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1. CI SN MUS TL 47 v ci j Y AS D bw 7 DESCRIPTION vas HEADFURM CALIBRA TION 28 40225 LUMBAR SPINE amp NECK DUMMIES 5 7 2650 i Copyright 2007 First Technology Safety Systens Inc Figure 18 Head form 6 1 26508 BALANCE WEIGHT 8 2 5000628 SCREW SHCOSSSM5X 8X40 9 2 6002209 GL60 10k 354 HOLLOW SHAFT POTENTIOMETER 18 1 TE26507 ROD o O The total mass of the head form should be 2 69 0 05 kg including the instrumentation The interface to the part 572 pendulum should weigh 0 95 0 02 kg The neck or lumbar spine is attached upside down to this pendulum A head form is used to load the neck or lumbar spine This head form consists of two flat disks connected by an interface which allows certification of both the neck and
2. 2 3 FEO ES 7 2 4 9 2 5 a BY UP MEI EM EMEND 9 2 6 9 2 7 DUN RR 10 n 3 1 MID ELE 3 2 case 3 3 Accelerometer VIO ES eco etii poteit E ec M bera eec eta ec Lose iet Mea 12 3 4 Angular Velocity ve eaten E 14 3 5 Cable TOUUNS DEOEeCHOR ns octo Ioa 14 Assembly Disassembly 5 4 1 Vel N 15 4 2 15 4 3 17 4 4 20 4 5 spine and ADGOITIED 28 4 6 31 4 7 32 4 8 34 4 9 H 36 x EE Pe 36 5 Pretest CHECKS E 37 Contents 9 5 1 37 5 2 SCOPS GING Arm 39 5 3 Time Interval DetWeell 39 Dummy Parts List and Recommended Spare Parts 40 6 1 40 6 2 Recommended Share 43 Certification EqQuiDMe i ETO EEEO 44 7 1
3. Part No Part No pida P Left Right Assembly Arm assembly L or R 020 9300 020 9400 Upper Arm Assembly L or R 020 9301 020 9401 020 9305 020 9301 020 9401 5000328 c9 CY er A oo be 7 020 9901 2 020 9909 020 9302 020 9402 Figure 15 Arm Assemblies Assembly and Disassembly Disassembly The arm should not need dis assembly under normal circumstances If the arm needs to be removed from the dummy then follow the procedures described in section 4 4 Remove the upper arm at the clavicle scapula section 2 Remove the spring plunger 5000328 and motion stop screw 020 9901 3 Remove the shoulder screw connecting upper and lower parts of the arm Assembly Perform steps 3 under assembly in reverse order 2 Check that the rubber end stops are in the correct position inside the elbow joint before assembly of the lower arm 3 Align upper and lower arm at the shoulder screw hole and screw in shoulder screw 4 Place upper and lower arm under a 90 angle with respect to each other 5 Turn the motion stop screw into the arm as far as it will go Then turn back half turn and check that the motion of the lower arm is without significant friction The correct position for motion stop screw is the inside of the arm 6 Screw in the spring plunger in the hole next to the shoulder screw at the outside of the arm 7 Check the correct settings for the spring plungers see chapter 5 D
4. Dummy Shoulder Swivel Assembly 020 3000 24 Figure 10 IR TRACC attachment hardware spine 26 Figure 11 IR TRACC attachment hardware rib cage 27 Figure 12 Q3 side impact 1 arrangement 28 Figure 13 Tighten nut down on the lumbar ec oor uid tx 29 Figure 4 Dummy Abdomen Lumbar Spine and Pelvis parts of 020 4000 Error Bookmark not defined Figure 15 PATI 35 Figure 16 f 35 Figure 17 Q series neck and lumbar spine head form test set up for frontal 45 Figure 18 Q series neck and lumbar spine head form test set up for lateral 45 Figure 19 Head TORI DOLOS mE 46 Figure 20 full body impactor accelerometer not cece eee 48 Figure 21 Full body pendulum impactor suspension wire 49 Figure 22 Frontal Head drop certification set up 51 Figure 2
5. Figure 23 Q3 neck certification test set up for frontal test Data Processing Filter the pendulum acceleration at CFCI 80 2 Filter the potentiometer readings at CFC600 3 Filter the load cell readings at CFC600 4 Determine time zero of the impact by finding the g deceleration level in the pendulum signal after software filtering 5 Software zero all transducer readings by averaging the part of the signal before time zero and subtracting this from the transducer reading 6 Integrate the pendulum acceleration to check the deceleration velocity of the pendulum The velocity of the arm must be calculated at a point 1657 4 mm from the pendulum pivot point 7 Sum the potentiometer signals to derive the total head angle of the head form relative to pendulum arm Requirements The impact velocity should be between 3 8 and 4 0 m s 2 The pendulum velocity decrease should be as indicated in the table below Lower limit m s Upper limit m s 1 S 13 To meet the requirements of the frontal neck certification test 3 The maximum head angle first maximum should be between 53 5 and 66 5 degrees The peak moment shall be between 18 50 and 23 00 Nm Lateral Neck Test Set up 2 Assemble the complete neck Attach the IF 217 6 AXIS LOAD CELL and 2650 11 SPACER FLEXION HEAD FORM the head form Slide the head form over the neck and attach with 4 M5 x 12 SHCS Attach the neck to the
6. Q3 Advanced 3 year old child User Manual 020 9905 User Manual Q3 Advanced 3 year old child Rev C Page 1 of 65 2011 Humanetics Innovative Solutions P U RA A QD 5 I U edi D wm Cn 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 734 451 7878 Fax 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 2011 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 E Y 3 List K 5 le 6 2 General Description and Features iode sere e sees so pao eoa aoa eaa Pe Re sb Ee ee EORR Eee Sa eaa oos 7 2 1 Design LOY EA 2 2 ADOL
7. EE 0207011 PelvisAssemblyFrontal Ji o o 020 7001 Pelviscastingmachined 1 0207010 1 1 3 J OS 020 7100 Hip Joint Assembly LH pu pM 020 7101 HipJointLowerLH i s 0207102 Hip Joint UppertH i 0207103 DetentPeg 0207104 Spring Retainer Plate Tt 500050 Spring amp 3 34 50040 MaxsBHCS 1 2 5000098 020 7110 Hip Joint Assembly RH Tt 0207105 HipJointtowrRH i 0207106 HipJointUpperRH i 0207103 DetentPeg 1 020 7104 Spring Retainer Piate Ji 500060 50040 6 a2 5000098 6 S2 EL c Jod 020 8000 Suit i Qty per Description dummy 020 9100 LeftLeg Assembly 1 i 0209101 UpperLeftLegAssemby Ji 3 020 9102 LowerLeftLegAssembly tT 020 9908 ShoulderScrewModified Knee 1 020 9901 StopScrew ee Upper Right Leg Assembly Lower Right Leg A
8. s on the special mount IT 900 3 5 Cable routing and protection The Q3 dummy transducers have been designed and selected for use with small cross section cables These cables do not need much space and ensure minimum interference with the kinematics of the dummy In the design of the Q3 dummy paths for the transducer cables have been defined The general rule is that all cables should be routed towards the thoracic spine of the dummy Cables should run from the top to the base of the thoracic spine At the lumbar spine thorax interface the cables go either towards the left or the right side The abdomen has been formed to allow the routing of the cables in such a way that they lie recessed between the rib cage and the pelvis skin A cable guide 020 441 cover is mounted on the back of the thoracic spine 4 Assembly Disassembly 4 1 General Overview The Q dummy consists of the following main components e head e neck e thorax e lumbar spine e abdomen e pelvis e arms e legs The dummy is dressed in a tight fitting suit This suit is an integral part of the dummy and should be worn during all tests A full description of the instrumentation capabilities is given in section 3 The tools needed for assembly and disassembly of the Q3 dummy are e screwdrivers e metric hex keys 4 2 Construction The head assembly consists of the following parts see also Figure 5 Head rear assembly 02041025
9. 44 7 2 E LI ADI MM 44 7 3 Egu Prent RONS 49 Certification Tests c si RII UIS I E 50 8 1 Fead Certii dtiol 50 8 2 IC OUOM of 52 8 3 Of the 56 8 4 Cerulicaon or the ADOODIe sitio deett tore EET ddr EA LAE 61 8 5 Cenincauon of 62 Referentes 64 List of Figures Figure Q dummy family from left to right 1 5 Q3 Q0 Q6 and 6 Figure 2 Accelerometer mounts for Q3 2 ioca uds cp ue usua tae 13 Figure 3 ARS 0I left and ARS 06 flanged version 14 Figure 4 DTS ARS s on the special mount IT 900 14 Figure 5 Head Assembly including ee eae nnne 16 Figure 6 Q3 Dummy Neck 35 ty tx eas td 18 Figure 7 Dummy Head Neck Assembly nene nennen nnn 20 Figure 8 Thorax Assembly Part of torso assembly 020 4400 22 Figure 9
10. ScrewsBHCSM5x1l2 500060 4 Load Cell structural replacement 020 2007 1 ScrewFHCSMSx10 5000084 Accelerometer mounting base standard 020 1013 1 ScrewSHCSM8x40 500049 ScrewSHCSM3xi10 500019 2 The head consists of two parts the front assembly skull and skin and a rear assembly skull cap The rear assembly may be removed by unscrewing the four M5x12 button head cap screws located at the rear of the head The head skin and skull are molded together and cannot be separated Inside the head is a large cavity which may be used to mount various types of instrumentation The standard arrangement is to have the head mounting block bolted in the head which will accept 3 uni axial accelerometers Optionally a bracket for combined accelerometer angular rate sensor application 020 1014 can be used 020 1025 020 1014 optional 020 1013A standard 020 1020 020 2007 load cell structural _ replacement Screws 5000084 amp 5000565 S a e _ 220 NU Figure 5 Head Assembly including instrumentation Head instrumentation both accelerometer bracket arrangements 020 1013 standard and 020 1014 optional ARS version shown Assembly and Disassembly Disassembly The head is attached to the neck though the load cell or the structural replacement To disassemble the head first detach the load cell from the neck First remove the he
11. easy adjustment of the head in any orientation Position the head in such a way that the mid sagittal plane has an angle of 35 2 degrees with the horizontal axis and the anterior posterior axis is horizontal degrees This corresponds to an angle between the horizontal plane and the head base plane of 55 2 degrees see Figure 22 When released the head should impact the surface with the side of its head 3 The lowest point of the head should be 130 mm above the impact surface 4 Release the head 5 The minimum time interval to observe between tests on the head is 30 minutes Figure 22 Lateral Impact Head certification set up rear view of head Data Processing All three accelerations should be filtered at CFC 1000 2 Determine the resultant head acceleration Requirement The maximum resultant head acceleration response should be between 100 and 130 g 2 The acceleration in X direction should be between 20 and 20 g 8 2 Certification of the Neck General The neck test is a component test which is performed using a pendulum as defined in CFR49 part 572 To certify the Q3 neck remove it from the dummy The complete neck consists of the following parts Neck Molding 020 2101 Neck Cable assembly 020 2200 Screw FHCS x 8 5000116 The neck is attached upside down to this pendulum A head form is used to load the neck This head form consists of two flat disks connected by an interface which
