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Flex PLI GTR User Manual

1. 70 Assembly of flesh second ayer iie ene poe ae ibn eas oja d dje ad ui 71 Rubber flesh assembly Velcro POSItIONS ccccccccseeeeeeeeeeeeeeaeeeeeseeeeeseeeseeeseeeeeesaaeeeesaaeees 71 Rubber flesh tied on with Velcro nennen nnne nnns 71 Leg With UST COVER TING aes ane t 72 String potentiometer pull wire length 1mm ne 15 Example of fixing Teflon sheet to base plate 78 Bone and knee fixture 133 8120 for static assembly bending test femur shown 79 Static certification fixture 133 8120 showing knee cc ccceceeceeeeeeeeseeeeeeeseeeeeeseeeeeesaaeeeeeas 80 Bone Assembly Fixture femur shown under DeNnding csecccccseseeeceeeeeeeseeeeeeeaeeeeeseeeess 81 Femur assembly certification corridor moment vs deflection showing typical results 82 Tibia assembly certification corridor moment vs deflection showing a typical results 82 Knee Cenificaton FIXUS iii ne nalane ci nota a a de a a peak teb eat ee 83 Figure MCL sensor elongation Upper and lower corridor 84 Figure ACL and PCL upper and lower corridors ne 84 Diagram of Dynamic Pendulum Fixture nennen 85 Exploded view Dynamic Rig part nr 133 8400 na 87 Check s rews With 8 NM TOFQUG uai s eelo oe one ecu es k ualeat 89 Stop cable clearance adjustment usin
2. 33 Wiring diagram for 12 channel SLICE aaa 34 Typical 12 channel Slice wiring to knee eeseeeessseesseeeeenennnmm nnn 34 SLICE disconnect connecter uaa addi udo secu ur gu de amiet 35 LH of leg with knee covers fitted 12 channels Leg wires are not shown secured 35 SLICE Right hand side of knee 12 channels showing connectors 36 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 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 GTR9 9 07 Leg with disconnect wire TDAS interface and power SUPDI cccccceeeeeceeeeeeeeeeeeeeees 36 Optional SLICE unit 24 channel option right Side ccccecceeseeeeeeeeeeeeeeaeeeeeseeeeeeseeeeeeeas 37 Left side wiring example of 24 channel SLICE cc cccecccccseeeeeeeeeeeeesaeeeeesseeeeeeseeeeesaeeeees 37 DTI DAS left hand side of knee showing Di Mod AUDS cc cccceeeceecseeeeeeeeeeeeeeaeeeeeaeeeees 38 DTI DAS right hand side of knee showing crash recorder on the left and DiMod hub on the HON PCT 39 DTI DAS General
3. 20 Optional instrumentation tor TID a un dese an cote oa veo UR Estan Deo wes dose Conde de bej Edi 21 Leg E cal Sign CONVENON assas aaa une lera a ea te URP ee re oet nd Dn 25 Leg manipulations for positive output 26 Clamping Arrangement and Position for Off board Wires 27 Off Board wiring left hand side of impact face 28 Off Board wiring right hand side of impact face 28 Wiring Diagram for 12 channel M zBUS eesssesssseeseneenee nennen nnns 29 M BUS arrangement in knee 12 channels LH side to impact direction 30 M BUS arrangement 12 channels RH side of impact direction 30 Clamping of M BUS Disconnect Connector ne 30 M BUS Terminator housing installation in upper knee eeeeeeeeeseeeee 31 Fixing M BUS Wire to Launcher sinji aii ee a EA t eve D adi i wowed 31 Right hand side of knee M BUS 24 channels sensors not connected 32 Top right hand side of knee M BUS 24 channels sensors connected 32 Bottom right hand side of knee M BUS 24 channels sensors connected 32 Top left hand side of knee Messring 24 channels sensors connected 33 Bottom left hand side of knee M BUS 24 channels sensors connected
4. cccccccceececeeeeseeeeeeeesaeeeseeeeseeeseueeseeeaeeesaeeess 56 Bone exit cable restraint use cable ties ties not shown trimmed or tightened of Knee Assembly Exploded View nana 58 Meniscus string pot assembly wire feed a 60 Meniscus with all string pots assembled String pots identified 61 Meniscus Wire Clamp niesen aa a aaa 61 Attachment plate crimp wires in tension with spacers ready for knee femur block assembly EEN EE E T 62 Cross wire feed through on knee nee 62 Tibia Assembly Exploded VIGW uu segle iooi kai peto box ia a eu ee lead jini 63 Typical shim arrangement with 05 shim inside captive shim 67 Assembly of last two segments on tibia na 68 Ples COVErSYSlO Mean nA mA k EE 69 Assembly Of firsCflesh Iayel ausser dan oe oa ivo o S 70 Figure 72 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 Figure 101 GTR9 9 07 Zipper locations alternating on the sides schematic cross section
5. JabNab Magnetic Connector sO K3872 8 Stationary nxi Controller KJEBO OSO Bus Extender Figure 46 Schematic layout of 12 channel Micro Dau T o v NEN 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 42 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 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 l DIP 50A Trigger zem o DIC 56A 3 3 kh KB USB R205 U2C BF10BK SP 5m Im i 00 Be ee eps DIC 58A 580 DIC 52A 050 TA BEES DIC 50A 040 ACL aaa DIC 50A 100 MCL CL Z DIC 50A 100 DIS 506A U 1Ch 6Ch 5 T3 DIC 51A 040 1 DIC 54A 050 DIC 52A 220 F2 7 9 DIC 51A 040 DIS 506A D Knee Acc EI DIC 50A 170 7 LCL CTI DIC 50A 170 PCL T7 DIC 50A 170 7Ch 12Ch Figure 47 Kyowa 12 Channel System Configuration Diagram GTR9 9 07 One logger is installed on the front side of the tibia knee block and the other is on the rear side of
6. Repeat for the next 3 segments For the last 2 segments fit 133 5502 Bone clamp thick to the last blue segment 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 GTR9 9 07 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 8129 push down with two hands 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 56 133 8129 base with 133 5514 segment and bone clamps inside NN 133 9900
7. Draft Page 5 of 103 02013 Humanetics Innovative Solutions GTR9 9 07 3 3 Knee Exploded View a Figure 61 Knee Assembly Exploded View DESCRIPTION KNEE BLOCK TIBIA FLEX PLI MENISCUS ASSEMBLY SCREW SHCS M5 X 8 X 10 LOWHEAD 8 9003159 SPRING 12X40 AMISTARDB 12x40 SPRING 18 X 80 AMISTAR DB 18 x 80 8 8 13353100 SPRINGCAP FEMUR 0 9 8 1335311 CABLEWASHER 0 10 8 1335350 CABLEASSEMBLY KNEEML GTR9 9 07 9000203 SCREW FHCS M3 X 0 5 X 10 i 55 COVER KNEE FEMUR RIGHT SIDE 13 2 133530 COVER KNEE 19 4 5000850 SCREW BHCSM8X1 25X35 ZINC EET Em 22 1 15535 COVER LOWER KNEE FLEXPL 23 8 1335318 SPRINGCAPTIBA 0 00 Table 11 Knee Assembly Parts List 3 3 1 Knee Disassembly Remove the four aluminum side covers retained with M4 FHCS Remove the two front blue plastic covers if these have not already been removed The blue plastic covers are prized off the knee blocks by inserting a screw driver or similar into one of the holes and gently levering away from the strong double sided tape that fixes them Take off the accelerometer if not already removed then remove the 8 large springs 4 each end by unscrewing the eight M5 Nyloc nuts on the stainless steel wires Hold the wire on its end with an 1 8 open ended wrench to allow this Remove the washers Lay the knee on its side and pull out the eight wires and sp
8. should be bonded to the inside of the top plate Remove the 16 shoulder bolts 133 5106 and 14 links 133 5515 Remove the 4 M6 BHCS from each side of the top blue segment Slide the top aluminium segment off the bone the inner clamps along with their shims should come out as well as an assembly Slide off all the blue segments one by one be careful not to rock the segment too much when sliding off to avoid any damage to the strain gages and wires that run down the centre of the bone Remove the four M6 BHCS each side of the remaining aluminium segment and loosen the two M8 set screws on the non impact side Remove the base clamp if fitted used for stability then slide the segment off the bottom of the bone The two bone clamps will also come off along with any shims The bone is now free of any parts and can be inspected Try and keep all the segments laid out so that all the shimmed spacer bone contact parts are orientated the same for easier reassembly The retained shims for bone fit attached in the blue segments can be disassembled by removing the two M6 BHCS on the non impact side Shims for each segment should be kept together Removal of both the curved spacer bone contact thick 133 5505 and non impact side spacer bone contact thin 133 5507 from the blue segment is not necessary at this stage unless detail inspection of the spacers are required The double sided tape can be reused if still sticky and if it is not folded over It will
9. 50 ms after impact For further details of the test requirements refer to document ECE TRANS WP 2 9 GSRP 2009 21 9 8 Inverse Femur Corridors The femur corridors are not a regulatory requirement they are for monitoring to assess the satisfactory condition of the femur Zero crossover timing corridors are listed below Inverse Femur Zero Cross Timing Corridors for monitoring Femur gage 1 28 to 58 ms Femur gage 2 28 to 58 ms Femur gage 3 29 to 59 ms 10 1 10 2 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 GTR9 9 07 Section 10 Vehicle Test 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 Leg Preparation for Car Test Check alignment of upper and lower blue knee covers 133 5304 133 5305 Check knee block alignment no twist no shear with straight edge Figure 91 align if necessary Fit flesh and skin covers as described in 3 3 4 Check all wires are in position and restrained Hang assembled legform in launch apparatus Initiate DAS and zero sensors with leg hanging down vertically in launch apparatus Conduct tes
10. 9 07 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 TaPIANGIG Wrenches acendis ionn ei a S ea en ae eh lec 11 FISK Wrenches nenia a uta ii A A iii ia a a RN 12 Ratchet offset wrench with hex bits kit sse 12 Leg Wire Setting tool 1393 51 12 3 5 uL bass dx c e ed uat Ld abus el ERR aa a Dn VLA DEG Rd id 13 Knee spacer tool 139 5 T1932 m aeo Cu ee ee ud mu sies eed ru 13 Tibia and Femur base tool 133 8114 or 133 8129 ne 13 Optional Instrumentation for Femur nennen nnne nnn 17 Detail A Exploded View upper and lower knee 133 7507 ccc ccccc cece ecceeeeseeeneeeeeeneeeees 18 Wire routing for Detail A optional sensors 133 7507 sse 18 Wire routing out of segment for optional sensors Detail A in upper knee 19 Similar arrangement to Detail A but with 2 uniax Kyowa accels Assembly 133 7600 19 Sensor IES 3103 ARS example locations knee lower ne 20 Kyowa accel 3 axis option for leg top and bottom locations mount 133 7530
