size The honeycomb block is covered with paper cloth of less than 1mm thick See Figure 96 The paper cloth is wrapped around the honeycomb and taped at the back to hold in position The paper helps to prevent damage to the leg covers It is recommended to fix the Honeycomb to the impactor using strong double sided tape to help maintain position on impact The top of the impactor plate must be in line
65. le tests The internal inspections should be carried out during every disassembly e g when a part has been replaced during bone re shimming during recalibration of sensors or when investigating an internal problem If the femur knee or tibia has been reassembled static certification should be carried out along with as a minimum a pendulum certification to ensure the leg is functioning correctly 4 2 General External Damage inspection If any parts should become cracked or worn they should be replaced Examples would be front impact segments or worn side link holes or shoulder screws where the links become very lose Double sided tape is used in a number of areas This can be reused if still sticky and not folded over otherwise it should always be replaced All rubber bumpers and rubber flesh sheets should be free of damage 4 3 Support Roller Check the blue polymer roller in the top support U bracket at the top of the femur that it is not damaged or worn 4 4 Red Neoprene Suit Covers The suit covers particularly the outer cover is prone to damage as it is the soft contact surface to the vehicle bumper Small cuts and tears are not a problem but large tears or zipper damage will require replacement The zipper maintains the tight fit of the covers and this fit should be maintained If the leg is not in use or being transported the covers must always be removed as they will become stretched and indented internally by the legs parts 4 5 Pr
66. length does not exceed the regulatory requirement Each individual femur and tibia segment can be instrumented with a uniax accelerometer in impact direction Tri axial accelerometers and or angular rate sensors are also available at various locations It is recommended that damped accelerometers are used on FLEX PLI GTR9 6 06 See Detail A Figure 7 Optional Instrumentation for Femur 133 9900 User Manual FLEX PLI GTR Rev E Page 16 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 8 Detail A Exploded View upper and lower knee SN W 1 1 1 3 w a x 9 Wire routing for Detail A optional sensors 133 9900 User Manual FLEX PLI GTR Rev E Page 17 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 5 T A uL ws Figure 10 Wire routing out of segment for optional sensors Detail A in upper knee Figure 11 Similar arrangement to Detail A but with 2 uniax Kyowa accels Assembly 133 7600 There is also an alternate mirror image of 133 7600 available 133 7540 to route wires to the opposite side for DAS connection to prevent wires going around the knee thus avoiding wire damage GTR9 6 06 Sensor IES 3103 ARS triax can be installed in the first segment from knee in the femur and tibia The sensor bolts directly to the aluminium segment in each case The sensor can also be mounted so that the cable can ex
67. ment and to 133 5108 Segment top femur using 2x M6 x 18 BHCS for the blue segment and 2x M6 x 16 for the top aluminium segment Replace the previous large shim shim bone clamp that went over the clamp 133 5503 Bone clamp thin and fix into the aluminium segment 133 5108 using 2x M6 x 16 BHCS Also fit the 2x M6 x 18 BHCS through the back of the blue segment and tighten Slide or push these two segments over the top of the bone If the fit is loose over either of the segments add more 0 05 shims until the fit is tight A higher push force will probably be needed for this fit as the inner dimension of the two segments may not be perfectly identical placing the leg on the ground with assembly base part 133 8114 and pushing with two hands down on the two segments Once the fit is tight tighten all the screws to 3 Nm Check the distance between the top of the bone and the top of the aluminium segment This should be between 1 5 and 2 mm and should match the small rubber buffer glued to the underside of the stainless steel top plate This buffer removes any end play on the bone On initial assembly this buffer may have been padded out to prevent bone end play It is important no end play is present Fit the top plate with 4x M6 x 18 BHCS Figure 55 133 8129 base with 133 5514 segment and bone clamps inside Page 51 of 99 133 9900 User Manual FLEX PLI GTR Rev E 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 56 133 8129 base wi
