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Q1.5 (Advanced 1.5 year old child) User Manual

1. Hd doa i Ds Rune 32 Fig re l6 Leg Assemblies sore eio netta itu d EU DU t 34 Figure 7 Arm Assembly 35 Figure 18 Arm Assembly 36 Figure 19 3021 5 Impacto 44 Figure 20 Wire ndi etus teu tepido ua d que CUM ON M UBL a RUE 45 Figure 2L Head dereud eoe Gu da iens 46 Figure 22 Head form Lumbar Spine set up sssseseeeeeeeeetenttettettententtnntententtntnttententenus 47 Dipurg 24 Head drop ON ME DS HE nds an 5 Figure 24 Head Drop Lateral ooo Dedi abe dv Ue c De 52 Figure 25 Lumbar Spine Frontal tette eos reatu 57 Figure 26 Lumbar Spine Lateral iterare ehe nieto eredi 58 Figure 27 Abdomen Certification oed etta rd te d oa EN Men edd ra edu 59 Introduction In the late 1970 s and early 1980 s 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 with the development of a new series of child dummies as a successor to the P series This ne
2. 4 SY 0485100 Leg Assemblyten 048 9101 UpperLeftlegAssemby 485102 Lower Lefi Leg Assembly 0355901 Shoulder Bot 0205901 POP RPP RF Tit pens pen g mmo dummy 018 5200 LegAssemblyRight 3 048 9201 Upper Right Leg Assemby 1 S 0489202 LowerRightLeg Assembly 1 1 1 036 9901 _ Shoulder Modified 7 020901 StopScrew put Upper Left Assembly Tower Arm Assembly Shoulder Bolt Modea E E A m B 048 9300 048 9301 048 9302 036 9901 020 9901 EJ E ArmAssemblyRight Upper Right Arm Assembly Lower Right Arm Assembly Shoulder Bolt Modified 7 5000328 048 9400 048 9401 048 9402 036 9901 020 9901 5000328 8 Spring Plunger Side Impact String Pot Caddy Complete 048 3103A Side Impact Caddy Assembly 1 048 3103 Side Impact Caddy 1 9000791 ScewFHCS256x5 6 1 9000792 ScrewFHCS 2 56 x 3 8 1 Optional rotational acceleromter brackt 020 1014 Head Rotational Bracket Assy 1 020 1015 5 Mounting Bracket rh 1 020 101
3. Figure 6 and Neck Assembly 048 9900 User Manual Q1 5 Rev D Page 21 of 63 2012 Humanetics Innovative Solutions 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 A picture can be found in Figure 7 Description Part No Qty in Assembly Neck Torso Interface plate 048 3004 1 Thorax Assembly 048 3000 1 Rib Cage Assembly Q1 5 048 3001 1 Clavicle Q1 5 048 3010 1 Shoulder Spine Interface Ass y RH rubber 048 3011 1 Shoulder Spine Interface Ass y LH rubber 048 3015 1 Clavicle Retainer 048 3005 1 Shoulder Ball Retaining Ring 036 3002 2 Shoulder Ball 036 3004 2 Thoracic Spine 048 3101 1 String Pot Caddy 036 4002 1 String Potentiometer attachment 036 4003 1 Cable Tray 048 4303 1 Screw 4 10 BHCS 5000010 6 Screw M5x8 FHCS 5000662 7 Screw 5 16 BHSC 5000416 8 Screw M5x12 FHCS 5000096 5 Screw M4x16 FHSC 5000447 2 Screw M3x16 SHCS 5000663 2 Lumbar Spine Mounting Screw 020 9902 2 Marked ltem can be seen in Figure 8 Assembly and Disassembly Disassembly Upper Lower Torso l 2 3 The suit should be re
4. 7 2 2 Application P 7 2 3 7 2 4 Instrumentation options 01 5 dummy e eeeesenttttteenntttts 9 2 5 9 2 6 Mass Distrib tion 10 2 7 Standard DUMMY E 10 3 Instrumentation 3 1 I 3 2 Transducers te n lI 3 3 Accelerometer MOLES sic tt e et a a 13 3 4 Angular Velocity Sensor MOunting ssssssssesssccssessscccssssesscssssseccesssecsesnsssececnssssesesnssscescnssseesesnnseesenneseesennesseesenees 14 3 5 Cable Routing and Protection ee naain i 14 4 Assembly Disassembly 21 4 4 4 4 4 4 2 6 sesso teen ossa sese seen 15 4 1 General Overview iR d 15 4 2 ER 15 4 3 RR 19 4 4
5. AN IA AA C Wiis IVI MING TINS Innovative Solutions 01 5 Advanced 1 5 year old child User Manual 048 9900 User Manual Q1 5 Rev D Page 1 of 63 2012 Humanetics Innovative Solutions Nar ga MAN T IVI VIN D atives U nnov gt ns 1 ti oy ON vy 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 Content enl 3 Ll Introd ctionz iie ROS ti ER qut t et RERUM RR 6 2 General Description and Features 11 11 nane en nasse ena sese 7 2 1 Design cottidie