11. 9900 User Manual FLEX PLI GTR Rev F Draft Page 84 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 Section 8 Pendulum Dynamic Certification 8 1 Introduction The dynamic pendulum certification test is carried out on the Dynamic Certification Test Rig Part Nr 133 8400 or similar and is diagrammatically shown in Figure 87 Only 7 channels are reguired and must meet the GTR9 requirement see Table 15 Femur zero crossover timing corridors are also shown for functional guidance and will be monitored For assembly instructions of 133 8400 test rig refer to section 8 2 The leg should be tested with it s on board DAS to obtain complete certification of the tool Additional Mass Tibia Dynamic Certification Test Rig FlexPLI with Flesh cross sectional image Pendulum type Pin joint q Suspension A angle B ut 15 1 deg Sa t 5i0 2 988512 Released Free fall around the pin joint Knee joint Additional Mass center Mass 5 0 kg 0 05 with screws line Inertia 0 0061 0 0006 kgm impactor side c MANNA ZMA 0120 1 CD Center of gravity of additional mass Dimension units mm Figure 87 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 and temp must be recorded The leg assemb
12. A uade kalija bo ae a boke lai A ea aaa 74 4 7 2 Knee spring cables and bone stopper cables ne 74 4 8 Sensor and Electrical Maintenance cccccssccccssseecceeseeecceseeeceaueeecseeecseseesssaseeessaneeessageeesssaaes 15 4 8 1 General Electrical Maintenance nennen nennen nnn nnne 15 AGO 2y BohseVlalDteria6B iso i dr ond aa does am vied a dode ri RN dacs de ve A CEDE ELE 15 4 8 3 String Potentiometer Maintenance aaa 15 Section 5 jefe di aii re ee ee P 76 Section 6 WeIGht SPCCIICAUON anni ea ee ok eb ee PN ae ione ee 76 Section 7 Calibration and Certification Testilig si deri rio vp eo me ed debi pe e le eb 77 7 1 Calibration and Certification Overview 17 7 2 Femur and Tibia Bone Assembly Certification a 78 T5251 Tgisgels Be T o ERR IST et RE a EO PRO AEO A OTA EORR 18 GTR9 9 07 7 2 2 Femur and Tibia assembly Certification ccccccccsceeceeeeeeeceeeeeeaeeeeeeseeeeeeseeeeeesseeeeeeseeeeeeeas 78 Ts KROS COMIMCAUIOMN nn ECT PL aa o aaa nd a ke da ro A ee a ana 83 Section 8 Pendulum Dynamic Cer tili CANOO sivi van ae ano vak E le ati vlaki 85 8 1 NIP UETE Gl CLC TOU Man T m 85 8 2 Pendulum Rig Assembly Instruction nana 86 8 3 Leg Preparation for Pendulum Dynamic Certification 89 8 4 Pendulum RIG PM ED al AMO ia en eta e
13. Lower we 28 additional m Lower ere 29 additional Knee Lower MIL 30 additional anes Lower ga Rate 31 additional nea Lower ue Rate 32 additional nea Lower Angular Rate WZ additional Tibia Segment 1 Acceleration Y additional Tibia Segment 2 Acceleration Y additional Tibia Segment 3 Acceleration Y additional d o ti G x W N rH O O O O O UP tr AC G o HU tr D lt 0 HU tr gt lt Et HU HU TU HU HU gt gt gt O O lt lt Q Q HU O tr gt O Z Er Ex E HU i O Z Er Ex E HU ba O Z Er Ex HU ba lt EA HU gt lt tU gt O TIBI o TU gt Q TIBI o TU gt O TIBI HU ba O Tibia Segment 5 Acceleration Y additional Tibia Segment 6 Acceleration Y additional Tibia Segment 7 Acceleration Y additional Tibia Segment 8 Acceleration Y additional TIBI O Ul rj AC TIBI HU tr gt TIBI o HU tr ba tu Er Er H tri Er e Ds Tibia Segment 4 Acceleration Y additional TIBI U tr gt E GTR9 9 07 Tibia Bottom Acceleration X additional D 0 TIBI BO 00 PF AC X C Tibia Bottom Acceleration Y additional 42 Tibia Bottom Acceleration Z additional Table 7 ISO MME Sensor Code table Wire Label TRIAX Sensor Location Description Code wire label ISOMMECODE code 3 DOKNEELCOOPFDSZC_ DOKWEEA
14. MAJE z z pr 81 301 05 01 ACCEL A557 ASE A F FIN MALE LATCH ME ID SCREW FRCS MA X L7 X i m7 IREXPIICOWERRATE J PLU COVER PLATE u l ira POCOO OUSING ASSEMBLY p BODAL HOUSING ASSEMBLY imus pcm BONE a r 4 CH TIA T PCB BONE ASEY 1 CHANNEL smi ji adi A 007 a s CILE ot cem TI E M HUMANETICS eher prre Free TTERY RODA HUE ROBATTERY FOLSIRG ASSEMILY h J Cni FEMUR T L3 womi L SEE LIS MA SSE MEY DETAILS 1 SEE MODULES XI ETIB 33 5711 133 5712 AND 13 5713 POR WIRING AND ASSEMALY DETAILS FLEX PLI MICBODALI Eod SrsTEM CABLE ASSEMBLY I 133 7000 M12 TE k 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 User Manual FLEX PLI GTR Rev F Draft Page 41 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 Figure 45 Left hand side of impact face covers fitted 133 5710 Flex PLI Leg Assembly 133 5711 MicraHub 133 5712 MicroD au KM3861 Battery And MicroHub
15. NYLOK 133 5025 TAPE IMPACT SEGMENT 4 SHIM T0 5 OPTIONAL NOT SHOWN SHIM BONE CLAMP T0 05 OPTIONAL NOT SHOWN SHIM BONE CLAMP T0 5 OPTIONAL NOT SHOWN SHIM BONE CLAMP T0 6 OPTIONAL NOT SHOWN SHIM T0 6 OPTIONAL NOT SHOWN SHIM 05 OPTIONAL NOT SHOWN Table 10 Femur Assembly Parts List 4 4 1 4 2 5 O 16 GTR9 9 07 3 2 1 Femur Disassembly Remove the end cover 133 5516 by removing the four M5 BHCS and launch guide 133 5103 by removing the two M6 SHCS and washers It is advised to lay the parts on the bench in the order and orientation as they are removed so that parts can be reassembled in the same order This is not critical but is recommended 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 Remove the eight blue impact covers over each segment These are taped to the segments and located over M6 BHCS so need to be peeled off Remove the four stopper wires by unscrewing the M5 Nyloc nuts Replace the washers and nut on to the cable once removed to keep them together The assembly can be placed in the holding base tool 133 8114 or 133 8129 and locked in place This will stabilise the assembly and can make disassembly easier The femur will be dismantled starting from the top part 133 5102 Remove the four M6 BHCS that hold on the top plate and remove the top plate A rubber buffer
16. Neoprene 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 GTR 9 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 9 Angular Rate Sensors ARS Flex GTR has symmetric design so can represent a right or left leg The manual structure is as follows Tools Standard Instrumentation Optional Instrumentation ISO Codes DAS Options Disassembly and Assembly Maintenance Storage Weight Spec Calibration and Certification Leg Preparation f
17. Page 28 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 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 ToSensors Leg Form Launcher ge To Sensors Terminator Quick Disconnect Gateway Coax cable To PC Figure 20 Wiring Diagram for 12 channel M BUS For leg wire routing please refer 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
18. Sensor Code table noir Ie pd cer ed oae Esse oben eu MERO aad ed ile eve ae 24 Table 8 Wire label codes for all sensors nennen nennen nnns 25 Tale 9 FEX TEL ats EISE en oi ola aa al aet a eif uot Raab Duda 48 Table 10 Femur Assembly Parts LIS ice aite coe ome e Send ed Eu ieee 51 Table 11 Khee Assembly PANS AIS ise sored ets wile ek eae Emus Ere ei eU deo reque seti ues Piu usce R pue E Ev ede 59 Table 12 Tibia Assembly Parts Bist 4 ence emt deo ea deese c seo be eum eot ee osa Cete de e blati 64 Table 13 Plex PENG TR MASS ERU TEENS 76 Table 14 FLEX PLI GTR certification Steps ace eke So Rs ee ele Re eee 77 Table 15 Parts List for static fixture 133 8120 iaronn ted Great ween thi cure no ue vw bo vesli 80 Table 16 Pendulum Dynamic RIG Part UST an seni aisa A oa ae ej aucune end 88 Table 17 Pendulum test corridors peak values within 250 ms after impact 94 Table 18 Inverse test corridors peak values within 50 ms after impact 99 Table 19 Threshold values for injury channels ccccccseeeceeeeeeeeeeeeeeeeeeeeeeeseeeeeesseeeeesseeeeeeeaeeeeeas 101 GTR9 9 07 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 i
19. User Manual FLEX PLI GTR Rev F Draft Page 54 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 Figure 57 133 8129 base with 133 5514 segment bone clamps and bone assembly Figure 58 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 60 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 9 07 Figure 59 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 9521 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
20. against the bone Note 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 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 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
21. aligning them before pressing down on the double sided tape that fixes them If the tape is damaged folded over or not sticky it should be replaced Fit the 4x aluminium side covers with the M4 FHCS be careful wires and connectors are not crushed and are free to move when the knee is flexed A loop in the wires should be made for wires crossing the knee joint 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 ties to allow for the femur to bend and not pull on the wire GTR9 9 07 Figure 54 Screws to be tightened to 8 Nm non impact side a gt d O o njjnj ang mzz 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 49 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 3 2 Femur Exploded View Figure 55 Femur Assembly Exploded View NEIN a 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 50 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 4 1 133 5506 BONE CLAMP THICK KNEE 6 5 133 5505 SPACER BONE CONTACT THICK SHIM BONE CLAMP 4 THICK OPTIONAL 8 1 13355100 RUBBERBUFFER FEMURITIBAEND 9 5 133 5507 SPACER BONE CONTACT THIN 10 5 133 5509 SHIM 0 4 THICK OPTIONAL 133 5108 SEGMENT TOP FEMUR 133 5107 ROLLER 133 5521 WASHER CABLE 133 5110 CABLE ASSEMBLY FEMUR 5000522 HEX NUT M5 X 0 8
22. also be important to check for any damaged parts that would need replacement see maintenance section 4 3 2 2 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 GTR9 9 07 Start the assembly from the knee end of the bone The tibia femur base tool 133 8129 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 56 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 int