68. mmer shims into place You should feel high resistance when pushing this assembly in You can check the fit by rotating the segment on the bone Z axis If there is any play remove and add a 0 05 mm 133 5012 0 1 mm 133 5029 or 0 2 mm 133 5030 flat shim inside the captive shim or any combination of these to get a tight fit When the spacer assembly does not fit usually you only need to remove a 0 05 shim and that will be as tight as you can achieve When fit is as tight as possible with thumb pressure ensure screw holes are aligned then fix the shim assembly with 2x M6 x 18 BHCS fitted diagonally and tighten front and rear screws to 3 Nm Use the set screw key if needed to align the holes if not aligned by inserting into the hole and levering the inner assembly into position For the next segment assembly attach a spacer bone contact thick to the blue segment part 133 5534 using 2x M6 x 18 zinc plated BHCS fitted diagonally as per the previous segment Slide over the bone with rubber buffers on top side and spacer to the front impact side Try fitting the same rear shim arrangement as the previous shim assembly Adjust shims if still loose remove a 0 05 shim if the GTR9 6 06 assembly cannot be pushed into the segment Align holes to the segment and fit the two rear M6 x 18 BHCS diagonally and torque all 4x M6 screws front and rear to 3 Nm Repeat for the next 3 segments For the last 2 segments fit 133 5502 Bone clamp thick to the last blue seg
69. munication through the standard Kistler Crash Designer software For detailed operation of the MicroDAU system and Crash Designer software please refer to Kistler documentation The MicroDAU system consists of 4 modules The battery module 133 5713 contains the battery charger USB hub the leg power comm exit cable and communication to the rest of the modules The battery is lithium manganese chemistry and provides power for 30 minutes of operation Three additional sensor modules 133 5710 133 5711 and 133 5712 contain 3 or 6 data acquisition channels Each module provides connectors for single channels such as potentiometers or three channels such as femur or tibia moments Modules 133 5711 and 133 5712 also provide power comm inputs and outputs while module 133 5710 contains only power comm inputs Modules are designed to be daisy chained as shown in Figure 43 The battery module begins the chain with each module connected to next module Module 133 5710 is the last module in the chain Clearance is provided under each module for power comm and sensor cables The clearance is tight due to space restraints so care must be take to assure cables are not overlapping or pinched during assembly GTR9 6 06 EEVISPON FISTURT MODULE CONTAINS ITEM 11 rna PE SEE 115 5710 FOR DETAILS mas A TO PRODUCTION anon 8 CHANGED POTENTIOMETER PARTS 977082 1 CONTAINS MEMS 10 AND 11
70. nch 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 Step 7 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 GTR9 6 06 Figure 91 Attaching Pendulum Ballast Weight 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 Figure 92 Attaching Pendulum Rig Pivot hinge Step 9 See next step in section 7 4 for rig preparation The checking and adjustment of the pendulum Impact Block Part 133 8423 must be done with 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 7 4 Pendulum Rig Preparation Suspend the bare leg without suit on the fixture with the Pivot Hinge in the Pivot Clearance Block and the Shoulder Bolt Figure 86 item 17 and 20 Check that the distance from the bottom of the Impact Block is 30 1mm above the top of the plastic blue Meniscus Figure 60 item 2 Part Nr 133 5313 of the knee and 13 2 mm from the front of the impact face