6. 048 1010 5000565 048 1020 Figure 3 Head Assembly Assembly and Disassembly Disassembly The head is attached to the neck though the load cell or the structural replacement To disassemble the head first remove the upper neck load cell or its replacement from the neck Head First remove the head rear assembly by unscrewing the four button head cap screws at the back of the head 2 Now the accelerometer array can be removed in order to provide access to 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 048 9900 User Manual Q1 5 Rev D Page 16 of 63 manetics Innovative Solutions Assembly Head 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 base 020 1013 from the head cavity by unscrewing the three cap head screws The uni axial accelerometers must first be mounted onto a mounting block or 4 Bolt the m
7. 22 4 5 L mbar 27 4 6 30 4 7 EET 33 4 8 35 4 9 Abdomen 37 2 10 RRU RR cea ae oa RG MN NA E 37 b Pre test Checks nore tr rehenes oh en ere os o Un Vt on Pn Un e os ore Ua on Fn e e 460 6040066 956 0 666 38 5 1 a RA Ea RNR 38 5 2 Click Stops and Arm GdjUStent secssosessccccssesecccsseesseccssssecccesssesecesssseescsssesescenseseesesnsscsesnuseessnueseeseensseesensesecs 38 5 3 Time Interval Between Tests kid 39 6 Dummy Parts 56 1 1 1 1 311111110000 33131 40 7 Certification Equipmient ciens repeti EP aep 43 7 1 Requirements ERR SERRE AUR URN ERREUR DRE RES ERE ERR 43 7 2 Equipment RARUS RUM MEINER 44 7 3 Equipment RIR RUBRA Te IDEE Eri die 49 8 Certification Tests 50 8 1 Flead Cer fIGaGtion EE RR RD RR E AD RR NEIN 50 8 2 Certification of iie tae d d a Ta ile 53 8 3 Certification of the Lumbar Spine u ssssscsssssessccssssseccessesec
8. SUPPONI GA S eS Abdomen Test Q1 amp Q1 5 TE 036 9920 Full Body Probe Q1 amp Q1 5 Thorax Test Q1 amp Q1 5 8 Certification Tests 8 1 Head Certification To certify the QI 5 head assembly 048 1000 remove it from the neck The parts and part numbers of the head assembly are mentioned below Description Parts Q3 Qty Head front assembly 048 1020 1 Head rear assembly 048 1010 1 Head Accelerometer Mounting Base 020 1013 1 Screw BHCS M5 x 12 5000564 4 Screw SHCS M3 x 10 5000119 2 Screw SHCS M3 x 40 5000649 1 Mass block 1 2 IF 217 020 1050 1 Screw FHCS M5 x 10 5000094 4 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 2 version March 1995 data channels should be filtered using a hardware filter prior to A D conversion according to SAE 211 version March 1995 Instrumentation Mount three uni axial accelerometers on the accelerometer mounting block I AD or 1 Data Processing All three accelerations should be filtered 000 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 net to contain the head The net has a piece of steel attached to it which allows the use of a magne
9. 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 3 5 Legs 3 Remove the left and right legs To do so put the dummy on its back or chest and remove the two 5 12 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 Skin 5 When the legs are removed the pelvis flesh can be removed from the pelvis casting by pulling it downwards The pelvis casting is now exposed see figure Pelvis 020 7111 1 5000653 020 7104 Hip Joint assembly Right 020 7110 Figure 14 Hip Joint Right 5000098 Qty in each Description Part No Left Part No Right Assombi Hip Joint Assembly L or R 020 7100 020 7110 1 Hip Joint Lower L or R 020 7101 020 7111 1 Hip Joint Upper L or R 020 7102 020 7112 1 Detent Peg 020 7103 1 Spring Retainer Plate 020 7104 1 Spring 5000650 1 Screw M3x8 BHCS 5000653 2 Screw M3x6 FHCS 5000098 2 020 7103 EM 1 020 7102 5000650 020 7101 020 7104 7000633 Hip Joint assembly Left 020 7100 Figure 15 Hip Joint Left 5000098 Instrumentation Accelerometers The pelvis can be equipped with a mounting block accepting three uni
10. 020 2204 1 Screws FHCS M3 x 8 5000116 2 lt eon 020 2204 included in 020 2200 assembly 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 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 In case the load cell is not used a load cell structural replacement 020 2007 with identical shape and mass is installed onto the neck The neck cable assembly contains high yield strength low stretch synthetic fiber cord This neck cable 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 Figure 5 Neck Assembly Assembly and Disassembly Disassembly Head amp Neck l To disassemble the neck remove the head and upper neck load cell structural replacement as described above 2 After removing the head assembly and load cell structural replacement the screws at the base of the neck can be reached and removed 3 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