12. is a component test The abdomen should be removed from the dummy The test equipment is described in paragraph 7 2 To test the correct performance of the dummy abdomen an Additional mass is placed on the top plate Instrumentation The only instrumentation necessary to perform this test is a tape measure or calliper rule to measure the distance between the two plates Equipment required Top plate mass 2 05 0 05 kg Additional mass 8 05 0 050 kg Total mass 10 10 0 050 kg Abdomen support block part no TE 020 9910 Description Additional mass Total mass Figure 27 Abdomen certification test set up Test Procedure Place the abdomen on the appropriate Q3 abdomen certification support block TE 020 9910 Ensure a good fit and orientation of the abdomen over the block Lower the top plate with a mass of 2 05 0 05 kg on the abdomen Determine this point as zero for the displacement measurement 2 Place the additional mass 8 05 0 05 kg on the top plate this mass differs for the QI QI 5 and Q3 Q6 dummies Let the force exerted by this mass apply as indicated in Figure 27 This must be done within 10 seconds after placing the initial load Let the top plate compress the abdomen for a period of 2 minutes 0 sec 4 Read the displacement measurement UJ 5 Remove the mass and top plate 6 Observe an interval of at least 30 minutes between successive tests on the same abdomen D
13. per Description dummy 020 3000 Shoulder Swivel Assembly J2 020 3002 ShoulderSwivelBody 2 020 3005 ShoulderRetainingCap O J2 gt 4 5000328 M8 Spring Plunger o Je 3 J 0207103 DetentPeg 1 1 2 J 50006560 SpingtCMosoF1MWW 50006581 ti2mmlntemalCicinp J2 3 3 5 5000065 M4xi2BHCS a8 EE 020 3100 Scapula Moulding Rigt Ji 020 3101 Scapula Moulding Left dep 020 3201 Clavicle Moulding Fronta Dummy tT p E e 020 3310 Shoulder Spine Interface assy RH rubber 7 020 3320 Shoulder Spine Interface Assy LH rubber 1 5 pue p xul eu 0205000 Abdomen Test Cert amp 5 produ 020 6000 Lumbar Spine Assembly TESTEDANDC 1 020 6001 Lumbar Spine Central Moulding Ji S 020 9902 Lumbar Spine MountingScrew J2 020 6100 LumbarCableAssemby 1 3 500003 M Nylocnut 1 5000094 je PlinWaser i 4
14. protection in case of lumbar spine damage or failure The abdomen is full foam part covered by a plastic skin The parts of the lumbar spine and abdomen are listed below see also Figure 13 Description Qty in Assembly Lumbar Spine Assembly tested and certified 020 6000 Lumbar Spine central molding pre tested 020 6001 Lumbar Cable 020 6100 1 M6 nut self locking 5000093 LN M6Plain Washer 500094 1 Load cell structural replacement 0202007 Screw SHCS M5x12 0 5000002 4 ScewFHOSM5x10 1 5000084 4 X Assembly and Disassembly Disassembly Remove the upper torso by removing the two M6 x 43 screws at the thoracic spine lumbar spine interface 2 Remove the abdomen from the lower torso 3 Remove the four M5 x 12 countersunk head screws which are used to fasten the load cell or structural replacement to the pelvis 4 Remove the load cell or load cell structural replacement from the lumbar spine by removing the four M5 x 12 socket head cap screws The cable assembly should not need to be removed under normal circumstances If it becomes necessary use a screwdriver in the slot at the top of the cable to prevent the cable from turning and unscrew the self locking nut with a wrench In the steel cable there is no pretension required the nut should be tightened up until the play between the cable and neck is eliminated Tighten nut until there is no gap between the nut a
15. replace broken parts To separate the lower from the upper leg Remove the motion stop screw 020 9901 located on the inside of the knee joint 2 Remove the M5x20 socket head shoulder screw 5000626 connecting the two parts of the leg Assembly 2 3 Check that the rubber end stops are in the correct position inside the upper knee joint before assembly of the lower leg Align upper and lower leg at shoulder screw holes and screw in shoulder screw Before inserting the motion stop screw place upper and lower leg in a 90 angle with respect to each other Turn the motion stop screw into the leg as far as it will go Then turn it back half a turn and check that the motion of the lower leg is without significant friction Instrumentation No 4 8 instrumentation is used in the legs Arms Construction The arms consist of an upper and lower section connected at the elbow with a joint At the upper end a shoulder joint allows a number of degrees of freedom The main joint is of the ball and socket type with a limited range of motion The upper arm can rotate around its vertical axis Furthermore the entire arm can rotate around the shoulder lateral axis At the elbow joint the range of motion is limited At the end of the range of motion rubber stops in the joint ensure a smooth arrest of motion This prevents hard contact and reduces spikes on measurement signals The parts of the arms are listed below
16. the lumbar spine The head form has different configurations one for testing the neck and one for testing the lumbar spine e For testing the neck the large end of the central block is facing towards the pendulum arm and a steel disk is assembled between the neck and the central block see 16 left and 17 left When testing the neck a load cell IF 217 or load cell structural replacement is mounted between the neck and the head form see 16 left e For testing the lumbar spine the discs need to be removed and mounted on the central block upside down Consequently the large end of the central block is facing away from the pendulum The lumbar mounts directly to the small end of the central block In the lumbar spine test no load cell or load cell structural replacement is required between the lumbar spine and the head form see 15 right and 16 right Two rotational potentiometers are used to measure the angle of the head form relative to the pendulum arm One potentiometer is attached to the pendulum interface the other to the head form see 16 andl7 A thin rod connects the potentiometers The rod should be fixed to the head form potentiometer using an M3 set screw but be able to slide freely through the hub on the axis of the pendulum interface potentiometer The rod must be protruding from both potentiometer axes equal length A balance mass is attached to the opposite side of the head form to assure symmetrical loading of the neck and lu
17. up to the play is eliminated Abdomen The abdomen should be checked periodically 10 tests for tearing of the PVC skin Note that the wear of the abdomen is reduced by observing the proper installation procedure First remove the upper torso The abdomen can then be removed by simply lifting it out of the pelvis Arms Check the friction setting of the shoulder arm regularly Check the spring plungers in the elbows See paragraph 5 2 for instructions Cable Routing Always provide sufficient slack in the cables to allow the dummy to deform without putting any strain on the cables This is especially important for the instrumentation located in the head accelerometers load cell Please note that the slack can cause the cables to snag behind some other object in the test set up which can result in damage of the head instrumentation Dummy Certification Besides the inspections to be performed before each test as described above the dummy should be regularly certified to check its performance It is advised to certify the dummy regularly as described in chapter 8 020 9905 User Manual Q3 Advanced 3 year old child Rev C Page 38 of 65 2011 Humanetics Innovative Solutions 5 2 Click Stops and Arm adjustment Shoulder The upper arms can be put in two stable positions The first is vertically along the body the second one 20 degrees forward from the vertical Again the arms should be able to rotate freely until they reach the click st
18. 0 2 Set time zero at the g deceleration level in the Impactor signal after filtering with CFC600 software filter 3 Calculate the Impactor force by multiplying the Impactor acceleration in m s by the Impactor mass Requirement To pass the certification requirements for frontal thoracic impact The impactor velocity should be between 4 2 and 4 4 m s 2 maximum thorax deflection should be between 22 5 25 5 mm 3 The force at the maximum deflection should be between 0 90 and 1 10 Side Impact Thorax Test Instrumentation The dummy does not need to be equipped with the standard IR TRACC to measure the chest displacement It is recommended to remove the IR TRACC from the dummy to mount it in the side impact position Do not leave the IR TRACC in its frontal test position as the side impact test can cause damage to the IR TRACC Use the 3 80 kg test probe as described in section 7 2 equipped with an accelerometer to measure the impact deceleration The impact velocity must be measured and recorded This can be done with the speed vane on the test probe Test Procedure Dummy positioning dummy should be seated on a clean dry surface consisting of two 0 60 x 0 65 m flat plates of 2 mm Teflon sheeting e Place the dummy with its thoracic spine in a vertical orientation within 1 degree with the vertical To stabilize the sitting position of the dummy rotate the upper legs outwards toes po
19. 0006 02044341 A 1 Items marked are not shown in Figure 8 but in Figure 9 Shoulder Assembly Sy A a a REPO PPO 4 5000002 020 2015 020 2007 5000084 020 441 Screws 5000447 020 4405 020 4402 020 4403 020 4404 Screw 5000406 020 3000 020 3320 LH 020 3310 RH Screws 5000005 020 3101 LH 020 3100 RH Screws 5000386 5000139 020 3201 020 4200 Screw 5000374 020 4401 Screws 5000416 020 4100 020 4406 Screw 5000023 9002975 Spacers 020 4407 Figure 8 Thorax Assembly Part of torso assembly 020 4400 020 9905 User Manual Q3 Advanced 3 year old child Rev C Page 22 of 65 2011 Humanetics Innovative Solutions Assembly and Disassembly Disassembly Upper Lower Torso The suit should be removed for proper access to the thorax assembly 2 Remove the cable cover at the back of the thoracic spine 020 4401 3 The upper part of the body can easily be separated from the lower part of the body by removing the two M6 x 43 countersunk head screws located at the base of the thoracic spine First loosen the two bottom screws at the base of the rib assembly than unscrew and remove the M6 x 43 counter sunk screws The upper body can then be lifted from the lower part of the dummy when operating on the upper torso section of the dummy for example when installing or removing