23. 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 I 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 31 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 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 F Draft Page 32 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 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 7 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 bridge 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 is 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
24. leg with knee covers fitted 12 channels Leg wires are not shown secured S hd cc 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 35 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 Figure 35 SLICE Right hand side of knee 12 channels showing connectors Figure 36 Leg with disconnect wire TDAS interface and power supply I 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 36 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 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 Figure 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 RFI 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 wo
25. 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 vehicle 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 assemblies have been reassembled it is recommended that 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 probl
26. of the screw To access the other leg attachment screws in the knee carefully prize away the two blue impact side plastic covers if assembled Use a screw driver or similar inside one of the blue cover lightening holes and gently lever away from the double sided tape attaching it to the knee Remove the accelerometer if fitted to prevent damage then remove the 2x M8 BHCS from each knee block The femur and the tibia can then be pulled out of the knee 3 1 2 Leg Assembly Insert the Femur into the knee block femur 133 5320 ensuring it is the correct way round with impact segments on the impact side Fit two M8x35 BHCS into the knee block impact side counter bored holes and tighten see Figure 54 Fit or tighten the two M8x30 set screws at the non impact side of the leg and screw in to their stops Carry out the same fitting for the tibia All these M8 screws must be tightened to 8 Nm as do the 4x non impact side M8 set screws in the aluminum leg segments see Figure 54 Note when tightening the segment screws start with the screw nearest to the knee to avoid the inner spacer levering over inside the segments Reconnect all the sensor connectors to the DAS For off board or on board configurations wires will require careful routing and securing see section 2 Fit the accelerometer to the impact side of the knee tibia block and connect wire to DAS and route the cable safely Fit the blue impact covers to the impact side of the knee blocks by carefully
27. 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 I 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 33 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 If required there is provision to wire in a tape switch for T lt 0 a wire is provided for this option out of the super cap housing Pendulum SLICE ick Di Connect Distributer interfac Quick Disconnect hace istributer interface at top of leg SLICE 7 2 ch unit Power Supply Tape switch Test m c option option Sensors 6 ch Sensors 6 ch 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 NN 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 34 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 Figure 33 SLICE disconnect connector To assemble the SLICE fit the SLICE unit with the higher stac
28. som sne E o on kia Ne frd apu eida 25 2 3 2 Signal Polarity Sensor function check na 26 2 3 3 FST Sii E HD PEE 26 2 4 Dalta Axe GUIS IMON IS QMO 2 a pp dede ee A NOTE touc Ae S 27 2 5 O ee t Ee O A ER RAI 27 2 6 Messring M BUS On Board Data Acguisition nne 29 2 6 1 MeBUSdESCIPUON ea EE E tates hate T 29 2 6 2 2h ChapnebM SBUS aci on pase Olea ae ae O S avo elo pa as Nel 31 2 7 DTS O DOGA SLICE NANO DA ena z Ne RU Tc ea attin aes 33 2 7 1 SLIGE 24 Channel Options nine hace Sed ae ee ee sesta 37 2 1 2 plecirical Qiii le ction owen Aina DT 3 2 8 DTbEentschel Onboard DAS ait te ata Na dina a ee bej ek Mene dika 38 2 8 1 PTI ISSCMP OM er 38 2 9 KT MichoDAU Onboard DAS E 40 2 9 1 METODA DESNO eo one ei EO E DUE 40 2 10 Kyowa 6 Das System O ME ere EO A A AO NEON ME MARAM PER A ANAT 43 Section 3 Disassembly and ASSSETDIV asouiedsosesvaa dolosa densateusa dione cra dost sited Saw dka aje eve na Vek ai 47 3 2 FEMU TE XDIOGSO M Ac EE 50 920 TemurDISdsserribly vsi esa rane os eate o ee kak van pole ch du ovi a a enake 52 3 2 2 Femur Upper Leg Assembly sinusi podi s ale bie ib Ene Mi bi bled in eat ea Ma veli 52 3 2 3 Femur assembly after static certification cc ccccccceecccecseeeeeeeeeeeeeeeeeeeeaeeeeesseeeeeseeseeesaeeeeeaas of 3 3 INES Exploded VIEW Aie 58 Seoul aS ISAS Se IMM RR ET EUER o9 GTR9 9 07 Sz KNEE ASSEM aries epa a ai lad ae dul obja oven lea tein thd bne oa ek
29. to prevent this The springs in the knee and the elastic response from the rubber flesh create a strong rebound If there is any doubt about safety allow the leg to bounce after impact Step 6 Detach leg from rig and remove the skin and flesh after each test GTR9 9 07 If a test is to be repeated the leg should rest for 20 minutes minimum before repeating If another flesh set is used the test does not need to wait 20 minutes 8 6 Data Processing All data shall be filtered CFC180 The certification corridors of all the GTR9 injury channels are given in Table 15 These peak values are to be within 250 ms after impact Certification Channels Peak Moment Tibia Peak Moment Tibia Peak Moment Tibia Peak Moment Tibia Peak ACL Elongation Peak PCL Elongation Peak MCL Elongation GTR Pendulum Table 17 Pendulum test regulation corridors peak values within 250 ms after impact 8 7 Pendulum Femur Corridors The femur corridors are not a regulatory requirement they are for monitoring to assess the satisfactory condition of the femur Zero crossover timing corridors are listed below Pendulum Femur Zero Cross Timing Corridors for monitoring Femur gage 1 164 to 194 ms Femur gage 2 164 to 194 ms Femur gage 3 164 to 194 ms Section 9 Dynamic Inverse Certification Test 9 1 Introduction After the initial manufacturers inverse test the leg is recommended to be inverse tested before each vehicle test series and mandatory af
30. 0 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 9 07 Figure 69 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 67 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 60 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 to allow fitting to the calibration fixture Keep all parts together ready for final assembly 3 4 3 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 4 4 Fitting flesh and Covers On the day of the test or for certification the flesh covers are fitted over the leg To simplify the fitting of the flesh system all the covers should be laid on the bench in reverse order of assembly GTR9 9 07 245 285 nn o N1F N2F 1 sheet 1 s
31. 133 5518 COVER ENDIMPACT Z O 7 183 5001 SHIM T0 5 OPTIONAL NOT SHOWN 2 133 5002 SHIM E CLAMP n os OPTIONAL NOT AMAA 2 133 5003 SHIM BONE CLAMP TO 5 OPTIONAL NOT SHOWN 2 133 5004 SHIM BONE CLAMP Tos OPTIONAL val EE 7 133 5005 SHIM T0 6 OPTIONAL NOT SHOWN SHIM I E E 6 5000072 SCREW BHCSM6X16 N42 BR m SID IN IN gt 2 K 20 22 23 24 25 26 27 28 29 2 30 a sa 35 36 37 38 39 Table 12 Tibia Assembly Parts List GTR9 9 07 3 4 1 Tibia Disassembly It is advised to lay the parts on the bench in the order and orientation as they are removed so that parts can be reassembled in the same order This is not critical but is recommended 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 Remove the end cover 133 5516 by removing the four M5 BHCS Remove the 10 blue impact covers over each segment These are taped to the segments and located over M6 BHCS so will need to be peeled off Remove the four stopper wires by unscrewing the M5 Nyloc nuts Replace the washers and nut on to the cable once removed to keep them together The assembly can be placed upside down in the holding base tool 133 81
32. 29 and locked in place This will stabilise the assembly and can make disassembly easier The tibia will be dismantled starting from the bottom part 133 5511 Remove the 20 shoulder bolts 133 5106 and 18 links 133 5515 Remove the four M6 BHCS from both sides of the top aluminium part segment bottom tibia 133 5511 if the base clamp is fitted and the four BHCS from the next blue segment pull off the aluminium segment There should be a rubber buffer bonded to the inside of this part There may be additional packing please maintain this packing if fitted as it would prevent any end play on the bone The two bone clamps 133 5502 and 133 5503 and shims may pull off as well as the next blue segment it not pull these clamps and shims out along with the first blue segment Slide off all the blue segments one by one be careful not to rock the segment too much when sliding off to avoid any damage to the strain gages and wires that run down the centre of the bone Remove the two M6 BHCS on the impact side of the remaining aluminium segment and loosen the two M6 set screws on the non impact side Remove the base clamp if fitted for used for stability then slide the segment off the bottom of the bone The two bone clamps will also come off along with any shims The bone is now free of any parts and can be inspected Try and keep all the segments laid out so that all the shimmed spacer bone contact parts are orientated the same for easier reassembly The r