71. oment Knee bending moment Nm 50 0 5 10 15 20 25 30 MCL Elogation mm Figure 84 Figure MCL sensor elongation Upper and lower corridor ACL and PCL elongation mm Force mm Figure 85 Figure ACL and PCL upper and lower corridors 133 9900 User Manual FLEX PLI GTR Rev E Page 81 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Section 7 Pendulum Dynamic Certification 7 1 Introduction The dynamic pendulum certification test is carried out on the Dynamic Certification Test Rig Part Nr 133 8400 as diagrammatically shown in Figure 86 Only 7 channels are required and must meet the proposed GTRO9 requirement see Table 15 For assembly instructions of the test rig refer to 7 2 Additional Mass Tibia Dynamic Certification Test Rig gw Pin joint Pendulum type Suspension angle 15 1 deg FlexPLI with Flesh cross sectional image Released Free fall around the pin joint Knee u joint Additional Mass center Mass 5 0 kg 0 05 with screws line Inertia 0 0061 0 0006 kgm Impactor side 4 0120 1 CD Center of gravity of additional mass Dimension units mm Figure 86 Diagram of Dynamic Pendulum Fixture This test is carried out at build and mandatory after every 10 vehicle tests This test can be carried out at any time if required to check the leg before testing The test must be carried out at a stabilized temperature of 20 C 2 an
72. oscillations in the leg when fired adjusting the height of the bone pushing pads on the launcher plate should prevent this The thicker covers of the femur and tibia are softer than the knee which can generate more pushing load at the knee than over the bones creating an oscillation in flight The aim would be to get an even push along the whole length of the leg Depending on the acceleration and stiffness of the pusher different users will need different pusher pad heights to avoid oscillation The side link shoulder screws on the aluminium segments can become loose in testing It is an option to use a weak thread lock on these to prevent them coming loose 9 3 WARNING VIOLENT REBOUND After impact with the vehicle the leg can be thrown high into the air or can be deflected some distance in any direction depending on the geometry of the bumper Therefore it will be important to protect anyone exposed in the test lab Laboratory staff must be clear of the test site and they must be behind suitable barriers during the launch 9 4 Catch Rope A catch rope attachment bracket is available to attach at each end of the leg allowing a 4 point rope attachment The protective covers are removed and replaced with high strength aluminum Catch Rope Bracket see Figure 98 This allows the leg to be tied into a frame preventing any damage or injury from rebound The ropes are quickly retracted after impact to keep the leg inside the frame GTR9 6 06 Fig
73. oss member is in line with the impact face Fit the pivot clearance block Fit the control release box this can be fitted either side depending on user requirement Fit the release latch and connect up to the control box tape or loop the wire to the frame The control box comes with a gate switch If a safety barrier is required around the fixture during testing this gate switch can be used in the barrier to ensure the barrier gate is closed during the testing GTR9 6 06 amp 8 GJ el e Figure 87 Exploded view Dynamic Rig part nr 133 8400 133 9900 User Manual FLEX PLI GTR Rev E 02013 Humanetics Innovative Solutions Page 84 of 99 GTR9 6 06 am 6 8 18844 AFRAMESUPPORT 8 1 i84 TOPCHOSSMEMBER 9 1 WASHER FLAT M12 13 0 ID X 24 0 OD X 2 5 15 8 500052 WASHER FLAT 8 4 ID X 16 0 OD X 1 6 THK 6 924 WASHERRIATW 0000 RELEASE SYSTEM TENNEN BV 099 005 A WASHER FLAT M10 10 85 ID X 20 OD X 2 5 EYEBOLT M6 X 1 X 12 ZINC PLATED MCM 3107T41 RELEASE SYSTEM CONTROL BOX TENNEN BV TE RSCB 100 s 6 SCREWSHOSMBXIX20 000002 83 1 6001588 CONNECTOR SOCKET NOT SHOWN 34 2 6001588 SOCKET TERMINAL NOT SHOWN PIN TERMINAL 60618 1 NEWARK 36 1 6001738 CONNECTOR MATE N LOCK NOT SHOWN SERVICE CORD 16A