20. 3 Lateral Impact Head certification set up rear view of 52 Figure 24 neck certification test set up for frontal 54 Figure 25 neck certification test set up for lateral test 55 Figure 26 lumbar spine certification test set up for frontal 58 Figure 27 lumbar spine certification test set up for lateral test 60 Figure 28 Abdomen certification test set nnne 61 Introduction In the late 1970s and early 1980s TNO and others developed the P dummies a series of child dummies that covers almost the complete child population up to 12 years The P series dummies are still test tools for the European regulation ECE R44 and are also adopted by many other standards In 1993 the International Child Dummy Working Group started the development of a new series of child dummies as a successor to the P series This new series was called the Q series As of September 2004 the series is available in four age groups representing a Newborn year 1 2 year 3 year and 6 year old child In 2004 a major update of the Q dummy series was performed resulting in th
21. I9 full body impactor accelerometer not shown The impactor is suspended as a guided pendulum by eight 7 x 7 stainless steel wires 2 mm diameter Figure 20 shows a front view of the impactor and four of the suspension wires in the required cross configuration A six wire configuration may be used where the front crossed wires are omitted A flat horizontal surface should be available to sit the dummy on The impact velocity of the impactor must be measured and recorded 020 9905 User Manual Q3 Advanced 3 year old child Rev C Page 48 of 65 2011 Humanetics Innovative Solutions M L Mr Figure 20 Full body pendulum impactor suspension wire diagram Abdomen Test Rig The abdomen test compresses the abdominal insert between a Q3 abdomen certification support block Part number TE 020 9910 and a flat plate The support block shape matches the shape of the inside of the abdomen The support is placed on a horizontal surface and the abdomen is placed on the block with the front outer surface facing up A flat plate should be placed parallel to the horizontal base plate on top of the abdomen The dimensions of this plate are 300 by 250 mm and the mass is 2 05 0 05 kg A scheme of the set up is shown in Figure 27 An additional weight of 8 05 05 kg is required 73 Equipment Parts List 020 1050 Head Certification Mass Q Dummies Head Drop Test 8 Certification Tests Besides the inspections to be performed before each
22. ONLY accept tri axial transducers with a side entry cable The following accelerometers and mounts can be used for the Q3 dummy Only uni axial accelerometers Accelerometer Type Head Mount only uni axial accels ENTRAN EGAS FS 50 KYOWA ASM 200BA ENDEVCO 7264 2000 7264 2000 ENDEVCO 7264A 2000 7264 2000 MSC 126M CM Figure 2 Accelerometer mounts for Q3 Tri axial Location Accelerometer Type Head Mount only TEN Pelvis uni axial accels ENDEVCO o Use Endevco Use Endevco 3 4 Angular Velocity Sensor Mounting The application of angular velocity sensors is possible in the head There are two options ATA ARS 0I or ARS 06 flanged version see Figure 3 with special mount block 020 101 4 The mount block 020 1014 consists of a base and three ATA ARS sensor blanks of similar weight and size Any of these ARS sensor blanks can be replaced with an ATA ARS OI or ARS 06 flanged version sensor The 020 2014 mounting block will accept the same mount block as the standard accelerometer mounting for the head I AD or see Figure 2 The ATA ARS sensor blanks should not be removed if there are no sensors to replace them Figure 3 ARS OI left and ARS 06 flanged version right 2 DTS ARS I2K with special combine accelerometer ARS mount FTSS part IT 900 on the standard bracket 020 1013A The sensor and the mount are shown in Figure 4 Figure 4 DTS ARS
23. Q3 Tolerance i Dimension mm mm Seating height head tilted forward Bb44 Shoulder height sitting 985 9 Chest depth Shoulder width maximum 259 9 Hip width Back of buttocks to frontknee 305 9 Back of buttocks to popliteus siting 0253 9 Measurements are valid for the dummy without suit f Chest depth is measured at the centre line of the fixation hole for the displacement transducer 2 6 Mass Distribution The table below shows the masses of the various components of the dummy The masses given include accelerometer mounts the IR TRACC and all screws and fixings Q3 Tolerance Head Neck incl acc mount Torso incl acc Mounts amp IR TRACC Ttal 4 140 0 40 2 7 Standard Dummy The standard Q dummy is delivered with the following items One piece of clothing a yellow suit Structural replacements in the location of the load cells One set of mounting blocks for use with uni axial accelerometers 3 Instrumentation 3 1 General The dummy accepts both accelerometers and load cells as standard instrumentation Angular velocity sensors DTS ARS and Applied Technologies Associates type 5 01 or ARS 06 flanged version can be fitted to the head this requires an alternative head accelerometer mount The dummy can be equipped with uni axial accelerometers for all locations Tri axial accelerometers can be used on the pelvis and
24. TRACC arrangement optional To use the IR TRACC IF 362 for side impacts the IR TRACC should first be equipped with its attachment hardware as shown in Figure 2 2 First mount the rod end mount base in the end of the IR TRACC and secure it with the M2 screw item 6 3 Attach the brackets item and 2 to each other using the M5 x 12 screws 4 Connect the IR TRACC rod end to the bracket using the shoulder screw item 4 and cone spacers item 3 5 Attach the rib attachment hardware to the top end of the IR TRACC 6 Remove two of the M5 button head rib cage attachment screws on the far side of the chosen impact side 7 Mount the bracket with IR TRACC on the side of the rib cage with the two M5 x 20 screws and attach the top end to the rib cage with two M4 counter sink screw 4 5 Lumbar Spine and Abdomen Construction The lumbar spine assembly consists of a rubber column with metal interfaces bonded to the top and bottom The top interface is U shaped vertical elements at the front and back The thoracic spine fits into this bracket and is secured using the two M6 x 43 screws At the bottom side four M5 x 12 cap head screws are used to attach the lumbar spine assembly to either the model IF 217 load cell or the load cell structural replacement 020 2007 The lumbar spine assembly has a cable fitted through the centre This is used to pre tension the spine to achieve the correct dynamic properties and as a security measure
25. ad rear assembly by unscrewing the four button head cap screws at the back of the head 2 The accelerometer array can be removed in order to reach the screws in the upper neck load cell or the load cell replacement 3 With the accelerometer array removed the M5 SHCS screws that attach the load cell to the neck can be reached through the top of the head 4 Remove the head and upper neck load cell or structural replacement from the neck 5 Turn the head upside down and remove the FHCS screws at the base of the head 020 9905 User Manual Q3 Advanced 3 year old child Rev C Page 16 of 65 2011 Humanetics Innovative Solutions Assembly The head can be assembled to the dummy by reversing the order of the disassembly Instrumentation Standard Instrumentation To install the accelerometers first remove the head rear assembly by unscrewing the four 5 12 button head screws 2 Remove the head accelerometer mounting block 020 1013A from the head cavity by unscrewing the three cap head screws The uni axial accelerometers must first be mounted onto a mounting block 4 Bolt the mounting block onto head accelerometer block using the two socket head cap screws supplied with the mount Mount the interface inside the head front assembly 5 Replace the head rear assembly and tighten the four bolts UJ Note As shown in the head assembly section it is advised mount the head onto the neck before placing the accelerometers i
26. allows certification of both the neck and the lumbar spine The head form rotation during the test is measured using two rotational potentiometers One is installed on the base of the neck pendulum interface the second one is attached to the head form Both potentiometers are linked with a thin shaft see Figure 23 and 24 The sum of the two angles measured on the potentiometers is the angle of the head relative to the pendulum Moment is measured using an upper neck load cell IF 217 mounted between the head form and the neck The data acquisition system and all instrumentation must comply with the requirements of SAE 211 All data channels should be filtered using a hardware filter prior to A D conversion according to SAE 211 The pendulum acceleration should be measured with an accelerometer which is located on the pendulum arm 1657 4 mm from the pendulum pivot in accordance with the CFR 49 Part 572 Frontal Neck Test Set up Assemble the complete neck as described in section 4 3 2 Attach the IF 217 6 AXIS LOAD CELL and 2650 SPACER FLEXION HEAD FORM the head form Slide the head form over the neck and attach with 4 M5 x 12 SHCS 3 Attach the neck to the pendulum interface plate 4 x M5 Place the modified 020 2015 TE 2650 9 intermediate plate between the neck and pendulum interface Align the neck and the interface making sure that longitudinal axis of the neck is in the direction of movement of the pendulum arm se
27. alue should occur between 126 and 146 ms from the time zero point Lateral Lumbar Spine Test Set up 2 Slide the certification head form over the spine thorax interface bracket Attach the spine to the pendulum interface plate Align the lumbar spine and the interface making sure that lateral axis of the head form is in the direction of movement of the pendulum arm see Figure 26 Also make sure that the bending direction of the neck in the certification is the same as the initial bending direction experienced in the test the dummy is being certified for LHS or RHS Attach the head spine system to the part 572 pendulum The side of the head form should point in the direction of motion of the pendulum see Figure 26 Lift the pendulum up to its pre test height and check that the head form is in the correct initial position Install the potentiometers to the mounting interface and the on the head form central block Mount the balance mass for the potentiometer on the other side of the central block This ensures that the inertial properties of the head are symmetrical in the impact direction Insert the rod connecting the axes of the potentiometers and tighten the screw on the bottom most axis to secure the rod to that potentiometer The other end of the rod should be able to slide freely through the upper most transducer axis The rod must be protruding from both sides of the transducers axes equal length The minimum time inter