33. B 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 taken to assure cables are not overlapping or pinched during assembly 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 40 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 MODULE CONTAINS ITEM il SEE LIP 5700 FORI DETAILS MODULE CONTAINS MEHS 10 AND 11 n in 5711 ME CRAs MODULE CONTAINS ITEMS 10 AND li SEE 131 5712 FOR DETAILS FARTS LIST Qrv PART Mune SCRIPT TELJI MICRODAU MODULE MM TEME MICROBATTERY O MIC Kac 5 li j EINE jMUCRODAUMUB SST CEL ASSY STA POT L TO FIN MME amp 1 50 D54D DO CEU ASS STE POT A TOT PIN
34. COOPFDSZC_ DOKNEEPCOOPFDSZC_ DOKWEEMCOOPFDSZC_ 3 DOTIBILOO0PEMOXC npOKNEEBOOOPFACYC A FT SS SS SS SS p L Femur Moment 3 Upper X Femur Moment 2 Middle X Femur Moment 1 Lower X Knee LCL Elongation T T T T F1 Knee ACL Elongation Knee PCL Elongation Knee MCL Elongation Tibia Moment 4 Lower X Knee Bottom Acceleration Y AY KB Femur Segment 1 Acceleration Y AY S1 Femur Segment 2 Acceleration Y AY S2 Femur Segment 3 Acceleration Y AY S3 K AR KU rr E 3 A K 3 2 1 T1 bi Femur Top Acceleration Z AZ FT Femur Segment 4 Acceleration Y AY S4 AR KL Tibia Segment 1 Acceleration Y AY S7 DOTIBIOL00PFACYC Tibia Segment 2 Acceleration Y AY S8 DOTIBIOZO0PFACYC Tibia Segment 3 Acceleration Y AY S9 DOTIBIO300PFACYC Tibia Segment 4 Acceleration Y AY STO DOTIBIO400PFACYC Tibia Segment 5 Acceleration Y AY S11 DOTIBIO5S00PFACYC Tibia Segment 6 Acceleration Y AY S12 DOTIBIO600PFACYC L L GTR9 9 07 Tibia Segment 7 Acceleration Y AY S13 DOTIBIO700PFACYC Tibia Segment 8 Acceleration Y AY S14 DOTIBIO80OPFACYC Tibia Bottom Acceleration X AY TB ME DOTIBIBOOOPFACYC DOTIBIBOOOPFACZC Tibia Bottom Acceleration Y AY TB Tibia Bottom Acceleration Z AZ TB Table 8 Wire label codes for all sensors 2 3 1 Co ordinate System The recommended local co ordinate syst
35. ER DIS 506A Figure 52 Kyowa Rear side in 24ch Please refer to the Kyowa 6 user s manual regarding its use 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 46 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 Section 3 Disassembly and Assembly 4x 5000770 4x 5000584 RC 2 Figure 53 Leg assembly Exploded View a m gt O OJOOJJ 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 47 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 ITEM PART NO DESCRIPTION 2 1 1335500 TIBIAASSEMBLY FLEXPLE Z o Z 2 1 3 1 133 5100 FEMUR ASSEMBLY FLEX PLI 6 1 133504 COVER OUTER FEMUR NOT SHOWN 8 1 133 5016 COVER OUTER TIBIA NOT SHOWN 9 1 133 5017 COVER FLEX PLI GTR NOT SHOWN 10 6 133 5019 VELCRO BUNDLE TIE 500mm LONG NOT SHOWN Table 9 Flex PLI Parts List 3 1 1 Leg Disassembly When the leg is not being used or shipped the tight fitting flesh system should always be removed to prevent stretching and long term indentation from the leg components Remove the four aluminium side covers each held on with 4x M4 FHCS Disconnect the 1x femur 2x tibia and 1x accelerometer DAS connectors and any other optional connectors if fitted coming out of the knee assembly These connectors are labelled for refitting on assembly Loosen the two M8 MSSFP screws from the non impact side of the leg on each knee block by about three turns
36. GTR9 9 07 Flex PLI GTR User Manual ao sj 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 1 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 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 9 07 Table of Contents Section 1 ee ejo ae rene etn errr en te eee T ee ee ee ee er 10 1 1 CON TVW future PE AE RA OE EO NR 10 1 2 Tools and Recommended Spares nana 11 Section 2 PES CREAT CAD OM cep cere ee EP 16 2 1 Standard 12 Channel instrumentation nee 16 2 2 Optional Instr rmentatlOD 5 oer oe Eur to e eeu ee oe ud s eee ee 16 2 3 SOMME COdES a vii ka i E E 22 2 3 1 Co ordinate Syste aroun ti eo prebilo poj dre
37. IMPACT BLOCK 22 SCREW SHCS M8 X 1 25 X 50 23 9000244 WASHER FLAT 4 24 BRACKET RELEASE MECH NO C1 6002571 RELEASE SYSTEM TENNEN BV 099 005 A 9000499 SCREW SHCS M8 X 1 25 X 60 133 8436 CALIBRATION BALLAST FEMUR WASHER FLAT M10 10 85 ID X 20 OD X 2 5 THK EYEBOLT M6 X 1 X 12 ZINC PLATED MCM 3107T41 RELEASE SYSTEM CONTROL BOX TENNEN BV TE RSCB 100 SCREW SHCS M6 X 1 X 20 SCREW SHCS M8 X 1 25 X 25 CONNECTOR SOCKET NOT SHOWN SOCKET TERMINAL NOT SHOWN PIN TERMINAL 60618 1 NEWARK 6001738 CONNECTOR AMP MATE N LOCK NOT SHOWN 11 FT 6003042 SERVICE CORD 16AWG 2 CONDUCTOR NOT SHOWN NIN NIO N Co 1 N co 0 1 1 Q2 C9 Q C2 O O1 Co N 3 oO K Table 16 Pendulum Dynamic Rig Part List GTR9 9 07 8 3 Leg Preparation for Pendulum Dynamic Certification Step 1 Check the alignment of the blue upper and lower knee covers 133 5304 133 5305 Step 2 Check the eight M8 set screws shown in Figure 89 are tightened to 8 Nm Figure 89 Check screws with 8 Nm torgue Step 3 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 4 Check the four stop cable clearances passing through the femur are set to 9 1 mm and 10 3 on the tibia See Figure 90 a special tool 133 5112 is used for this I 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 89 of 103 2013 Humanetics Innovat
38. Overview 39 Exploded view of knee showing Micro Dau integration 40 Showing drawing of Micro Dau part numbers ne 41 Right hand side of impact face lower covers removed eesseeseseneeeeere 41 Left hand side of impact face covers fitted eeeeeeesessesseeseseneeeenn 42 Schematic layout of 12 channel Micro Dau sseeessssessseeeeennnennenn nemen 42 Kyowa 12 Channel System Configuration Diagram ccccseecceceseeeeeseseeeeaeeeeeesaeeeeeaaeees 43 KY OWa SIGS IM TOL anni sane dele vee ian eo dupl orden aa cM URN 44 KyOWa Real Side M AZO ai nuna Na bte edness sa Mit Rae eaae ote Mai Godel la Rena 44 Kyowa Disconnect ConlTector uu e ro om Dod std aep Mid Loue rd ciu d 45 Kyowa Front Side TN ZZ4C P sisuissbusexhs ii za bd a vaste Mid Oo oaa bu ee C aM AER NS 45 KV OW a Rear side In ZZ odo rbi uu ea adil avra onu bd eulx tue uasa av opes Data laja 46 Leg assembly Exploded View nana 47 Screws to be tightened to 8 Nm non impact side 49 Femur Assembly Exploded View 50 133 8129 base with 133 5514 segment and bone clamps inside 54 133 8129 base with 133 5514 segment bone clamps and bone assembly 55 Fitting and tightening first blue segment nn 55 Fitting thin bone spacer with captive SNIM
39. ake a loop of steel wire rope of the proper length such that the drop angle matches the required suspension angle of 15 x 1 above horizontal Figure 87 Suspend the leg with the Pivot Hinge to the Pendulum Rig The leg is lifted up to the release mechanism Figure 95 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 x 1 Check the angle with a digital inclinometer laid 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 The Pendulum Rig is now ready for running a test GTR9 9 07 Manual release button Wire in latch Figure 95 Examples of release latches 8 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 Step 2 Fit the leg to the pivot block on the rig using the M10 Socket Head Shoulder Screw SHSS Route the disconnect wire as required out of the end of the tibia or below the knee depending on type of DAS and tape up to the rig so that it does not interfere with the free swing motion of the leg when tested If using off board DAS the wires are routed out of the top of the leg Step 3 With the leg hanging down vertically start up and initiate the DAS and set the DAS such tha
40. ange recommended Tibia Assembly Bending Test Knee Assembly Bending Test Dynamic Pendulum Impact 3 After exceeding injury thresholds 10 tibia 4 4 After maintenance and or component 2 peak elongation MCL exchange PCL and ACL 1 Annually 1 Peak bending moment 2 After 30 vehicle tests tibia 1 tibia 2 tibia 3 and 3 After exceeding injury thresholds 10 tibia 4 4 After maintenance and or component 2 Peak elongation MCL exchange PCL and ACL Dynamic Linear Guided Impact 1 Annually 1 Peak bending moment 2 After 10 vehicle tests max tibia 1 tibia 2 tibia 3 and 3 http www veci vrci com VRCI P 100A pdf Industry standard wire wound and non wire wound precision potentiometers GTR9 9 07 7 2 Femur and Tibia Bone Assembly Certification 7 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 sensitivity 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 Passing static corridors is a regulatory reguirement which help assure successful dynamic certification 7 2 2 Femur and Tibia assembly Certification This o
41. ar 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 68 locate against the spacer bone contact thin 133 5507 see Figure 59 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 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 us
42. assembly tightly around the leg using the six Velcro straps The thick wider part of the rubber system fits just above the top of the femur knee block See Figure 75 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 Figure 74 Rubber flesh assembly Velcro positions Figure 75 Rubber flesh tied on with Velcro 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 71 of 103 02013 Humanetics Innovative Solutions GTR9 9 07 Step 7 Finally pass any off board or disconnect wires through any holes in the outer cover if applicable For pendulum testing allow for the electrical wires to exit at the top of the pivot hinge at the top of the upside down leg For inverse and car testing check all wires are correctly positioned and restrained to avoid damage or disconnect Step 8 Wrap the outer cover around the leg The outer cover is zipped up from the bottom of the leg to make zipper fitting easier Some DAS systems have a disconnect wire 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 put the zipper Velcro tag over to pr
43. ata 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 17 If off board cables are not used the clamps should be replaced with washer 133 5105 item 16 in Figure 67 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 Clampi
44. 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 M 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 38 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 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 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 Flex PLI Figure 41 shows a schematic overview of the sy