11. 10 screws to attach the mounting block inside the cavity The longest side of the mounting base should be facing upwards Load cell The 1 5 dummy cannot be equipped with a lower neck load cell String Potentiometer The thoracic spine can be equipped with a string potentiometer which fits into the cavity directly below the cavity for the accelerometers The string potentiometer is always used in combination with a string potentiometer caddy The string potentiometer is mounted onto this caddy using two imperial 2 56 counter sunk screws The string potentiometer can be used for both frontal and side impact Figure 8 String pot attachment Frontal Impacts To use the string potentiometer for frontal impacts insert the string potentiometer caddy into the cavity in the spine from the rear The transducer signal cable should exit the cavity at the rear the string of the potentiometer at the front top The string potentiometer caddy is fixed using the two M3x20 screws Pull out the string towards the sternum of the ribcage and put the ball in the socket of the string potentiometer attachment 036 4003 Pull string potentiometer attachment towards the ribcage and align string attachment with the hole in the ribcage Insert screw in the hole and screw string attachment to the ribcage assembly To dismount the string potentiometer perform steps 1 4 in reverse order P 4 048 3101 5000312 048 3103
12. 5000384 SeewM esSHcS 2 penu BEER 036 5000 eo gt Qty per 6000 8 Lumbar Spine Assembly TESTED CERT 0555001 LumbarSpimeCenraMoudng 020 5100 LumbarCable Assembly 1 1 000093 5000094 020 9902 Lumbar Spine Mounting Screw gt J pepe er 0487000 0457001 07002 1020 2007 Load cell Structural replacement 5000084 SeewM amp xiorHcs O SCS 2 5000002 2 7 0207100 207107 020 7102 20 10 020 7104 5000 Sing 500410 ScewM eBHcS 2 5000098 SeewM erHcs gt 5000002 SeewM amp xizSHcS 2 p o ATE 0202110 HipJoitAssemblypRH 0202105 Hip JointLowerRight 1 1 0202106 020710 Spring Retainer Pate 5000690 Spring 500410 5000098 ScewM erHcs gt o y 5000002 M amp xizSHcS 2 MN CR RR 5800 Su
13. ELEME DES Figure 21 Head Form ITEM QTY PART NO DESCRIPTION 1 1 TE 2650 2 CENTRAL BLOCK 2 1 TE 2650 13 CENTRAL BLOCK Q1 Q1 5 NOT SHOWN 3 2 TE 2650 8 HEAD FORM DISC 4 16 5000020 SCREW SHCS 5 X 8 X 16 5 2 TE 2650 4 YOKE POTENTIOMETER 6 1 TE 2650 8 BALANCE WEIGHT 7 1 2650 1 PENDULUM INTERFACE 8 2 5000628 SCREW SHCS SS M5 X 8 X 40 9 2 6002209 GL60 10k 354 HOLLOW SHAFT CONTELEC 10 2 TE 2650 5 SHAFT POTENTIOMETER 11 2 5000477 PIN DOWEL M4 X 16 12 2 TE 2650 6 FORK 13 1 2650 7 ROD 14 2 5000470 SCREW SSCP M3 X 0 5 X 4 15 1 2650 11 SPACER FLEXION HEAD FORM 16 4 5000394 SCREW 5 5 X 0 8 25 17 2 5000156 NUT LOCKNUT SS 5 X 0 8 18 4 5000300 SCREW SHCS M5 X 8 X 14 19 1 TE 2650 9 NECK TORSO INTERFACE PLATE The total mass of the head form should be 2 69 0 05 kg including the instrumentation interface to the part 572 pendulum should weigh 0 95 0 02 kg 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 These are shown on the right hand side of the head form 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 axis of the pendulum interface potentiometer The rod must be protruding from both potentiometer
14. Observe an interval of at least 30 minutes between successive tests on the same abdomen A w Data Processing l Subtract the final reading from the initial reading Requirement The deformation of the abdomen should be between and including 12 mm and 16 mm 8 5 Certification of the Thorax General Set Up A complete standard 1 5 dummy must be used in this test The dummy is to be tested with the suit on Prior to the test the dummy should be inspected for possible damage Particularly important for the thorax tests is to check the condition of the rib cage the shoulder spine interface and the clavicle No tears of the skin rubber or synthetic materials are allowed Also check that all screws have been tightened properly As the performance of the critical dummy 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 past their applicable certifications tests successfully The data acquisition system and all instrumentation must comply with the requirements of SAE 2 version March 1995 All data channels should be filtered using a hardware filter prior to A D conversion according to SAE 211 version March 1995 Frontal Impact Thorax Test Instrumentation The dummy must be equipped with the standard string potentiometer in the cavity inside the thoracic spine The string should be attached on the front of the