74. otective Plastic End Covers Part 133 5516 These are to protect the ends of the leg when it makes contact with the ground on rebound These should be durable now metal inserts have been molded into the part It is advised to take precautions against severe continuous ground impact for instance by the use of catch ropes or cushioning of the test surroundings If the leg is likely to be rebounding on the ground after impact the end covers should be fitted otherwise damage will occur to the end aluminum segments of the leg The end covers should be replaced if they can no longer be fitted due to damage For details on catch rope bracket refer to section 9 vehicle test GTR9 6 06 4 6 Tibia and Femur 4 6 1 Assembly Segment Play With use the bone segments will become lose due to small indentations to the bone and light wear to the curved magnesium interfaces with the bone If there is concern with the amount of play the tibia or femur assembly should be re shimmed and statically recertified See section 6 2 The tibia and femur segments should always be reassembled as tight as possible on any rebuild There is no specific play limit to when the bone requires re shimming If the bone is passing dynamic tests it is OK to use Should there be significant wear to the curved magnesium interfaces i e a prominent flat these should be replaced but this has not be yet been seen in these parts 4 6 2 Buffers between segments The two rubber buffers b
75. out after fitting GTR9 6 06 7 6 Data Processing All data shall be filtered CFC180 The certification corridors of all the GTR9 injury channels are given Table 15 These peak values are to be within 250 ms after impact Dynamic Calibration Peak Moment Tibia Peak Moment Tibia Peak Moment 9 Tibia Peak Moment Tibia Peak ACL Elongation Peak PCL Elongation Peak MCL Elongation E 3 2 ws Table 15 Pendulum test corridors peak values within 250 ms after impact GTR9 6 06 Section 8 Dynamic Inverse Certification Test 8 1 Introduction After the initial manufacturers inverse test the leg is recommended to be inverse tested before each vehicle test series and mandatory after every 30 car tests The preparation for the leg and execution of the test is described in this section The 7 injury channels must meet the test corridors as per the proposed GTH 9 specification 8 2 Inverse Test Description The inverse test is a dynamic calibration test where the fully assembled leg is suspended stationary vertically 2 from a sprung hook which releases within 10 ms after impact The leg is struck with a linear guided impactor of 8 15 0 1 kg mass including the honeycomb face with an impact velocity of 11 1 0 2 m s 40 kph the same speed as the 9 vehicle test The linear guided impactor face must contact the knee within 2 mm vertically from the top of the blue Meniscus top of tibia knee bloc
76. provided with the leg on delivery Note A strong double sided tape is used extensively on the Flex leg Humanetics recommends the use of this tape or a tape with the same strength to maintain performance GTR9 6 06 Section 2 Instrumentation 2 1 Standard 12 Channel instrumentation FLEX PLI GTR is offered with 12 channel standard instrumentation measuring tibia and femur bending moments and knee ligament elongations as well as tibia acceleration in impact direction The standard instrumentation channels are listed in Table 2 The channels intended for injury assessment are the 4 tibia bending moments knee medial collateral ligament MCL elongation and ACL and PCL elongations are being monitored These channels are controlled by the certification procedures given in Sections 8 and 9 Ku Channels p Semet DAS Femurmoment1 2and3 moment 1 2 and 3 Tibia moment 1 2 3 and 4 w Tibia Tibia Top Acceleration AX Acceleration AX Standard Injury Option xD iDummy ACL elongation PCL elongation LCL elongation p Table 2 12 Channel Instrumentation 2 2 Optional instrumentation The FLEX PLI offers a range of optional instrumentation for research purpose Examples are using ARS for in flight stability and accelerometers for local force measurement When running regulatory tests with optional instrumentation it is recommended to check that the total mass of the tool including a certain amount of cable