28. ata Processing Subtract the final reading from the initial reading Requirement The deformation of the abdomen should be between 13 and 7 mm 8 5 Certification of the Thorax General A complete standard Q3 dummy must be used in this test The dummy is to be tested with the suit Prior to the test the dummy should be inspected for possible damage It is particularly important for the thorax tests to check the condition of the rib cage the shoulder spine interface and the clavicle No cracks or tears are allowed Also check that all screws have been tightened properly As the performance of several components will affect this full body thorax impact test make sure that this test is performed as the last test in the certification procedure where all dummy parts have passed their applicable certifications tests successfully The data acquisition system and all instrumentation must comply with the requirements of SAE 211 version March 1995 All data channels should be filtered using a hardware filter prior to A D conversion according to SAE 21 I version March 1995 Frontal Impact Thorax Test Instrumentation The dummy must be equipped with the standard IR TRACC to measure frontal chest deflection Use the 3 80 Kg test probe as described in section 7 2 equipped with an accelerometer to measure the impact deceleration The impact velocity must be measured and recorded This can be done with the speed vane on the test probe Test P
29. ation level in the impactor signal after filtering with CFC600 software filter Calculate the Impactor force by multiplying the Impactor acceleration in m s by the Impactor mass Requirement To pass the certification requirements for lateral thoracic impact The impactor velocity should be between 4 2 and 4 4 m s 2 The maximum impact force should be between 1 25 and 1 55 kN 9 References CREST Child Restraint System for Cars EC contract number C RTD SMT4 CT95 2019 1996 2000 CHILD Child Injury Led Design EC contract number G3RD CT 2002 00791 2002 2006 ASSESSING NEW CHILD DUMMIES AND CRITERIA FOR CHILD OCCUPANT PROTECTION IN FRONTAL IMPACT Kate de Jager Michiel van Ratingen TNO Science and Industry Philippe Lesire Herv Guillemot LAB France Claus Pastor Britta Schnottale BASt Germany Gon al Tejera Applus IDIADA Spain Jean Philippe Lepretre UTAC France Paper no 05 0157 Progress Report and Results from the NPACS Research Project R Lowne Third International Conference on the Protection of Children in Cars Munich December 2005 Manual Update Log Rev B May 2010 Pg 27 added These parts are included in the Q3 Side Impact Kit Rev C Sept 2011 Manual changed from FTSS to Humanetics
30. be worn during all tests To put the suit on first put on the lower half legs first and pull the pants section well into the crotch of the dummy Then put the arms through the sleeves of the suit and pull it upwards Close the suit at the back using the hook and loop fasteners Velcro The dummy does not wear shoes 5 Pre test Checks 5 1 Inspection Before performing a test a visual inspection of the dummy should be made Special attention should be paid to the following items Neck The rubber molded part of the neck should not be damaged that is it should be complete and not show any tear and wear By bending the neck slightly small cracks can also be detected The neck cable should be checked carefully to check that there is no visible damage to the cord Shoulders Periodically examine the shoulder to spine interface for damage Clavicle Inspect the clavicle for cracks in the material Rib Cage Check the rib cage for tears and cracks in the material Deform the rib by hand as this will show cracks if present Cracks can be hidden by PVC skin that covers the outside of the rib cage To find significant damage pay special attention to the rib cage edges Lumbar Spine The lumbar spine rubber should not be damaged Inspect the rubber molding for tears and cracks Replace if the spine is damaged The cable must be inserted and the nut at the top properly screwed on There is no pretension required the nut should be tightened
31. commended inspect the dummy as described in chapter 5 before each test and certify the dummy regularly as described in chapter 8 To safeguard continuous operation with the Q3 dummy it is recommended to take and maintain the following spare parts in stock 020 9402 7 Certification Equipment 7 1 Requirements The frequency of the Q3 certification and the number of tests that can be performed between certifications strongly depends on the type and severity of the tests in which the dummy is used as well as the test frequency Which certification tests have to be carried out depends on the dummy application ECE R44 NCAP Airbag and is different for frontal and side impact tests When used in side impact applications the dummy must be certified depending on the side of impact The dummy and dummy parts should be kept in the test environment at least 4 hours prior to the use in a test The testing laboratory environment should be controlled to have e atemperature of 20 2 degrees Celsius e arelative humidity of 40 3076 When conducting certification tests a time interval of at least 30 minutes should be observed between two consecutive tests This also applies when for example a lateral test is followed by a frontal test using the same dummy or dummy component When certifying the dummy a particular order of operation should be observed e first perform the component tests head neck lumbar spine and abdomen e then perform t
32. components or installing instrumentation it is convenient first to remove the head and neck see the paragraphs above for the procedure how to do this and then divide the dummy in two parts by removing the thorax lumbar spine screws This gives easy access to the internals of the upper torso and to the various bolts and screws Note to prevent unnecessary wear the rib cage and shoulders should not be removed from the thoracic spine under normal circumstances Arms The first step is to remove the arms To do so turn the dummy sideways At the back of the scapula are two countersunk M5x20 screws 5000386 Rotate the upper arm around the shoulder lateral axis until the screws become accessible Remove the first screw rotate the arm slightly and remove the second screw Remove the scapula by pulling it towards the back The arm may now be removed Repeat this procedure for the other arm Clavicle 2 clavicles are attached to the shoulder spine interface 020 33 10 020 3320 with a single M6xl6 countersunk screw 5000097 on each side Remove these screws 3 Remove the M5 x 12 countersunk head screw which is used to mount the clavicle retainer 5000096 and clamp the clavicle to the rib cage Rib Cage 4 Remove the rib cage by unscrewing the six M5 x 6 button head cap screws three on each side of the thoracic spine Shoulders 5 Finally the shoulder spine interfaces 020 3310 amp 020 3320 can be removed by unscr
33. e Figure 23 4 Attach the head form neck system to the Part 572 pendulum The front of the neck should point in the direction of motion of the pendulum see Figure 23 5 Install che potentiometers to the mounting interface and the on the head form Mount the balance weight for the potentiometer on the other side of the head form This ensures that the inertial properties of the head are symmetrical in the impact direction 6 Insert the rod connecting the axes of the potentiometers and tighten the screw on the bottom most axis to secure the rod The other end of the rod should be able to slide freely through the upper most transducer axis The rod must be protruding from both sides of the transducers axes equal length 7 The minimum time interval to observe between tests on the neck is 30 minutes Performing the test Attach honeycomb material to arrest the pendulum Proposed is to use sheets of 28 8 kg m with crush strength of 1 8 Ibs cu ft with a nominal length of 152 4 mm 6 inches 2 Auto balancing and shunt calibration of the transducer signals should be performed with the pendulum arm in the vertical position 3 Lift the pendulum up to its pre test height and check that the head form is in the correct initial position symmetric with respect to neck top yoke Do not leave the head neck system in this position for more than minute as the neck will start to deform due to the mass of the head form 4 Release the pendulum
34. e completion of the series from through The 1 5 dummy and the QO were added to the series and modifications were made to enhance durability and measurement capabilities Part of the development of the Q dummies has taken place within the European Research programs CREST 1 and CHILD 2 both aimed at improving child safety in cars FTSS reserves the right to make improvements or implement changes to the dummy the certification or the user manual if this is deemed necessary We will of course inform our customers of any changes or modifications as they occur Figure Q dummy family from left to right QI 5 Q3 Q0 Q6 and 020 9905 User Manual Q3 Advanced 3 year old child Rev C Page 6 of 65 2011 Humanetics Innovative Solutions 2 General Description and Features 2 1 Design History The development of the Q series directed by the International Child Dummy Working Group resulted Q3 dummy in 1998 followed by the addition of the Q6 dummy 1999 and the 2000 Based on customer feedback and test results FTSS has received comments on the dummies performance and durability This has resulted in an update program that was started in 2004 This update was aimed at a number of issues with the Q dummies in the shoulder and head neck area During this period the and 1 5 were added to the family based on Q series anthropometry and biofidelity data The European Enhanced Vehicle safety Committe
35. e performed an extensive evaluation program of the Q series in 2004 A full report on a possible recommendation for use of the dummies in ECE R44 tests is expected in 2005 Results of the first evaluations have been published at the 19 Enhanced Safety of Vehicles conference in 2005 3 In 2006 the New Programme for the Assessment of Child restraint Systems NPACS adopted the Q dummies for their test protocols 2 2 Application The Q6 dummy is suitable for frontal as well as side impact CRS evaluations to be used for both homologation consumer rating and research purposes Possible applications include Child Restraint Systems CRS testing This includes the European ECE R44 and the US FMVSS 213 regulations The Q dummies have been designed to succeed the P dummies in CRS evaluation regulations EuroNCAP tests The dummy has been designed to withstand impact with closing velocities up to an average EuroNCAP level NPACS tests The New Programme for the Assessment of Child restraint Systems NPACS protocols calls for the Q series for their frontal and side impact consumer test procedures for CRS performance rating 4 Out of position tests OOP including airbag interaction SO side impact procedure 2 3 Features The Q dummies have improved biofidelity over the P series Biomechanical information from children and scaled adult biomechanical response curves has been used to define the dummy response The anthro