15. axes equal length When testing the neck a 6 axis load transducer IF 217 is mounted between the neck and the head form The load cell is not required for testing the lumbar spine The neck or lumbar spine is attached upside down to this pendulum The head form is used to load the neck This head form consists of two flat disks connected by an interface which allows certification of both the neck and the lumbar spine TE 2650 13 QI QI 5 Central Block Figure 22 Head form Lumbar Spine set up The neck and lumbar spine test fixture can be used for both frontal and lateral testing of the head and lumbar spine For testing in frontal direction the head form centre line and discs are parallel to the axis of the pendulum For lateral testing the head form centre line is perpendicular to the axis of the pendulum see Figure Neck Lateral and Lumbar Spine Lateral The head form has different configurations one for testing the neck and one for testing the lumbar spine 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 Figure Head form 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 see Figure Head form A special central bloc
16. 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 through the pubic area when replacing the pelvis flesh 47 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 Description Part No Left PartNo Right ly in each Assembly Leg assembly L or R 048 9100 048 9200 1 Upper Leg Assembly L or R 048 9101 048 9201 1 Lower Leg Assembly L or R 048 9102 048 9202 1 Stop Screw 020 9901 1 Assembly and Disassembly Disassembly It is not advised to disassemble the legs except to replace broken parts To separate the lower from the upper leg l Remove the motion stop screw 020 9901 located on the inside of th
17. cell and fix the four 5 12 cap head screws The base plate of the load cell should be facing down and the cable exits at the rear of the dummy when the assembly is put onto the pelvis casting 5 Mount the assembly onto the pelvis casting using four 5 12 counter sunk screws o Abdomen and Lumbar Spine Assembly Figure 12 Abdomen and Lumbar Assembly 4 6 Pelvis Construction The pelvis assembly consists of Description Part No Qty in Assembly Pelvis assembly 048 7000 1 Pelvis casting machined 048 7001 1 Pelvis Flesh 036 7002 1 Load cell Structural replacement 020 2007 1 Hip joint assembly Left 020 7100 1 Hip joint assembly Right 020 7110 1 Screw 5 10 FHCS 5000084 4 Screw M5x12 SHCS 5000002 8 These screws are shown in the Figure 12 Abdomen 4 pcs are shown in Figure 12 Abdomen 4 pcs are shown in the Figure 13 Pelvis The pelvis casting is a single metal casting which fits into the pelvis flesh The two items are completely separable The upper leg with the ball and socket hip joint assemblies fit into the two openings at the left and right side of the pelvis Pelvis Assembly Figure 13 020 7110 gt Pelvis Assembly 020 7100 048 7001 5000002 036 7002 Assembly and Disassembly Disassembly Start necessary remove the dummy s upper part
18. e first perform the component tests head neck lumbar spine abdomen e then perform the full body test on the dummy with the certified components thorax To perform the calibrations certain certification 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 7 2 Equipment Head Drop Table For the free fall head drop test a support and release mechanism is necessary as well as steel plate which will act as an impact surface This plate is described in the US regulation CFR 49 Part 572 Hybrid head drop test and should have equal roughness and size Full Body Pendulum The full body pendulum see figure 1 5 Full Body Impactor consists of a hollow metal tube with 77 mm diameter Impactor face The total mass including instrumentation suspension discs and speed vane should be 2 60 x 0 05 kg Description Q1 amp Q1 5 Probe Probe weight including speed vane accelerometers and hardware SOUS 0 050 kg Probe Diameter 77 mm Edge Radius 5 mm The accelerometer which measures the longitudinal acceleration is mounted on the rear plug An Endevco model 2262 200 or equivalent is recommended Figure 19 Q1 5 Full Body Impactor The pendulum is suspended by eight wires 2 mm diameter type 7x7 stainless steel wire Figure 20 Wire Suspension below