45. 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 91 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 78 The testing machine must be fitted with 0100mm D shaped profile part 133 8105 see Figure 80 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 Th
46. e 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 be 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 9 07 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 8 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 a
47. e 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 8129 and pushing with two hands down on the two segments Once fit is tight tighten all eight screws to 3 Nm Figure 68 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 is being used 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 only used for off board wires or to restrain or guide wires if required To fit stopper cables first remove the assembly fixture part number 133 8129 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 1
48. e 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 negative The results must be inside the corridors given in Figure 85 and 86 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 84 Knee Certification Fixture RA m my AI I Oe rm r r L m OY C AMO re Mie amp nmiinl bk L Y LJ LJ LY Sis b wry IQ MA Q AT I 4 Ur m I2 f A F m AWV Jr 2 L alle QO JI Il LJ AMI I L LLI M H LI us Fi M dg NAM V V bi CAITL J i MUV UY VI Ww A 4 tub GTR9 9 07 400 390 300 250 200 150 moment L 100 moment U Knee bending moment Nm 50 0 5 10 15 20 25 30 MCL Elogation mm Figure 85 Figure MCL sensor elongation Upper and lower corridor ACL and PCL elongation mm Force N Figure 86 Figure ACL and PCL upper and lower corridors 133
49. e va AN eo ae aaa an 92 8 5 RUNNING A OST ER 93 8 6 Data diee cst LE 94 8 7 Pendulum Femun Bro dero lo foe 94 Section 9 Dynamic Inverse Certification Test nennen nennen nennen nnn nnn 94 9 1 MEMEO GUC ON ee a np LL A E LL ea ee uae TIUS EIL A DAE LAM re edina 94 9 2 VESE TES DE CNI PON ani ana enje aja seeds See ete kove ele rab se evod sadi Me 95 9 3 Preparation of the Inverse Test set up aaa 95 9 4 Impactor Friction Stroke Phases and Speed Measurement nee 96 9 5 Leg Preparation of the leg for Dynamic Inverse TeSt cccccccccseeeeeseeeeeeeseeeeeeseeeeeeeaeeeesseeseeeeaees 97 9 6 RUANING a Dynamic Inverse T6SL zu ida oec a d Uo en d D ate tie Rud det sa e ER edd dd de 98 9 7 bala PrO ESSINJ nan ima nn kai ni medi Rai a N 99 9 8 Inverse Femur COMIGORS d sni pina thd poi ea a c aepo di alna DN satio di el un uy Cu Men dan 99 SECON TO Vehlecle TOSTI ie cen a od ai a E tate ao boje aaa dh Gon ie eti ido 100 TOS JOK OGUE MON stood die ie AN a ait ide a net rei bedijo A jn iP a stage a d as Ob ut anal i 100 102 Leg Preparation TOF Can 6 Stene ini edis Date buro a a a do denuo ae ka amar obe o up ei un 101 TOS JTnjUry LH hresrolgS nana ado ab a a deo ae nah jan a bik be 1011 10 4 Leg loading limits in free flight nnnm 101 10 5 o o tnt anum diis ten A A a a a 102 10 6 Impact pusher plate seni su iii nut ii edad Sela aa a ee Nea iv es 102 GTR9
50. eck alignment after any adjustment Step 6 Check all segment screws and side aluminum shoulder screws are tightened to 3 Nm Step 7 Fit the flesh and skin covers as described in 3 3 4 Check all wires are correctly positioned to avoid damage and any exit wires are restrained Step 8 Hook up the sensors on the Data Acquisition System DAS as applicable GTR9 9 07 9 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 in relation to the lateral vertical plane The roll angle of the impactor rotation around x 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 t2 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 98 below Impactor Direction Figure 98 Launch guide with 15 tilt toward guided
51. em 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 Protective 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 10 vehicle test GTR9 9 07 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 7 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 t
52. em for standardization follows the SAE J 211 dummy co ordinate system Pa OTE Te TAPA Th Fh C C E a z a f Figure 15 Leg Local Sign Convention GTR9 9 07 2 3 2 Signal Polarity Sensor function check The leg can be manipulated manually as shown in Figure 16 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 low bending angles ACL and PCL will be negative when initially manipulated In the diagram below Figure 16 they are shown positive To obtain a positive signal the bend angle would have to be more significant For accelerometers signal polarity a blow in the direction of the positive axis should result in a positive acceleration output Figure 16 Example a blow 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 tout PCL tout Push tibia 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 9 07 2 4 Data Acquisition Options The FLEX PLI can be used with various options for d
53. ensured e The lower edge of the rubber sheets R1 and the femur Neoprene sheets N1F N2F shall align with the upper end of the femur knee block e The recess of the rubber part R2 shall align with the upper end of the femur knee block e The upper edge of the tibia Neoprene sheets N1T N2T shall align with the lower end of the tibia Knee block e The outer cover N3 shall be centered to the leg assembly without hanger or ballast weight GTR9 9 07 Step 3 Fit the black plastic protective end covers to the ends of the leg with 4x M5 BHCS for inverse and car testing Src d E P i o os Le di e podi ki i m zu 3 L4 uu na I Figure 71 Assembly of first flesh layer Figure 72 Zipper locations alternating on the sides schematic cross section Step 4 Do up the zippers on Thigh 1 and Leg 1 making sure each zipper is positioned on the side of the leg in the area of the shoulder bolts Step 5 Turn the leg over and do up the Thigh 2 and Leg 2 zippers making sure these zippers are on the opposite side to the first No zipper should be at the back or the front of the leg or it will interfere with the flat surface of the launcher plate or sustain damage due the impact NEIN NENNEN NNNM NN NNNM NENNEN NE UE 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 70 of 103 02013 Humanetics Innovative Solutions GTR9 9 07 Sec US TA ABT es AB Figure 73 prome of flesh Second dise Step 6 Wrap the rubber buffer
54. etained shims for bone fit attached in the blue segments can be disassembled by removing the two M6 BHCS on the non impact side Shims for each segment should be kept together Removal of both the curved spacer bone contact thick 133 5505 and non impact side spacer bone contact thin 133 5507 from the blue segment is not necessary at this stage unless detail inspection of the spacers is required The double sided tape can 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 maintenance section 4 3 4 2 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 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 super glue 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 GTR9 9 07 stable when building and simplify segment assembly The part 133 8129 from the bone static fixture can also be used and
55. ews Figure 93 Attaching Pendulum Rig Pivot hinge Step 10 See next step in section 8 4 for rig preparation The checking and adjustment of the pendulum Impact Block Part 133 8423 must be done with a bare leg without the suit Check the Impact block is adjusted to the specification Step 11 Fit the flesh and skin covers as described in 3 4 4 allowing for the electrical wires to exit at the top of the upside down leg The leg is now ready to be hung on the rig MM 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 91 of 103 02013 Humanetics Innovative Solutions GTR9 9 07 8 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 88 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 61 item 2 Part Nr 133 5313 of the knee and 13 2 mm from the front of the impact face point nearest to the leg to the impact segments of the tibia See Figure 94 Adjust the height of the Impact Block by moving the Impact Bar Weldment Figure 88 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 10 2 Figure 94 Checking the Impact Block position adjustment Next step is to m
56. ews 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 im fi L K p Me na do P E w m Figure 62 Meniscus string pot assembly wire feed NEIN a 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 60 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 LIGIMENT BUSHES WIDER NON IMPACT SIDE Figure 63 Meniscus with all string pots assembled String pots identified Figure 64 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 65 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 smaller 212 x 40 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 EINEN KW o NN VI I 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 61 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 carefully over the tibia knee block guiding the wires across to their designated holes and locating over the attachment plate see Figure 66 Double check the knee femur block is the right way round ref exploded view Fig
57. g setting tool 90 Recommended method to align knee to remove any twist and shear 90 Attaching Pendulum Ballast Weight na 91 Attaching Pendulum Rig Pivot hinge nena 91 Checking the Impact Block position AdjUStMENL ccc ecceeseeeeeeeeeeeeeseeeeeesaeeeeeseaeeeesaeeeeeens 92 Examples of release latches aaa 93 Diagram of Dynamic Inverse Certification Test set up 95 Paper cloth wrapping of honeycomb aaa 96 Launch guide with 15 tilt toward guided impactor 98 Optional catch rope bracket 133 5034 a 102 Impactor guide width setting 113mMm na 102 Humanetics Launch plate Part Nr 133 8200 Aluminum and Carbon Fiber 103 GTR9 9 07 Table List Table 1 Contents of the tool kit provided with the leg on delivery sseseseeeeeeeeeeees 14 Table 2 crew abbrevialiOlis muc si e edo ane S ee ae atin iar deb eee 14 Tapew Torque Requirements Ge a adiu je e A sa cobro ia tis sla e aptat 14 Table SSpare Pants Hist sna ka ie ses oe aa o a ds e o a le vaba piae Pert bos ate bi 15 Table 5 12 Channel Instrumentation nana 16 Table 6 Example of Optional Instrumentation Parts List 21 Table 7 ISO MME