36. ell first remove the load cell structural replacement To do so remove the head as shown above Remove the four M5 x 10 FHCS screws that attach the load cell to the base of the head assembly Remove the load cell structural replacement and install the load cell FTSS type IF 217 or IF 218 The round base plate should be facing up and the cable exits facing downwards at the rear and the back of the neck Fasten the load cell to the base of the head using the four 5 0 counter sunk head cap screws Assemble head and load cell onto the top of the neck using the four M5 x 12 SHCS screws Mount the head instrumentation in the head and close the head with the skull cap Note Always mount the upper neck load cell BEFORE the head accelerometers as the accelerometer array will block the top access to the screws through the head 5000654 020 1100 load replacement 020 2007 020 2100 5000003 Figure 7 Dummy Head Neck Assembly 4 4 Torso Construction The torso consists of a metal thoracic spine left and right shoulder assemblies a clavicle and a rib section The rib cage is made of a deformable synthetic composite The shoulders are connected with the clavicle element which attaches to the left and right shoulders and to the rib cage sternum The parts of the Thorax assembly are listed below 020 9905 User Manual Q3 Advanced 3 year old child Rev C Page 20 of 65 2011 Humanetics Innovative Solutions Th
37. erations Abdomen The abdomen is foam covered with skin Biomechanical data from children has been used to determine the required stiffness Lumbar Spine The lumbar spine is a flexible rubber column which allows shear and bending in all directions A six channel load cell can be mounted between the lumbar spine and the pelvis Pelvis The Q dummy pelvis has removable hip joints An accelerometer array can be mounted in the pelvis Special hip joints are available that allow to position the dummy in a standing position Legs The knee joints can be locked in any position This feature can be used to facilitate positioning the dummy in a standing position Note that the dummy does not have the ability to stand without support It must be placed against some object such as the dashboard 2 4 Instrumentation Options The complete list of instrumentation options includes 31 channels Head Ax Ay Az linear acceleration Head Wx Wy Wz angular velocity Upper Neck Fx Fy Fz forces and Mx My Mz moments Upper Neck Fx Fy Fz forces and Mx My Mz moments Thoracic Spine Ax Ay Az linear acceleration Thorax ribcage Dx or Dy deflection Lower Lumbar Spine Fx Fy Fz forces and Mx My Mz moments Pelvic Ax Ay Az linear acceleration 2 5 Main Dimensions The main dimensions of the Q dummy series are described below Note that dimensions have been based on a limited number of dummies and are subject to change Description
38. ewing the three 4 12 button head cap screws of each shoulder spine interface 6 The shoulder swivel assembly can be disassembled by removing the 4 M4 button head screws in the shoulder retaining cap Two holes are provided in the shoulder retaining cap to adjust the click stops in the shoulders as described in the pre test checks Assembly To assemble the thorax perform the operation described above in reverse order 500056 5000650 UL 020 7103 020 3002 5000328 020 3005 5000005 Figure9 Dummy Shoulder Swivel Assembly 020 3000 Instrumentation Standard Instrumentation Accelerometers The thorax can be equipped with three uni axial accelerometers or a tri axial accelerometer in the cavity located at the back and top of the thoracic spine The uni axial accelerometer must first be mounted onto the specified mounting block The tri axial accelerometer should be mounted using a mounting base Endevco type 23898 2 Use two SHCS M3 x 10 screws to attach the mounting block inside the cavity The longest side of the mounting base should be facing upwards Load cell To use the lower neck load cell IF 217 or IF 218 remove the load cell structural replacement 020 2007 If the neck is installed remove this first four M5 x 10 button head cap screws 2 Note that there is a Neck torso interface plate 020 2015 between the load cell structural replacement 020 2015 and the neck Remove the load ce
39. g three uni axial accelerometers or a single tri axial accelerometer In order to use accelerometers in the pelvis first mount them onto the mounting block the tri axial accelerometer should be mounted on a mounting plate Then remove the pelvis flesh as outlined in the paragraph above assembly and disassembly The mounting block should be attached at the inferior surface at the bottom of the pelvis casting with the long side of the base plate facing backwards The cables should be routed forwards when replacing the pelvis flesh 4 7 Legs Construction The legs consist of an upper leg and lower leg connected to each other with a knee joint At the hip side a ball and socket joint is used This joint should not be taken apart under normal operating circumstances In the knee joint a limited range of motion has been built in At the end of this range rubber stops are used to smoothly decelerate the motion and thereby preventing spikes on the measurement signals p Qty in each Leg assembly L or R 020 9100 020 9200 Upper Leg Assembly L or R 020 9101 020 9201 e Lower Leg Assembly L or R 020 9102 020 9202 Shoulder Screw SHSS M5 20 5000626 otop Screw 020 9901 ie be S 020 9101 020 9201 020 9901 t 020 9102 020 9202 rd N E d N s e E di E Figure 14 Leg Assemblies Assembly and Disassembly Disassembly It is not advised to disassemble the legs except to
40. he full body test on the dummy with the certified components thorax To perform the calibration tests certain equipment is required a head drop table a wire suspended pendulum for the full body impacts an abdomen compression device a part 572 pendulum and a Q series head form for neck and lumbar spine certifications 72 Equipment Head Drop Table For the free fall head drop test a support and release mechanism is necessary as well as steel plate with a thickness of at least 50 mm which will act as an impact surface This plate should be similar to the plate described in CFR 49 Part 572 Hybrid head drop test and should have equivalent roughness and size Neck and Lumbar Spine Certification Equipment A pendulum which meets the requirements of CFR 49 part 572 33 is needed to perform the certifications of the neck and lumbar spine see sections 8 6 and 8 7 The spine or neck is mounted upside down on the pendulum arm using an interface plate which replaces the standard part 572 pendulum mounting plate To load the part a head form is used which is shown in Figure 16 7 and 18 Figure 7 Q series neck and lumbar spine head form test set up for lateral test DESCRIPTION RELEASE TO PRODUCTION c Rn D x s Q z m
41. hen hold the gimbal ring 020 4405 at the end of the IR TRACC and slide the gimbal shaft 020 4403 through the holes in the gimbal ring and the hole in the back of the IR TRACC Now centre the gimbal shaft and tighten the set screw The two gimbal pivot pins can be inserted into the thoracic spine Screw in until they will just appear on the inside of the thoracic spine Hold the gimbal ring before the pin and screw in further until it holds Attach the hardware at the other side of the IR TRACC as shown in Figure 11 Insert M5 screw in the rib cage hole and screw attachment to the rib cage assembly 5000023 020 4406 9002975 2 020 4407 One on each side Figure 11 IR TRACC attachment hardware rib cage side Side Impacts The IF 362 IR TRACC can also be mounted in side impact orientation The bracket shown below is mounted onto the inside of the rib cage using the rib attachment holes These parts are included in Q3 side impact kit 020 Side Kit but not included in the standard dummy The side impact IR TRACC mounting bracket assembly consists of RTRACO sde impa 0204505 Li MIGNE 3 02487 2 _ 4 ScrewSHSS1 8x 9002049 1 5 Rodendmountbase 362044 1 6 _ 500082 1 7 SeewSHCSM5x20 5000371 amp 2 8 Screw SHCSM5x12 1 5000 2 2 Figure 2 Q3 side impact IR
42. int outwards and place the legs in a v shape The angle between the feet should be between 40 and 60 degrees e sure the dummy is motionless e Place the upper arms vertically along side the body and let the lower arms rotate downward to let the hands touch the seating surface 2 3 Lift the arm on the impact side above and over the head Tape the arm to the head to make sure the impactor cannot come in contact with the arm Impactor alignment Let the impactor hang in its lowest position Check that the Impactor is horizontal within 2 degrees The impactor front surface should be within 5 mm distance of the most lateral rib surface The height of the centre line of the impactor over the seating surface should be chosen in such a way that the centre line of the impactor is aligned with the rib halfway between the upper and lower edge of the rib The centre line of the Impactor should be line with the vertical plane through the IR TRACC attachment at the side of the rib Make sure that the IR TRACC is not mounted for frontal impact as the side impact test can cause damage to the IR TRACC when it in its set up position for frontal impacts 4 Measure and record the impact velocity with the speed vane on the probe 5 The minimum time interval to observe between tests on the thorax is 30 minutes Data Processing 2 3 All data channels should be filtered at CFC600 Set the time zero at the g deceler
43. le assembly is tested and pre stretched to ensure the correct length and the performance of the neck assembly The cable assembly should not be disassembled by the user The neck cable will act as a safety measure in case of rubber failure 5000116 020 2200 Do 020 2101 5000003 020 2204 included 020 2200 assembly Figure 6 Dummy Neck Assembly Assembly and Disassembly Disassembly Head amp Neck 2 To disassemble the neck remove the head and upper neck load cell structural replacement as described above After removing the head assembly and load cell structural replacement the screws at the base of the neck can be reached and removed To inspect the neck cable assembly remove the two FHCS M3 x 8 at the top of the neck and undo the nut at the bottom of the neck The Neck cable assembly can now be pulled out from the top The neck cable assembly should NOT be disassembled Do not unscrew the screws at the bottom of the clamping plates on the neck cable assembly The neck cable is pre stretched and clamped down at manufacturing and should not be disassembled In case of cable damage customers are recommended to replace the complete neck cable assembly 020 2200 There is no adjustable pretension in the cable The nut 020 2204 can be tightened firmly Assembly Head amp Neck Perform the steps described under disassembly in reverse order Instrumentation 2 3 To install a load c