77. replacing or re bonding When bonding the buffer ensure surfaces of both parts are prepared before bonding prepare plastic with 240 grit paper and rubber with 80 grit degrease then bond with Loctite 401 or similar When handling the bone core it is recommended that gloves are worn to prevent getting splinters in the hand Do not run your hand along the bone without protection Start the assembly from the knee end of the bone The tibia femur base tool will be required for assembly as this will allow the bone to be assembled flush with the end clamps make assembly stable when building and simplify segment assembly The part 133 8129 from the bone static fixture can also be used and is shown in Figure 55 Fit bone clamp thick 133 5506 inside the tool base with curved end upwards and groove side inwards Fix finger tight with 2x M8 x 20 screws Fit the inner segment knee 133 5514 over the clamp and attach finger tight with 2x M6 x 16 BHCS Place bone clamp thin 133 5508 over the bone PCB and insert bone and clamp together into the base see Figure 56 The PCB is on the rear of the leg non impact side Fit 2x M8 x 12 SSFP Socket Set Flat Point screws into the tool base then the 2x M8 x 16 SSFP into 133 5514 segment Tighten all the screws to 3 Nm Lay the PCB exit wire to the side required for the specific DAS wiring requirement If the knee assembly is to hand you will be able to check the DAS as to which side this needs to go Fit 133 5505 spacer
78. ridge SLICE can be stacked onto a base SLICE in this case one base SLICE handles 12 channels of data As the FLEX PLI has limited space to package the SLICE stack a mounting board has been designed by DTS to link four bridges together allowing one base SLICE to be used The unit 15 fixed using four M3 pozi head screws Sensor connection to the DAS is via either 7 or 16 pin round miniature connectors see Figure 31 amp 32 for 12 channel wiring arrangement After disconnect the SLICE is powered by a Super capacitor mounted on the same side of the knee as the standard 12 channel DAS See Figure 32 The super capacitor is quickly charged when reconnected The wire disconnect is a round 12 pin connector hard mounted to the launch guide bracket at the top of the femur see Figure 33 This disconnect position allows disconnect in the push phase from the launcher to avoid the connector affecting free flight stability On reconnect the test data can be downloaded to a PC _____ _ 133 9900 User Manual FLEX PLI GTR Rev E Page 32 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 If required there is provision to wire in a tape switch for 0 a wire is provided for this option out of the super cap housing Pendulum SLICE Quick Disconnect Connector T Distributer interface at top of leg SLICE li 2 ch unit Power Supply Tape switch Test m c option option Sensors 6 ch Sensors 6 ch
79. t deflection corridor Tibia Assembly Bending Test Knee Assembly Dynamic Pendulum Impact Dynamic Linear Guided Impact 2 3 Bending Test 1096 recommended 3 After maintenance and or component exchange recommended 1 Annually recommended 2 After exceeding injury thresholds 11096 recommended 3 After maintenance and or component exchange recommended 1 Annually 2 After 10 vehicle tests max 3 After exceeding injury thresholds 10 4 After maintenance and or component exchange 1 Annually 2 After 30 vehicle tests 3 After exceeding injury thresholds 10 4 After maintenance and or component exchange 2 Tibia centre bending moment deflection corridor 1 MCL moment elongation corridor 2 ACL and PCL moment elongation corridors 1 Peak bending moment tibia 1 tibia 2 tibia 3 and tibia 4 2 peak elongation MCL PCL and ACL 1 Peak bending moment tibia 1 tibia 2 tibia 3 and tibia 4 2 Peak elongation MCL PCL and ACL http www veci vrci com VRCI P 100A pdf Industry standard wire wound and non wire wound precision potentiometers GTR9 6 06 6 2 Femur and Tibia Bone Assembly Certification 6 2 1 Introduction Prior to the femur and tibia assembly certification the bone cores are tested to established corridors Each pair of gages on impact side and none impact side compression and tension are tested individually to check correct function and establish gage sensi