58. guide width setting 113mm I 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 102 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 Figure 101 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 I 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 103 of 103 2013 Humanetics Innovative Solutions
59. he 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 between 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 Thes
60. heet E N3 1 sheet 326 s R1 R2 2 sheets 2 sheets 402 100 Tolerance of length and width for N1 F T N2 F T and N3 10 mm Tolerance of length and width for R1 and R2 5 mm Thickness and its tolerance of R1 and R2 sheets 5 0 75 mm Thickness and its tolerance of N1 F T N2 F T and N3 sheets 5 6 0 75 mm Figure 70 Flesh Cover System N3 Neoprene outer cover N2 Neoprene second layer F lt Femur T lt Tibia N1 Neoprene first layer F lt Femur T lt Tibia R2 Rubber inner layers R1 Rubber outer layers Step 1 Place the large outer cover N3 on the bench with lettering face down Lay 6 strips of Velcro tape over with fluffy side down then place the rubber buffer sheet assembly 133 5020 over the strips 2x R1 and R2 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 74 Lay Thigh 2 and Leg 2 covers N2F N2T over with the two knee end inside arrows pointing towards each other allowing a gap for the knee area then do the same with Thigh 1 and leg 1 covers N1F N1T Step 2 Place the leg assembly onto the laid out flesh covers with thigh femur section over thigh covers and leg tibia over leg covers with the leg assembly on its side The following positions of the rubber and Neoprene sheets shall be
61. ibia bending moments knee Medial Collateral Ligament MCL Anterior Cruciate Ligament ACL and Posterior Cruciate Ligament PCL elongations These channels are controlled by the certification procedures given in Sections 8 and 9 Corridors are also provided for the femur channels See Table 18 section 8 7 These corridors are not a regulation requirement they are a guide to advise on the expected performance of the femur The accelerometer can be used for force calculation and the LCL provides information on elongation after rebound crossover of the knee Instrument Channels Purpose Standard DAS Femurmomeniizand 03 Tibia moment 1 2 3 and 4 Injury Assessment 4 T kree batom aserton 57000 3 Standard MCL elongation Injury Assessment 1 Option ACL elongation Injury Assessment Od iDummy PCL elongation Injury Assessment LCL elongation ao Toa o R Table 5 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 length does not exceed the regulatory requirement Each individual femur and tibia segment can be instrumented with a uniax acce
62. iction during free travel should be less than 100 N to avoid speed reduction To measure friction an accelerometer mounted to the impactor would be required to measure acceleration in GTR9 9 07 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 9 5 Leg Preparation for Dynamic Inverse Test Step 1 Check alignment of the blue upper and lower knee covers 133 5304 133 5305 Step 2 Check the eight M8 set screws shown in Figure 89 are tightened to 8 Nm Step 3 After 60 vehicle tests remove the knee front covers and check the 4x M8 button head screws attaching the legs are tightened to 8 Nm Step 4 Check the four stop cable clearances passing through the femur are set to 9 1 mm and 10 3 on the tibia See figure 90 a special tool 133 5112 is used for this Step 5 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 91 A straight edge can be used to double ch
63. igure 12 A special impact cover is reguired to accommodate the sensor Figure 12 Sensor IES 3103 ARS example location knee lower Figure 13 Kyowa accel 3 axis option for leg top and bottom locations mount 133 7530 EINEN JJ o MEME NN UNES 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 20 of 103 02013 Humanetics Innovative Solutions GTR9 9 07 a Z v Figure 14 Optional Instrumentation for Tibia DESCRIPTION Ta 4 1837508 ACCEL INSTRUMENTED OPTION LEG TOP 8 BOTTOM 2 6 133 7514 IMPACT SEGMENT INSTRUMENTED ASSEMBLY FEMUR 2 8 133 7514 IMPACT SEGMENT INSTRUMENTED ASSEMBLY TIBIA 83 1 138 707 ACCEL 8 ARS INSTRUMENTED OPTION FOR KNEE 4 1 1337502 KNEEENDACCELMOUNT o 5 1 133 7516 TAPE DOUBLE SIDED 6 1 5000164 SCREW SHCSM2X04X18 O 8 6 90310 SCREW SHCSHOB0OX516 1 MS 68C ACCELEROMETER LINEAR TRIAXIAL MEASUREMENT j SPECIALTIES MS 68C 133 7506 SPECIAL M2 ACCEL FIXING Table 6 Example of Optional Instrumentation Parts List lt 3 9900 User Manual FLEX PLI GTR Rev F Draft Page 21 of 103 Bae 3 Humanetics Innovative Solutions GTR9 9 07 2 3 ISO MME Codes For the identification of sensor channels and for computer processing of signals the following codes have been established for ISO MME Location Cat Test b ose L i L dus L du
64. 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 Step 5 Conduct test Step 6 Remove outer skin cover and inner flesh system after each test GTR9 9 07 If a test is to be repeated the leg should rest for 20 minutes minimum before repeating If another flesh set is used the test does not need to wait 20 minutes 9 7 Data Processing All data shall be filtered CFC180 The Inverse Certification corridors of all the GTR9 injury channels are 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 ge C gt O o D gt a O Calibration Results Peak ACL Elongation Peak PCL Elongation Table 18 Inverse test regulation corridors peak values within
65. ing 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 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 There may also be additional packing to prevent the bone moving this must be replaced For the last 2 segments fit 133 5502 Bone clamp thick to the last blue segment and 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 GTR9 9 07 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 69 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 th
66. ir ligament positions this is needed for DAS identification for sensitivity input Also see paragraph 4 8 3 for string pot check If pots are due or close to their due date they should be recalibrated GTR9 9 07 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 62 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 62 Attach the string pot with the 2 56 x 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 see Figure 63 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 64 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 This will prevent the scr
67. is shown in Figure 56 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 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 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 we
68. ith 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 GTR9 9 07 size or a inch cell size The honeycomb should have a density of 2 0 pcf pounds per cubic foot in combination with a 3 16 inch cell size or a density of 2 3 pcf in combination with a inch cell size The honeycomb block is covered with paper cloth of less than 1mm thick See Figure 97 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 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 Outlook Back side Front Impact side Paper cover Figure 97 Paper cloth wrapping of honeycomb 9 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 fr
69. ive Solutions GTR9 9 07 Figure 90 Stop cable clearance adjustment using setting tool Step 5 Check knee blocks are aligned to ensure knee is not twisted or in a shear condition before the test Using two egual 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 91 A straight edge can be used to double check alignment after any adjustment on two sides Figure 91 Recommended method to align knee to remove any twist and shear Step 6 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 7 Remove the aluminum launch guide Figure 55 item 18 Part Nr 133 5103 U shaped bracket fitted to the top of the femur along with the black protective cover Figure 55 item 28 Part Nr 133 5516 Step 8 Attach the ballast weight Part Nr 133 8436 as shown in Figure 92 to the top of the femur using two M8 x 50 long cap head screws MJU U ser Manual F L EX PLI GIR Rev F Draft GC INNAOVOTIV gt lll IVAGLUV GTR9 9 07 Figure 92 Attaching Pendulum Ballast Weight Step 9 Remove the black protective cover Part Nr 133 5516 from the tibia bottom and attach the Pivot Hinge Part Nr 133 8418 as shown in Figure 93 using four M6 x 18 long scr
70. k 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 adeguate 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 two 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
71. ko ojla nga o9 9 9 9 Assembly Aller Cercato coole etae eda petu tid Does idea ctc arcane ian ode D pe Ud 62 3 4 Merde NOC CGN M DUE E 63 odl 3buaDisassemblVasssentttstasiistret iate sud soda U o buxo la bna ko ee ab ne diste sud Rode 65 94 2 MDIRASSEMDY ao tetas te vo ditte ba do rala Uo dtt sia aaa drill el oven locat ode 65 949 ANS Calibraulon send pecene Dui sot a ea o sto AA 68 3 4 4 Fitting flesh and Covers nana 68 34o ISSN Disassembly naj rebri a aja deed ko Eo oboa de Sn dei eni 12 Section 4 Mantenan oa oa aa ee E va a a ane Aa m veni 73 4 1 MOJCI E TEE O UU ET uke RATIO Z 73 4 2 General External Damage inspection ccccccccsseeecceeseeecseseecceueeessaeeecseeeecseaseeessaseeessnseesssaes 73 4 3 SUD PONE ROM CK pe M eel ei 73 4 4 Red Neoprene oit COVES eese dta eno UM MEDII a MM SE DM MU tals 73 4 5 Protective Plastic End Covers Part 133 5516 ee 73 4 6 doje AIA Gir EV etcetera E OPA EV N E AN A ANO MA jon NARE NM KARAVANE NM NAVE T OMARE 74 4 6 1 Assembly Segment PIAY usine oerte Pteiji vadi jed Bee ota tos ee ea doses o ba jed debe ott 74 4 6 2 Buffers between segments ccccccccsssscccceseeccsseeccseueecseseeessageeecseeeecseuseeessgeeessageeessseaes 74 4 6 3 Shoulder Bolt and Segment Screw Tightness Check a 74 4 7 PTS O A A EO INV OT A O seth E 74 Aelia WANES MEISCUS iin Mi pla ta