44. ll structural replacement and the neck torso interface plate together by unscrewing the four M5 x 12 socket head cap screws 3 Remove the neck torso interface plate 020 2015 from the load cell structural replacement by unscrewing the four M5 x 10 countersunk screws 4 Install the load cell by reversing the procedure described above First attach the neck torso interface plate 020 2015 to the load cell with the four countersunk screws 5 Place the load cell on top of the thoracic spine 020 4401 The base plate should be facing upward and the cable exits should be at the rear cables leading downward Fasten the load cell with the four socket head cap screws 6 Finally assemble the neck back on the torso IR TRACC The thorax rib cage is equipped with an IR TRACC displacement sensor that fits into the cavity of the thoracic spine directly below the cavity for the accelerometers The IR TRACC attachment hardware consists of 1 E clips not shown 5000406 020 4404 020 4403 BED 5000751 020 4402 020 4405 Tighten set screw flat part of pin after pin is centred Figure 0 IR TRACC attachment hardware spine side Frontal Impacts 2 3 use the IR TRACC IF 362 for frontal impacts the IR TRACC should first be equipped with its attachment hardware First place the holding boss 020 4404 onto the back of the IR TRACC and unscrew the set screw T
45. lvis Standard 3 uni axial accelerometers or tri axial accelerometer on pelvis skeletal structure Ax Ay Az Notes IR TRACC sensor may be mounted in two ways either to measure frontal or lateral deformations The IR TRACC sensor cannot record the true deformation in oblique impacts It is recommended not be use the IR TRACC in tests with expected high oblique rib deformations this can cause damage to the IR TRACC sensor as it has limited range of motion in directions perpendicular to its sensitive deflection direction 2 Information on the installation of the instrumentation can be found in the assembly disassembly section of this manual 3 The Upper Neck Load Cell does not require any correction for measurement of the moment around the OC joint The theoretical OC joint coincides with the neutral axis of the moment measurement of the FTSS load cell 4 Additional accelerometers may be mounted in the dummy for extra redundant information There are no fixed points for attaching these accelerometers Instead double sided tape may be used to attach the accelerometer to the desired location Two accelerometers may be used to measure deformation velocity and the deformation itself The procedure is as follows Install the accelerometers in the dummy The sensitive axes of the transducers should be aligned as good as possible Furthermore the accelerometers should be installed in locations that are expected to retain their align
46. mbar spine The potentiometer and balance mass are mounted on the sides of the head form with their common centerline perpendicular to the movement of the pendulum This can be seen in 6 and 17 The neck and lumbar spine test fixture be used for both frontal and lateral testing of the head and lumbar spine For testing in frontal direction the head form discs are parallel to the axis of the pendulum see 16 For lateral testing the head form centre line is perpendicular to the axis of the pendulum seel 7 Both configurations use three screws for fixing the discs to the central block and the positions frontal and lateral of the angle transducer The angle transducer and the balance weight of the head form must be repositioned when changing from frontal to lateral testing and vice versa Full Body Pendulum The full body pendulum part number 020 9920 Q3 Probe Assembly see 18 consists of a hollow metal tube closed at both ends two axles with suspension pulleys and a speed vane An accelerometer which measures the longitudinal acceleration must be mounted on the rear end An Endevco model 2262CA 200 or equivalent is recommended The total mass including instrumentation suspension pulley wheels and speed vane as well as the impactor face dimensions are specified in the table below Q3 probe Probe weight including speed vane 3 80 0 05 kg accelerometers and hardware Probe Diameter 80 mm Round off radius 5 mm Figure
47. ment during the deformation phase Make sure that the accelerometers are not located on positions that may contact other parts of the dummy as a result of deformation To process and combine the data first filter both signals at 1000 according to SAE 211 Subtract the signals and integrate the result This results in the deformation velocity Numerical integration of this signal gives the deformation itself Note that this method gives an approximation of the actual deformation The accuracy is limited due to the fact that the accelerometers do not remain properly aligned during the test and the numerical integrations that include the small measurement errors of the accelerometers cumulative in the velocity and displacement result The longer the time interval is the larger the cumulative error can be Experience with the Q3 dummy shows that usage of the acceleration integration method results in an under estimation of the deformation At 4 3 m s initial impact velocity the error is approximately 10 At 6 7 m s it is approximately 20 3 3 Accelerometer Mounts FTSS support three brands models of accelerometers or equivalent e Endevco 7264 and 7267A series e Entran EGAS Series and EGE3 73 Tri axial e Kyowa ASM Series MSC 126 Uni axial accelerometers The tri axial accelerometers Endevco 7267A and Entran EGE3 073 can not be fitted to the head The head will only accept uni axial accelerometers Thorax and Pelvis locations will
48. n Lift the pendulum up to its pre test height and check that the head is in the correct initial position Do not leave the head spine system in this position for more than minute as the neck will start to deform due to the mass of the head form Release the pendulum Data Processing l 2 3 Filter the pendulum acceleration at CFC 80 Filter the potentiometer readings at CFC600 Determine time zero of the impact by finding the g deceleration level in the pendulum signal after filtering Software zero all transducer readings by averaging the part of the signal before time zero and subtracting this from the transducer reading Integrate the pendulum acceleration to check the deceleration velocity of the pendulum The velocity of the arm must be calculated at a point 1657 4 mm from the pendulum pivot point Sum the potentiometer signals to derive the total head relative to pendulum arm angle Requirements 2 The impact velocity should be between 4 3 and 4 5 m s The pendulum velocity decrease should be as indicated in the table below Lower limit m s Upper limit m s lbo 13 To meet the requirements of the frontal lumbar spine certification test 3 4 The maximum head angle first maximum should be between 40 0 and 50 0 degrees This value should occur between 42 and 62 ms from the time zero point The minimum head angle first minimum should be between 17 0 and 27 0 degrees This v
49. n conducting tests with the dummy or with dummy components a time interval of at least 30 minutes should be observed between consecutive tests This also applies when for example a lateral test is followed by a frontal test using the same dummy component 6 Dummy Parts List and Recommended Spare Parts 6 1 Dummy Parts List Qty per Description dummy 020 0001 103 Dummy Assembly Uninstrumented w 020 1100 AssyTest Cert TTP 020 1020 Front Skull assembly i 020 1025 JRearSkulCapAssy i 5000565 M5x12 12Long o la 020 1013A Headacclbracketassy 020 1013 Head Acel Bracket 1 5000119 w dosHS 2a J 50060499 M 54osSHOS SSS a 020 2007 Load Structuralreplacement fT 1 AS A 020 4400 Torso Assy Frontal Dummy Ji 020 4100 Rib Assembly Tested and Certified 1 y 020 4200 Clavicle Retainer 1 y 020 2007 Load cell Structural replacement 1 J 020 4401 Thoracic Spine Frontalimpact 5 3 0204402 JPivotPin Gima 2 JJ d 0204403 GimpalS
50. n the head cavity To remove the accelerometers the procedure described above must be performed in the reverse order Alternative Instrumentation The cavity in a Q3 dummy head is large enough to accept an array of angular velocity sensors type 0 or ARS 06 flanged version Applied Technologies ATA Sensors To mount these sensors the use of an alternative accelerometer mounting base is required part No 020 1014 On the standard head accelerometer mounting base 020 1013A the application of DTS ARS sensors is possible For additional information on the mounting of these sensors see Section 3 and Figure 5 4 3 Neck Construction The neck assembly consists of the following parts from top to bottom Qty in Assembly Neck Assembly Tested and Certified 020 2100 Neck Molded pre tested 020 2101 1 Eq Neck cable assembly 020 2200 Screws FHCS M3 x 8 5000116 Screws BHCS M5 x 0 8 x x12 5000003 The main part of the neck assembly consists of a rubber column with bonded metal interface plates attached to the top and bottom The neck assembly has four threaded inserts in the top surface which are used to mount the upper neck load cell FTSS model IF 217 or IF 218 or its structural replacement 020 2007 onto the neck The upper neck plate has two cut outs towards the rear to allow proper routing of the upper neck load cell cables The neck cable assembly contains high yield strength low stretch synthetic fiber cord This neck cab
51. natt 1 1 0 020 4404 Shaft Locking Boss o 1 0204405 GimbaiRing t 3 O 020 4406 BracketIR TRACC Attachment 1i 5 020 4407 Spacer IR TRACC Attachment 2 3 0204411 Cable Guide 3 J 50000 M4xi2BHCS BP 50008 MSxioFHCS 500002 M5x12sHces 500039 Mexi2FHCS a 500386 Msx20FHCS 1 4 5000374 M amp ti2FHCS T 50046 6 BHCS e 5000447 M4xi6FHCS 1 2 5000751 RetainingRing J2 020 9902 LumbarSpineMouningScrewv 2 oO 5000023 M4axioFHCS 02 j 9002975 5 40x5 8SHCS Ti 5000406 55568 J 0202015 Neck Torso Interface Plate Ji P y 0202100 New Neck Assy Test Cert Ji 0202101 Neck Moulding 0202200 NeckCordAssy 1 5000002 MSx10SHCS 04 J 5000966 MioFHCOS 1 da J 5000116 M3x5FHCS 2 y O Qty