80. ter bored holes and tighten see Figure 53 Fit two M8x30 set screws to the rear of the leg and screw in to their stops Carry out the same fitting for the tibia GTR9 6 06 All these 8x M8 screws must be tightened to 8 Nm as do the 4x non impact side 8 set screws in the aluminum leg segments see Figure 69 Note when tightening the segment screws start with the screw nearest to the knee to avoid the inner spacer levering over inside the segments Remove the four side knee covers if fitted and make wire connections For off board or on board configurations wires will require careful routing and securing see section 2 Fit the accelerometer to the front of the knee tibia block and connect wire to DAS and route the cable safely Refit all front and side covers The disconnect wire will either exit at the top of the leg or just below the knee depending on DAS used If exiting at the top make sure wire is tied to links and has sufficient play between to allow for the femur to bend and not pull on the wire Figure 69 Screws to be tightened to 8 Nm non impact side 3 3 5 Fitting flesh 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 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 1
81. th 133 5514 segment bone clamps and bone assembly Figure 57 Fitting and tightening first blue segment Pass the connector through a side link 133 5515 and fit all the links starting from the knee end and 4x end washers using the aluminium shoulder bolts as shown on assembly Figure 54 both sides The segments may need adjusting slightly to fit the shoulder bolts Torque all shoulder bolts to 3 Nm Note some links will need to be removed later for static certification Starting from the knee end with the links should pull segments to correct leg length and avoid further adjustment GTR9 6 06 Figure 58 Fitting thin bone spacer with captive shim To fit stopper cables first remove the assembly tool part 133 8129 or 133 8114 Place washer 133 5521 over each of the four stainless steel cables 133 5110 and from the knee end feed through the corner holes in the leg segments Place washer 133 5521 over threaded fitting and fit four M5 Nyloc nuts Set the gap between nut and washer to 9 1mm Check with spacer tool 133 5112 Humanetics recommends the Nyloc nuts should only be used twice after first removal If the double sided tape is not already fitted degrease all the front segments and fit the 6x double sided tape profiles 133 5025 to the plastic segments then fit all the impact segments 133 5517 locating over two BHCS When handling the bone assembly try to avoid touching the tape when it is exposed this will help extend
82. the sensors and hubs are configured according to these wishes The maximum number of channels this system can theoretically supply is 36 this system is therefore capable of keeping pace with possible future developments of the FlexPLI Figure 41 shows a schematic overview of the system set Sensor Hub A Hub B Data Recorder LED Quick Release Figure 41 DTI DAS General Overview The sensors including the leg bones require calibration with the DTI DAS as a complete unit If a sensor is changed the dimod has to be physically reconfigured and calibrated to allow for changes in the sensitivity 133 9900 User Manual FLEX PLI GTR Rev E Page 38 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 2 9 MicroDAU Onboard DAS 2 9 1 MicroDAU Description The Flex PLI leg can be configured to use a KT MicroDau onboard data acquisition system This configuration is a 12 channel system with battery backup and USB communication The design allows any existing leg to have a MicroDAU iDummy configuration with minimal additional parts MicroDAU modules are designed to replace the knee covers over each of the four knee cavities with three to six channels in each cavity A lithium battery is provided for approximately 30 minutes of standalone operation Figure 42 Exploded view of knee showing Micro Dau integration The MicroDAU configured leg requires 5 0v input at 600mA during operation using USB com