72. lerometer 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 9 07 See Detail A Figure 7 Optional Instrumentation for Femur I 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 17 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 Figure 8 Detail A Exploded View upper and lower knee 133 7507 Figure 9 Wire routing for Detail A optional sensors 133 7507 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 18 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 ai 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 and for 133 7507 the mirrored mount is 133 7545 to route wires to the opposite side for DAS connection to prevent wires going around the knee thus avoiding wire damage and good wire routing GTR9 9 07 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 exit either side See F
73. long 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 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 10 5 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 99 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 9 07 Figure 99 Optional catch rope bracket 133 5034 10 6 Impactor 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 100 below Figure 100 Impactor
74. ly 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 have similar loading level to a vehicle impact an additional 5 0kg mass is also added to the femur end GTR9 9 07 8 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 cross member is in line
75. ng Arrangement and Position for Off board Wires GTR9 9 07 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 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 F Draft
76. nnovative Solutions GTR9 9 07 Note Apart from the string potentiometer 2 56 UNC cap head screws and the ARS optional angular rate sensors which use 40 80 cap heads all the leg screws are metric Transport Case Table 1 Contents of the tool kit 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 1 3 Screw Abbreviations DESCRIPTION Table 2 Screw abbreviations 1 4 Torque Requirements DESCRIPTION TORQUE Nm Leg attachment to knee front M8 BHCS 8 Leg attachment to knee rear M8 MSSFP All segment M6 BHCS shoulder link screws M10 Table 3 Torque Requirements GTR9 9 07 1 5 Recommended Spares Cover inner femur Cover inner femur Cover inner tibia Cover outer tibia 1 1 1 1 2 3 3 Volt DAS system only Cable assy 150mm STR POT L to 7 pin male 3 3 Volt DAS system only 133 5017 2 133 5516 61 503 05 01 00 Table 4 Spare Parts List GTR9 9 07 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 acceleration in the knee bottom knee tibia block in impact direction The standard instrumentation channels are listed in Table 5 The channels intended for injury assessment are the 4 t
77. o 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 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 68 locate against the spacer bone contact thin 133 5507 see Figure 59 and push this assembly centrally into the gap
78. 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 9 07 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 User Manual FLEX PLI GTR Rev F Draft Page 30 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 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 itr pi n Figure 25 Fixing M BUS Wire to Launcher 2 6 2 24 Channel M BUS Four six channel loggers can be
79. or Dynamic Testing and Car Test Information GTR9 9 07 1 2 Tools and Recommended Spares Several types of standard tools are used in the assembly and disassembly of the dummy T handle wrenches Figure 1 and hex wrenches 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 I 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 11 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 Figure 2 Hex Wrenches San ae ETE m Figure 3 Ratchet offset wrench with hex bits kit An 8 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 along with 133 8129 figure 6 are provided with the leg as part of the tool box M 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 12 of 103 02013 Humanetics Innovative Solutions GTR9 9 07 Figure 4 Leg wire setting tool 133 5112 Figure 5 Knee spacer tool 133 5113 Figure 6 Tibia and Femur base tool 133 8129 NN 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 13 of 103 2013 Humanetics I
80. otect zipper and to prevent zipper coming undone T i D zi E TF v Lr LL o D im se e mr ome T o pian UO m a N Sere A Il i y a UN ges mia Se uno T cr ee R fumes Rut Zda c EU esc P ERU WR M ELI EPOR ie VE on Sl 2 we x Pt E ze LP T TS Er ow s x e Mr xg d y E i FE JE de i An TM z bie hf ETT Ve etl am Um VIH L Figure 76 Leg with outer cover fitted d zl NT 3 4 5 Flesh 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 M8 screws and set screws connecting the femur and tibia to the knee The leg parts can then be pulled out of the knee I 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 72 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 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
81. ouching the impact cover Each bone assembly is loaded to 380 Nm Check deflection moment output must be inside corridor see Figure 82 and 83 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 81 Bone Assembly Fixture femur shown under bending 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 81 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 400 390 300 250 200 150 Moment Nm 100 JO O O 5 10 15 20 25 Deflection mm Figure 82 Femur assembly certification corridor moment vs deflection showing typical results 400 350 300 250 200 150 Moment Nm 100 50 0 E e O sa 0 10 20 30 Deflection mm Figure 83 Tibia assembly certification corridor moment vs deflection showing a typical results GTR9 9 07 7 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 80 Temperature for this test must be between 20 2 C Locate the femur insert into the femur knee
82. peration requires the use of a materials testing load frame machine with high definition load cell and calibration fixture 133 8120 Before testing a 3 to 7 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 78 Figure 78 Example of fixing Teflon sheet to base plate Assemble the bone to the 133 8120 fixture see drawing Figure 79 for details Place the assembled fixture over the Teflon sheets see Figure 81 Do not tighten the two cap head screws item 7 in Figure 79 at the end segments of the assembly to allow free rotation a o S o v PENES 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 78 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 iji TEE COTE PAT SECHEST a INIT Lect oe Figure 79 Bone and knee fixture 133 8120 for static assembly bending test femur shown GTR9 9 07 Figure 80 Static certification fixture 133 8120 showing knee 2 500005 WASHER FLATM10 0 1 133 8105 KNEELOADNGPROFLE Table 15 Parts List for static fixture 133 8120 GTR9 9 07 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 eguipment The loading spigot is at zero load just t
83. potentiometer pull wire length 1mm GTR9 9 07 Section 5 Storage The blue plastic material used to make a number of leg parts can absorb moisture in high humidity environments The water absorption can weaken these parts and make them expand a little This weakness however should not affect the function of the Flex PLI but as a precaution if the leg is being used in extreme environmental conditions it should be stored in a humidity controlled room or chamber or placed in an air sealed container or bag to prevent water absorption The Neoprene and rubber covers should always be removed from the leg when not in use to prevent stretching and indentation of the covers All leg components should be stored as close to the test temperature conditions 16 to 24 C as possible to allow the leg to reach require temperature during its 4 hour soak time Section 6 Weight Specification Leg Part Weight kg Weight Tol kg Table 13 Flex PLI GTR Mass If off board DAS is used knee has 0 1 kg allocated for cables Includes tape and Velcro straps The Flex PLI assembly mass and tolerances are given in Table 13 For dynamic certification tests pendulum and inverse as well as regulatory vehicle tests the leg must comply with the given limits GTR9 9 07 Section 7 Calibration and Certification Testing 7 1 Calibration and Certification Overview Certification of the FLEX PLI GTR requires nine different procedures to ensure certified pe
84. rformance 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 14 Table 14 FLEX PLI GTR certification steps Step Description When Reguired Pass Fail Reguirement Femur Gauge 1 Annually recommended 1 1 0 linearity full scale Calibration 2 After exceeding injury thresholds 10 2 2 0 hysteresis full Tibia Gauge for FLEX GTR in an application test scale Calibration recommended all gauges String 1 Annually 1 0 VRCI P 100A Potentiometer Calibration Ca Dl a Calibration 1 Annually recommended 1 Femur centre bending Bending Test 2 After exceeding injury thresholds moment deflection corridor 110 recommended 2 Tibia centre bending 3 After maintenance and or component moment deflection corridor exchange recommended 1 Annually recommended 1 MCL moment 2 After exceeding injury thresholds elongation corridor 110 recommended 2 ACL and PCL moment 3 After maintenance and or component elongation corridors exch
85. rings Replace the washers on the wire to keep them together 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 133 5302 to the femur block Now unscrew the four M5 Nyloc nuts holding the central cross wires and remove the four washers and smaller springs from the tibia block Lift the femur block away from the tibia block The fitting on the end of these wires can catch on the hole in the counter bore so the cables may require some realignment to free them Remove the wires and 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 screws should have been thread locked in so may be stiff If the string pots need servicing remove wire retaining clamps and unscrew the 22 56 cap screws fixing the pots Take note to check there has been no slippage on the crimps on 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 77 3 3 2 Knee Assembly Make a note of the string pot serial numbers and the