52. nd the lumbar Figure 13 Tighten nut down on the lumbar Assembly Perform steps to 4 under disassembly in reverse order 020 5000 020 9902 020 6000 020 6001 mold 020 6100 cable 5000093 nut 5000094 washer 5000084 020 2007 5000002 020 701 020 7110 RH 020 7100 LH 020 7010 5000002 020 7102 LH 020 7112 RH 020 7101 LH 020 7111 RH 020 7103 5000650 020 7104 5000098 5000410 Figure 14 Q3 Dummy Abdomen Lumbar Spine and Pelvis parts of 020 4000 Instrumentation Load Cell An FTSS IF 217 or IF 218 6 Axis Load cell may be mounted between the lumbar spine and pelvis To do so first remove the upper torso from the lumbar spine by removing the two M6x43 screws 2 Then unscrew the four M5x12 counter sunk head screws attaching the structural replacement to the pelvis Remove the lumbar spine structural replacement assembly from the pelvis casting 3 Unscrew the four M5x12 screws to remove the structural replacement from the lumbar spine Attach the load cell to the lumbar spine using four M5 x 12 SHCS 5 Mount the assembly onto the pelvis casting using four 5 2 counter sunk screws A 4 6 Pelvis Construction The pelvis casting is a single metal casting which fits into the pelvis flesh The two items are completely separable The upper legs with the ball and socket hip joint assemblies fit into the two openings at the left and right side of the pelvis The pa
53. o not over tighten the spring plunger Instrumentation No instrumentation is used in the arms 4 9 Abdomen Construction The abdomen 020 5000 consists of one part skinned foam which is inserted between the pelvis and rib cage It allows significant deformation of the dummy in the abdominal area see Figure 3 Assembly and Disassembly Disassembly To properly remove the abdomen from the dummy you need to perform the following steps Remove the upper part of the dummy from the lower part see procedure under lumbar spine and or thorax paragraphs by removing the two M6x43 screws from the lumbar spine thorax interface 2 The abdomen can then easily be taken from the dummy Note It is not advised to remove the abdomen from the assembled dummy as this places forces and strains upon the material which can in time result in wear and tear Removing the abdomen as outlined in this paragraph enhances the durability of the abdomen Assembly The dummy should be divided into the upper and lower half by unscrewing the two M6x43 screws at the lumbar spine 2 Insert the abdomen into the pelvis 3 Put the top of the dummy thorax and head back on the lumbar spine with the two M6x43 screws at the lumbar spine Instrumentation No instrumentation is used in the abdomen 4 10 Suit The dummy is dressed in a tight fitting neoprene suit part no 020 8000 This suit is an integral part of the dummy and should
54. op position The force exerted should be sufficient to resist the torques generated by the mass of the arm upon the shoulder joint The joints will be adjusted in new dummies supplied by FTSS In case they need to be readjusted proceed as follows Remove the dummy suit 2 Remove the shoulder retaining by removing the four M4x12 button head screws The arm can now be taken from the joint 3 In the aluminum ring two screws for adjusting the click stop force are visible With a screwdriver turn these spring plungers over a small angle to adjust them To verify whether the new settings are correct the upper arm and shoulder joint cap should be reassembled Elbow The spring plungers click stops in the elbow joint should keep the lower arm in one of two defined positions when a torque exerted by the lower arm mass and gravity is exerted upon the joint Adjust the click stop by making small adjustments with a screwdriver If the setting is correct the arm should stay in its position even when small forces are exerted upon it but start to rotate when significant forces are experienced To verify this push against the arm to force the arm out of the click stop position If the click stops are screwed in too far the friction between them and the arm will be too large and the arm will not rotate under gravitation Do not over tighten the spring plunger it could grind into the plastic elbow material 5 3 Time Interval between Tests Whe
55. oracic Spine 0280 4401 Load cell Structural replacement 020 2007 1 Neck Torso interface plate 020 205 ScewSHCSM5x08x12 5000002 4 GimbalRing 020 4465 PivtPin Gimal 1 020440 2 GimbalShaft n amp 020440 Retaining Ring 50007 2 Shaft Locking Boss 1 1 020440 1 Rib Cage Assembly o 20204100 1 BracketIR TRACC Attachment 020 4406 1 ScrewFHCSM4x0 7x10 1 0 500023 2 ScewBHCSM5x08x16 5000416 ScewBHCSM4x07x12 A 0 5000005 Clavicle 0 20203200 1T ScewFHCSM6x10x12 500039 2 Scapula Molding RH 0203100 ScapuaMoldngLH 0203101 ScrewFHCS M5x08x20 X 5008860 4 Shoulder Swivel assembly 020300 2 Shoulder Swivel Body 020302 2 ShoulderRetainngCap 020 3005 2 M88SprngPungr A 5000328 4 X DetntPg 31233 020 7103 2 SpringLCMO90F1MW 5000650 2 T2mmintemalCicip 1 _ 5000001 2 J M4i2BH S 6000005 ScrewFHCS 5 0 8 10 500084 4 Clavicle Retainer 0204200 1 ScrewFHCSM5x08x12 5000374 1 ScrewSHCS 5 40x5 B 1 0 1 _ 9002975 1 SpacerIR TRACC Attachment 1 020 447 2 ScrewSSCPM4x0 7x5 50
56. pendulum interface plate 4xM5 Place the modified 020 2015 TE 2650 9 intermediate plate between the neck and pendulum interface Align the neck and the interface making sure that lateral axis of the head is in the direction of movement of the pendulum arm see Figure 24 Also make sure that the bending direction of the neck in the certification is the same as the initial bending direction experienced in the test the dummy is being certified for LHS or RHS Attach the head form neck system to the part 572 pendulum The impact side of the neck should point in the direction of motion of the pendulum see Figure 24 Install the potentiometers to the mounting interface and on the head form s central block Mount the balance weight for the potentiometer on the other side of the central block This ensures that the inertial properties of the head are symmetrical in the impact direction Figure 24 indicates the proper position and orientation of the potentiometers Insert the rod connecting the axes of the potentiometers and tighten the screw on the bottom most axis to secure the rod to that potentiometer The other end of the rod should be able to slide freely through the upper most transducer axis The rod must be protruding from both sides of the transducer axes equal length The minimum time interval to observe between tests on the neck is 30 minutes Figure 24 Q3 neck certification test set up for lateral test Performing the test A
57. pometry of the dummy is based on CANDAT data The dummies can be equipped with accelerometers angular velocity sensors load cells and displacement sensors This allows evaluation of the injury risk under various circumstances Special attention has been paid to the handling characteristics of the dummy ensuring the dummy can be assembled and disassembled quickly and installing the dummy in the test configuration is simple and repeatable The influence of transducers upon the kinematics of the dummy is minimized and protection of transducers and cables is integrated in the dummy design Head The head is largely made from synthetics The head cavity is large enough to allow use of several instruments including linear accelerometers and angular velocity sensors Neck The neck is flexible and allows shear and bending in all directions The segmented design allows a realistic rotational behavior The neck is equipped with low stretch neck cord in order to prevent excessive elongation The neck cord is also designed to act as a safety cord in case of rubber failure A six channel load cell can be mounted at the neck head and neck torso interface Thorax The thorax of the child is represented by a single rib cage The deformation can be measured with an IR TRACC sensor The shoulders are connected with a flexible joint to the thorax allowing deformation forwards Accelerometers can be mounted on the spine to measure linear accel
58. re basket 265 to position the head The net has a piece of steel attached to it which allows the use of a magnet to keep the head in place The net allows easy adjustment of the head in any orientation A UJ The z axis of the head should make an angle of 28 2 degrees with the horizontal plane and the medial lateral axis should be horizontal degrees When released the head should impact the surface with its forehead The z axis of the head is parallel to the skull cap plane see Figure 21 The lowest point of the head should be 30 Imm above the impact surface Release the head The minimum time interval to observe between tests on the head is 30 minutes Figure 21 Frontal Head drop certification set up Data Processing l 2 All three accelerations should be filtered at 000 Determine the resultant head acceleration Requirement l 2 The maximum resultant head acceleration response should be between 95 and 125 g s The acceleration in Y direction should be between 10 and 10 g s Lateral Impact Head Certification Test Procedure The head is suspended above a rigid heavy metal plate The properties of this plate are described in section 7 2 under the heading Head Drop Table of this manual Users are advised to use a thin wire basket TE 2651 to position the head The net has a piece of steel attached to it which allows the use of a magnet to keep the head in place The net allows
59. rocedure Dummy positioning dummy should be seated on a clean dry surface consisting of two 0 60 x 0 65 m flat plates of 2 mm Teflon sheeting e Place the dummy with its thoracic spine in a vertical orientation within 1 degree with the vertical To stabilize the sitting position of the dummy rotate the upper legs outwards toes point outwards and place the legs in a v shape The angle between the feet should be between 40 and 60 degrees e Make sure the dummy is motionless e Place the upper arms vertically alongside the body and let the lower arms rotate downward to let the hands touch the seating surface 2 mpactor alignment e Let the impactor hang in its lowest position Check that the probe is in a horizontal position that is within 2 degrees e The impactor front surface should be directly in front of the dummy sternum within 5 mm height of the centre line of the impactor over the seating surface should be chosen in such a way that the centre line of the impactor aligns with the sternum halfway between the upper and lower edge of the rib This aligns the impactor with the IR TRACC attachment point on the rib cage e The centre line of the Impactor should be in the mid sagittal plane 3 Measure and record the impact velocity with the speed vane on the probe 4 The minimum time interval to observe between tests on the thorax is 30 minutes Data Processing All data channels should be filtered at CFC60