83. the side required for the specific DAS wiring requirement If the knee assembly is to hand you will be able to check the DAS as to which side this needs to go Fit 133 5505 spacer bone contact thick to segment 133 5535 blue segment with rubber buffers both sides using 2x M6 x 18 zinc plated BHCS Button head cap screw Fit screws diagonally then slide over the bone with the thick spacer on the impact side Take care not to damage the black strain gage cover running down the centre of the bone The difference in thickness between the rear thin curved spacers and the front impact thick curved spacers is 0 5mm 12 25 thin and 12 75mm thick The thinner spacer allows for the shim thickness The bone segments should have been laid out in the order they were disassembled this should help reassembly if not the process will still be the same If the leg has seen a number of tests some wear may have taken place and a different shim configuration would be required to ensure the bone is rebuilt with as tight a segment fit as possible This tight fit allows for wear in future testing and should help keep the leg certified Using the previous shim arrangement with its internal flat shims inside the captive shim see Figure 67 locate against the spacer bone contact thin 133 5507 see Figure 58 and push this assembly centrally into the gap against the bone Note When fitting the shim assembly use thumb force only pushing down on the top of the spacer Do not ha
84. the string pot mechanical wires The left hand and right hand pull wires should both be 61 5 mm from the stop at the potentiometer to the start of the ball fitting see Figure 76 It is recommended that the Knee assembly is re certified after reassembly GTR9 6 06 3 3 Tibia Exploded View Figure 66 Tibia Assembly Exploded View 133 9900 User Manual FLEX PLI GTR Rev E Page 61 of 99 2013 Humanetics Innovative Solutions GTR9 6 06 ITEM PART NO DESCRIPTION 1 1 183 5565 BONE ASSEMBLY TESTED amp CERTIFIED 1 133 5502 BONE CLAMP THICK FEMUR TIBIA 002 1 133 5508 BONE CLAMP THIN FEMUR TIBIA o Z o 1 133 5504 SHIM BONE CLAMP 4 THICK 7 188 5505 SPACER BONE CONTACT THICK 1 133 5506 BONE CLAMP THICK KNEE gt 7 133 5507 SPACER BONE CONTACT THIN 00 1 133 5508 BONE CLAMP THIN KNEE 7 133 5509 SHIM 0 4 THICK 10 1 133 5510 RUBBER BUFFER FEMUR TIBIAEND 11 1 133 5511 SEGMENT BOTTOM 12 7 133 5534 INNER SEGMENT ASSEMBLY 14 1 133 5514 INNERSEGMENT KNEE gt S o 15 18 133 5515 16 4 133 5104 WASHER i2IDX260DX3 0 18 8 133 5521 WASHER CABLE 0 0 O 19 4 133 5530 CABLE ASSEMBLY TIBIA gt 0 0 32 5000465 SCREW BHCSM6X1X18 4 5000522 HEXNUT MSXO 8NYLOK 1 183 5516 ENDCOVER 00
85. tivity at 380 Nm in the loaded direction It is highly recommended that this operation is carried out by Humanetics Bone gage sensitivities must be taken from the bone gage calibration sheet provided in the calibration report The assembly components are certified to ensure a certified response at component level and to assure passing dynamic certification 6 2 2 Femur and Tibia assembly Certification This operation requires the use of a materials testing load frame machine with high definition load cell and calibration fixture 133 8120 Before testing a 3 2 mm thick Teflon sheet is fixed to a base plate at each end using double sided tape to prevent the sheet sliding on the plate See pictures below Figure 77 Figure 77 Example of fixing Teflon sheet to base plate Assemble the bone to the 133 8120 fixture see drawing Figure 78 for details Place the assembled fixture over the Teflon sheets see Figure 80 Do not tighten the two cap head screws item 7 in Figure 78 at the end segments of the assembly to allow free rotation Page 75 of 99 133 9900 User Manual FLEX PLI GTR Rev E 02013 Humanetics Innovative Solutions GTR9 6 06 THIS Mec Toe s woewr iEC NT Bone and knee fixture 133 8120 for static assembly bending test femur shown Figure 78 GTR9 6 06 133 53001 KNEE ASSEMBLY FLEX PLI SHOWN WITHOUT COVERS 33 5304 33 5305 Figure 79 otatic certification fixture