86. rk 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 1 33 9900 User Manual FLEX PLI GTR Rev F Draft P Wu vw v X sa Cr bi sine ve Solutions AT 2013 Humanetics Innovati aja 27 nf 402 GTR9 9 07 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 The 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
87. s Physical Filter Description ategory Object Tum oxi 5 i ur Ion Dimension Class Femur Upper X standard FEMR UP PF MO X e Femur Middle X standard FEMR MI PF MO X e Femur Moment 1 Lower X standard FEMR LO PF MO X C a Stee ee o e om se se se se a PR 4 Elongation standard KNEE LC PF DS Z C ERE seti o o me se o me o a co 5 Elongation standard KNEE AC PF DS Z C Stee see Co o bem m oe e me a PR Elongation standard KNEE PC PF DS Z e Gengaton standard Elongation standard MC PF DS Z C Upper standard 1 Upper X standard Tibia Moment 2 Middle Upper X standard Tibia Moment 3 Middle Lower X standard tower standard 4 Lower X standard Knee Bottom m 12 standard qme i TA additional TIT Top E additional Femur Top ELT additional Tm Segment 1 Acceleration Y additional Femur Segment 2 Acceleration Y additional Femur Segment 3 Acceleration Y additional Femur Segment 4 Acceleration Y additional Femur Segment 5 Acceleration Y additional xi N 10 11 6 tr Er S aJ HJ Ud GTR9 9 07 Femur Segment 6 ee additional Knee Upper on additional Knee Upper ae additional FEMR 06 o o TU Hj KNEE Gh go HU tj gt KNEE G TU trj na O nea gro el additional nea Upper s rs Rate NM additional e Upper ee Rate 26 additional nes Upper oo Rate 27 additional ess
88. s 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 leg was intended to remain the same to ensure existing test data was still valid The components of the leg consist of a segmented femur with a suspension bracket at the top a knee consisting of two aluminium blocks connected together with wires and springs a segmented tibia as per the femur and a flesh system of rubber sheet and
89. 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 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 55 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 60 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 9 07 Figure 60 Bone exit cable restraint use cable ties ties not shown trimmed or tightened 3 2 3 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 M 133 9900 User Manual FLEX PLI GTR Rev F
90. stem set up Me Sensors Hub B m LED Quick Release sensor 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 NN 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 39 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 2 9 KT 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 reguires 5 0v input at 600mA during operation using USB communication 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 US
91. t Remove outer skin and flesh after each test If a test is to be repeated the leg should rest for 30 minutes minimum before repeating If another flesh set is used the test does not need to wait 30 minutes GTR9 9 07 10 3 Injury Thresholds There are 7 injury channels in the GTR9 regulation the thresholds for these are listed in the table below Instrument Channel Channel Qty Threshold Value Tibia Moments 340 380 Nm MCL Elongation ACL Elongation 01 Bem _ PCL elongation 1 Bem Tea 7 j A4 Table 19 Threshold values for injury channels Injury threshold applies to relaxation zone stiff areas of the bumper like tow hook locations max 264 wide This 380 relaxation threshold can be restricted in a contracting party s domestic legislation if it decides such restriction is appropriate 10 4 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 15 Nm 30 ms before impact and for knee ligaments MCL ACL PCL elongations are recommended to be less than 1mm If there are oscillations in the leg when fired adjusting the height of the bone pushing pads on the launcher plate should prevent this The thicker Neoprene 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 a
92. t 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 4 The leg is lifted up to the release mechanism and held in position using the steel wire rope loop attached to the ballast weight The rope has been made so that the angle of the leg before release is 15 above the horizontal Check once more the angle with a digital inclinometer on the back of the knee The steel rope is tied to the ballast weight via an eye bolt which can be used for fine height adjustment 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 5 Arm the DAS system and release the leg The trigger for data collection can be from the accelerometer on the leg started manually or from a speed gate After initial impact the leg will continue to bounce where possible the leg should be caught or stopped
93. t 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 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 certification timing for gage calibration is stated in Table 14 4 8 3 String Potentiometer Maintenance The timing for sensor recalibration is stated in Table 14 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 Be 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 77 String
94. ter 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 stated in the GTR9 9 07 GTR 9 regulation Femur corridors are also shown for functional guidance only The leg should be tested with it s on board DAS to obtain complete certification of the tool 9 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 GTR9 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 block A schematic of the test set up is given in Figure 96 Hanging System Z axis release the FlexPLI within 10 ms after the moving ram impact Y axis X axis Hanging Bracket tilted 15 towards ram FlexPLI with Flesh cross sectional image Moving ram Total mass 8 15 0 1 Kg incl honeycomb Impact speed 11 1 0 2 m s Impact face Moving ram guide Honeycomb Crash strength 75 10 psi Figure 96 Diagram of Dynamic Inverse Certification Test set up 9 3 Preparation of the Inverse Test set up The linear guide impactor face is covered w
95. the femur knee block This configuration is shown in Figures 48 and 49 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 EINEN uuu NEM NU MENS 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 44 of 103 02013 Humanetics Innovative Solutions GTR9 9 07 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 battery in the leg form is simultaneously charged when reconnected Front side and rear side of the 24ch standard system with four Kyowa6 units is shown in Figure 51 and 52 DATA LOGGER DIS 506A Figure 51 Kyowa Front side in 24ch I 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 45 of 103 2013 Humanetics Innovative Solutions GTR9 9 07 KYOWA DATA LOGG
96. the front tape blue impact covers and the side covers LJ o ovo o NN RN E UE 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 62 of 103 2013 Humanetics Innovative Solutions 3 4 GTR9 9 07 Tibia Exploded View ye jw 83 G G t Figure 67 Tibia Assembly Exploded View 133 9900 User Manual FLEX PLI GTR Rev F Draft Page 63 of 103 02013 Humanetics Innovative Solutions GTR9 9 07 QTY PART NO DESCRIPTION 3 1 133 5503 BONE CLAMP THIN FEMUR TIBIA SHIM BONE CLAMP 4 THICK 6 1 133 5506 BONE CLAMP THICK KNEE 8 1 133 5508 BONE CLAMP THIN KNEE Z 9 1 1328309 SHIM 04 THC aE O 12 7 1335534 INNER SEGMENT ASSEMBLY 18 1 133 5535 INNER SEGMENT ASSEMBLY CLOSES TO KNEE L 1 1 __ 133 5614 INNERSEGMENLKNEE 00000000 133 5515 ig 4 19 510 WASHER ZIDX3BODXS 8 133 5521 WASHER CABLE 32 5000465 SCREW BHCSM6X1X18 5e 4 5000522 HEXNUT M5X0 8NYLOK ZZ 1 133 5516 END COVER gt _ S O 4 5000814 SCREW BHCS M5X0 8X8 o 4 5000393 SCREW SHCSM3X 5X6 U OO 2 5000769 SCREW MSSFPM8X16 8 133 5025 TAPE IMPACT SEGMENT Z 1 133 5028 TAPE END COVER 12X24 O 4 133 5027 TAPE END COVER 10X12 2 133 5026 TAPE ENDCOVER 12X18 1 133 5519 COVER END IMPACT KNEE END 8 133 5517 IMPACT SEGMENT 1
97. ure 61 and the wires are in their correct aligned holes and not crossed over Carefully turn the whole assembly over and locate the remaining 012 springs over the wires Fit all four washers and Nyloc nuts tighten nuts down until the washers are exacily flush with the Femur block Two wrenches 8mm and 1 8 are reguired to tighten nuts Humanetics recommends that the Nyloc nuts are only used twice after first disassembly after that new nuts should be fitted Fix the attachment plate with 2x M3x8 countersunk screws and remove the spacer blocks It may be necessary to remove a spacer block to access the screw 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 5318 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 Figure 65 Attachment plate crimp wires in tension with spacers ready for knee femur block assembly a Figure 66 Cross wire feed through on knee 3 3 3 Assembly After Certification The remaining parts are fitted at the final leg assembly stage see 3 1 2 These are the single channel accelerometer to impact side of tibia block
98. 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 9 07 Y 39 a SECOLE Figure 88 Exploded view Dynamic Rig part nr 133 8400 900 User Manual FLEX PLI GTR Rev F Draft Page 87 of 103 2013 H in Bis Innovative Solutions GTR9 9 07 GT DESCRIPTION LEFT BASE SUPPORT WELDMENT BASE CROSS BAR WELDMENT RIGHT BASE SUPPORT WELDMENT PIVOT CROSS BAR WELDMENT IMPACT BAR WELDMENT A FRAME SUPPORT A FRAME SIDE SUPPORT TOP CROSS MEMBER NUT PLATE WASHER FLAT M12 13 0 ID X 24 0 OD X 2 5 THK 4 SCREW SHCS M8 X 1 25 X 70 2 SCREW SHCS M12 X 1 75 X 30 4 SCREW SHCS M10 X 1 5 X 16 10 SCREW SHCS M10 X 1 5 X 30 9000552 WASHER FLAT M8 8 4 ID X 16 0 OD X 1 6 THK 9000486 HEX NUT M8 NYLOK 133 8419 PIVOT CLEARANCE BLOCK 9000785 SCREW SHCS M10 X 1 5 X 120 Y 20 12 0 13 1 15 1 O ble da fl ele ru 9 PIVOT HINGE 20 SCREW SHSS M12 X 50 2

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