60. rts of the pelvis are listed below see also Figure 13 Qty in Assembly Pelvis assembly 020 7011 Pelvis casting machined 020 7001 Pelvis Flesh 020 7010 Hip joint assembly Left 020 7100 breakdown see below Hip joint assembly Right 020 7110 breakdown see below Screw SHCS M5 x 12 5000002 Left Right Qty in each DetntPg 020 7193 Spring Retainer Plate Spring Screw BHCS M3 x 8 screw FHCS M3 x 6 9000098 Assembly and Disassembly Disassembly If necessary remove the dummy s upper part by removing the M6x43 bolts 020 9902 at the lumbar spine thorax interface 2 Remove the lumbar spine and load cell or load cell structural replacement as described in section 4 5 Legs 3 Remove the left and right legs To do so put the dummy on its back or chest and remove the two M5x12 screws in the crotch area left and right four screws total These screws are used to retain the hip joint assemblies 4 With the screws removed from the dummy the legs can be removed from the pelvis by pulling them laterally outwards 5 Hip joint assemblies can be removed from the legs through separation of the upper and lower hip joint Do so by removal of the two button head M3 screws see Figure 13 Skin 6 When the legs are removed the pelvis flesh can be removed from the pelvis casting by pulling it downwards Instrumentation Accelerometers The pelvis can be equipped with a mounting block acceptin
61. ssembly 020 9200 020 9201 020 9202 020 9908 020 9901 020 9300 020 9301 020 9302 E EE ET E E E ES ES ES 020 9305 _ BN BN m ES B 3 ES EE ES E UpperLeftArm Assembly LowerLeftArm Assembly Arm Shoulder Shield 020 9909 020 9901 5000328 Upper Right Assembly LowerRight Arm Assembly Arm Shoulder Shield amp Shoulder Screw Modified Elbow E 020 9400 020 9401 020 9402 020 9305 020 9909 020 9901 9000328 8 Spring Plunger Optional rotational acceleromter bracket 020 1014 Head Rotational BracketAssy 1 020 1010 JATA Structural 3 9000208 10 32 FHCS x 1 2 Ig 5000679 M3x45SHCS l3 Optional OOPhipjonts 020 7200 Hip Joint Assembly RighULet Q3 OOP 2 702072001 Hip Jomtlower 1 7020 7202 Hip Joint Upper 1 5000008 M xi2BHCS 4 75000667 Belleville Spring Disc 39 6 2 Recommended Spare Parts During operation dummy parts can fail When the dummy is exposed to extreme pulses a failure can suddenly occur Normally however an early warning for a part that may fail soon is given by the certification procedures It is re
62. tach the lumbar spine and head form to the pendulum interface plate Align the lumbar spine and the interface plate making sure that longitudinal axis of the lumbar spine is in the direction of movement of the pendulum arm see Figure 25 4 Attach the head spine system to the part 5 2 pendulum The front of the head form should point in the direction of motion of the pendulum see Figure 25 5 Install the potentiometers to the mounting interface and on the head form Mount the balance weight for the potentiometer on the other side of the head This ensures that the inertial properties of the head are symmetrical in the impact direction 6 Insert the rod connecting in the axes of the potentiometers and tighten the screw on the bottom most axis to secure the rod to that potentiometer The other end of the rod should be able to slide freely through the upper most transducer axis The rod must be protruding from both sides of the transducers axes equal length 7 The minimum time interval to observe between tests on the lumbar spine is 30 minutes Figure 25 Q3 lumbar spine certification test set up for frontal test Performing the test 2 Attach honeycomb material to arrest the pendulum Proposed is to use Hexcel 28 8 kg m with crush strength of 1 8 Ibs cu ft with a nominal length of 76 2 mm 3 inches Auto balancing and shunt calibration of the transducer signals should be performed with the pendulum arm in the vertical positio
63. test as described in chapter 5 the dummy should be regularly certified to check its performance It is advised to certify the dummy each 10 tests when doubts on obtained measurements arise when parts are replaced and when injury criteria are significantly exceeded In this chapter the certification procedures are described 8 1 Head Certification General To certify the Q3 head remove it from the neck The parts list of the head assembly is shown below Screw BHCS M5 x 12 5000565 Screw SHCS M3 x 10 5000119 Screw SHCS M3 x 40 5000649 Load cell blank drop test i mass block representing half the load cell Screw FHCS M5 x 10 5000094 No tears of the skin or synthetic materials are allowed Also check that all screws have been tightened properly The data acquisition system and all instrumentation must comply with the requirements of SAE 211 version March 1995 All data channels should be filtered using a hardware filter prior to A D conversion according to SAE J2I1 version March 1995 Instrumentation Mount three uni axial accelerometers the accelerometer mounting block I AD or see Figure 2 in the head on the mounting base 020 1013A or 020 1014 Data Processing All three accelerations should be filtered at CFC 1000 2 Determine the resultant head acceleration Frontal Impact Head Certification Test Procedure The head is suspended above a Part 572 plate Users are advised to use a thin wi
64. thorax location The standard dummy will be delivered including mounting blocks for uni axial accelerometers The load cells or its structural replacements are a part of the dummy structure the structural replacements have to be used in absence of the actual transducer 6 channel load cell FTSS model IF 217 or IF 218 can be placed in the upper neck lower neck and lumbar spine location 3 2 Transducers The Q3 dummy can be fitted to measure any or all of the following parameters see also notes below Head Standard 3 uni axial accelerometers in head Ax Ay Az Optional 3 angular velocity sensors Applied Technologies Associates type 5 0 or ARS 06 flanged version or DTS ARS Neck Standard Upper neck 6 channel load cell 3 forces 3 moments Fx Fy Fz Mx My Mz FTSS Model IF 217 350 Ohm or IF 218 120 Ohm Lower neck 6 channel load cell 3 forces 3 moments Fx Fy Fz Mx My Mz FTSS Model IF 217 350 Ohm or IF 218 120 Ohm Thorax Standard 3 uni axial accelerometers or tri axial accelerometer in upper spine Ax Ay Az IR TRACC sensor to measure chest deformation frontal or lateral Dx or Dy FTSS model IF 362 Optional Additional accelerometers may be installed with double sided tape on the thoracic spine Ax Ay see notes below Lumbar Spine Standard 6 channel load cell at lumbar spine pelvis interface Fx Fy Fz Mx My Mz FTSS Model IF 217 350 Ohm or IF 218 120 Ohm Pe
65. ttach honeycomb material to arrest the pendulum Proposed is to use sheets of 28 8 kg m with crush strength of 1 8 Ibs cu ft with a nominal length of 152 4 mm 6 inches 2 Auto balancing and shunt calibration of the transducer signals should be performed with the pendulum arm in the vertical position 3 Lift the pendulum up to its pre test height Do not leave the head neck system in this position for more than minute as the neck will start to deform due to the mass of the head form 4 Release the pendulum Data Processing The data processing procedures of the lateral test is equal to the procedure mentioned in the frontal test Requirements The impact velocity should be between 3 8 and 4 0 m s 2 The pendulum velocity decrease should be as indicated in the table below To meet the requirements of the lateral neck certification test 3 The maximum head angle first maximum should be between 53 5 and 66 5 degrees The peak moment shall be between 18 50 and 23 00 Nm 8 3 Certification of the Lumbar Spine General The lumbar spine test is a component test which is performed using a pendulum as defined in CFR49 part 572 To certify the Q3 lumbar spine remove it from the dummy The complete Lumbar Spine consists of the following parts Lumbar Spine Molding 020 6001 Lumbar Spine Cable 020 6100 Nyloc Nut 50000093 Plain Washer 5000094 Screw SHCS M5 x 12 5000002 The lumbar spine is attached upside down to this pend
66. ulum A head form is used to load the lumbar spine This head form consists of two flat disks connected by an interface which allows certification of both the neck and the lumbar spine The head form rotation during the test is measured using two rotational potentiometers One is installed on the base of the neck pendulum interface the second one is attached to the head form Both potentiometers are linked with a thin shaft see 16 right and 17 right The sum of the two angles measured on the potentiometers is the angle of the head relative to the pendulum The data acquisition system and all instrumentation must comply with the requirements of SAE 211 version March 995 All data channels should be filtered using a hardware filter prior to A D conversion according to SAE J2I 1 version March 1995 The pendulum acceleration should be measured with an accelerometer which is located on the pendulum arm 1657 4 mm from the pendulum pivot in accordance with the CFR 49 Part 572 Frontal Spine Test The Lumbar Spine test is a component test which is performed using a pendulum as defined in CFR49 part 572 The complete Lumbar Spine consists of the following parts Set up Remove the lumbar spine assembly from the dummy Disassembly the disks of the head form and mount them in the correct position for lumbar spine testing 2 Slide the head form over the lumbar spine thorax interface bracket Insert and tighten the two M6 countersunk screws 3 At
67. val to observe between tests on the lumbar spine is 30 minutes Figure 26 lumbar spine certification test set up for lateral test Performing the test Attach honeycomb material to arrest the pendulum Proposed is to use Hexcel 28 8 kg m with crush strength of 1 8 lbs cu ft with a nominal length of 76 2 mm 3 inches 2 Auto balancing and shunt calibration of the transducer signals should be performed with the pendulum arm in the vertical position 3 Lift the pendulum up to its pre test height and check that the head is in the correct initial position Do not leave the head spine system in this position for more than minute as the neck will start to deform due to the mass of the head form 4 Release the pendulum Data Processing The data processing procedures of the lateral test is equal to the procedure mentioned in the frontal test Requirements The impact velocity should be 4 3 and 4 5 m s 2 The pendulum velocity decrease should be as indicated in the table below To meet the requirements of the lateral lumbar spine certification test 3 The maximum head angle first maximum should be between 42 0 and 52 0 degrees This value should occur between 45 and 65 ms from the time zero point 4 The minimum head angle first minimum should be between 17 0 and 27 0 degrees This value should occur between 130 and 150 ms from the time zero point 8 4 Certification of the Abdomen General The abdomen test

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