86. ttery in the leg form is simultaneously charged when reconnected Front side and rear side of the 24ch standard system with four units is shown in Figure 51 and 52 F rx M c HE I sui W xr a KYOWA DATA LOGGER DIS 506A Figure 51 Kyowa Front side in 24ch _ I mmm 133 9900 User Manual FLEX PLI GTR Rev E Page 44 of 99 2013 Humanetics Innovative Solutions GTR9 6 06 i v90S SIQ E aL 24 2 Figure 52 Kyowa Rear side in 24ch Please refer to the Kyowa 6 user s manual regarding its use I 133 9900 User Manual FLEX PLI GTR Rev E Page 45 of 99 2013 Humanetics Innovative Solutions GTR9 6 06 Section 3 Assembly and Disassembly 4x 5000770 4x 5000584 ou Figure 53 Leg assembly Exploded View 133 9900 User Manual FLEX PLI GTR Rev E Page 46 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 133 5300 KNEE ASSEMBLY FLEX PLI 1 133 5500 TIBIA ASSEMBLY FLEX PLI 1 o0 89 1 1835100 FEMURASSEMBLY FLEXPLI 00000000 1 1335020 BUFFER SHEET ASSEMBLY LEG NOT SHOWN 1 1335013 COVER INNER FEMUR NOT SHOWN 1 133504 COVER OUTER FEMUR NOT SHOWN 7 1 133515 INNER SHOWN 1 133 5016 COVER OUTER TIBIA SHOWN 1 1835017 COVER FLEX PLI GTR SHOWN
87. u ea tee 67 Zipper locations alternating on the sides schematic cross section 67 Assembly of flesh second layer wc eati Dp enema 68 Figure 73 Figure 74 Figure 75 Figure 76 Figure 77 Figure 78 Figure 79 Figure 80 Figure 81 Figure 82 Figure 83 Figure 84 Figure 85 Figure 86 Figure 87 Figure 88 Figure 89 Figure 90 Figure 91 Figure 92 Figure 93 Figure 94 Figure 95 Figure 96 Figure 97 Figure 98 Figure 99 Figure 100 GTR9 6 06 Rubber flesh assembly Velcro 68 RUDDEr VelGEO uci enata 68 LOG Wilh OULEL COVEN NMC RP 69 String potentiometer pull wire length 1 72 Example of fixing Teflon sheet to 75 Bone and knee fixture 133 8120 for static assembly bending test femur shown 76 Static certification fixture 133 8120 showing 77 Bone Assembly Fixture femur shown under 78 Femur assembly certification corridor moment vs deflection showing typical results 79 Tibia assembly certification corridor moment vs deflection showing a typical results 79 Knee Gerllicadoh FIUT u uuu uyu uuu uuu na usu assia asia 80 Figure MCL sensor elongation Upper and lower corridor
88. ure 98 Optional catch rope bracket 133 5034 9 5 Pusher Plate To obtain a stable release the pusher system must be very stiff and to help with acceleration away from the ram the pusher assembly should have low mass The impactor pusher guides must be set to 113mm as shown in Figure 99 below n ATE TIN i ee 00 gs song BO i L DEM Mt E Figure 99 Impactor guide width setting 113mm ll ll lJl f eCYV7 T O 133 9900 User Manual FLEX PLI GTR Rev E Page 98 of 99 92013 Humanetics Innovative Solutions GTR9 6 06 Figure 100 Humanetics Launch plate Part Nr 133 8200 Aluminum and Carbon Fiber The interface plate that attaches to the launcher is drilled to match customer hole pattern S Immm 133 9900 User Manual FLEX PLI GTR Rev E Page 99 of 99 2013 Humanetics Innovative Solutions
89. wo tie wraps fixing the bone gage wires coming out of each bone tibia and femur to the end link where it exits the leg Before fitting the covers note there are two covers with three holes one of these covers part 133 5314 must be fitted over the SLICE unit for screw head clearance as shown in Figure 34 the other cover 133 5315 is necessary for 24 channel DAS when two SLICE units are fitted If 24 channels are not being used this cover can go to any of the other three locations Figure 34 LH of leg with knee covers fitted 12 channels Leg wires are not shown secured 133 9900 User Manual FLEX GTR Rev Page 34 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 Figure 35 SLICE Right hand side of knee 12 channels showing connectors Figure 36 Leg with disconnect wire TDAS interface and power supply ee 133 9900 User Manual FLEX PLI GTR Rev E Page 35 of 99 02013 Humanetics Innovative Solutions GTR9 6 06 2 7 1 SLICE 24 Channel Option To complete the system to 24 channels for optional instrumentation an additional 12 channel SLICE unit is packaged on the opposite side to the standard 12 channel units in the upper knee for balance and for access to upper leg sensors to reduce the number of wires crossing the knee joint See below The arrangement of SLICE bridge units and wiring will vary depending on the optional sensors selected Figure 37 Optional SLICE unit 24 channel option right side Fi

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