19. potentiometer attachment to the rib Side impact bracket 048 3103 should be removed 4 5 Lumbar Spine Construction The lumbar spine consists of lumbar spine central moulding cable assembly load cell structural replacement screws 5 12 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 M6x43 screws 020 9902 At the bottom side four 5 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 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 protection in case of lumbar spine damage or failure Description Part No Qty in Assembly Lumbar Spine Assembly tested and certified 036 6000 1 Lumbar Spine central moulding pre tested 036 6001 1 Lumbar Cable 020 6100 1 M6 Nylon nut 5000093 1 M6 Plain Washer 5000094 1 Assembly and Disassembly 5000093 5000094 036 6001 pcd 020 6100 Lumbar Spine Assembly Figure 10 Lumbar Spine Assembly Tighten nut until there is no gap between the nut and the lumbar Disassembly Remove the upper torso by removing the two M6x43 screws at t
20. shows a front view of the Impactor and four of the suspension wires in the required cross configuration The front two cross wires my be omitted A flat horizontal surface should be available to sit the dummy on The impact velocity of the Impactor must be measured and recorded Figure 20 Wire Suspension Neck and Lumbar Spine Certification Equipment A pendulum which meets the requirements of CFR 49 part 572 33 c 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 Head form Note In this figure only the top and bottom parts of the arm of the part 572 pendulum are shown 15 8T B E li ES p qe E
21. the dummy and should be worn in 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 moulded 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 Lumbar spine The lumbar spine rubber may not be damaged Inspect the rubber moulding for tears and cracks Replace if the spine is damaged The cable must be inserted and the nut at the top properly screwed on Abdomen The abdomen should be checked periodically 10 tests for tearing of the PVC skin Note that the wear of the abdomen is greatly 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 Shoulders Periodically examine the shoulder to spine interface for damage Arms Check the friction setting of the shoulder arm regularly Clavicles Inspe
22. 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 alignment 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 CFC1000 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 decreased due to the fact that the accelerometers cannot be properly aligned during the test 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 1076 At 6 7 m s it is approximately 2076 3 3 Accelerometer Mounts FTSS support several brands models of accelerometers or equivalent E
23. 0 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 3 9 0 1 m s 2 The pendulum velocity decrease should be as indicated in the table below Lower limit m s Upper limit m s 10 05 13 To meet the requirements of the frontal neck certification test 3 The maximum head angle first maximum should be 60 0 6 5 degrees The peak moment shall be 20 75 2 25 Nm Lateral Neck Test Set up 1 Assemble the complete neck 2 Attach the IF 217 6 AXIS LOAD CELL and 2650 11 SPACER FLEXION HEAD FORM to 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 Place the modified 020 2015 TE 2650 9 intermediate plate between the neck and pendulum interface 5 Align the neck and the interface making
24. 150 ms and be between 17 degrees and 27 degrees deflection 8 4 Certification of the Abdomen General The abdomen test 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 performance an Additional weight is placed on the top plate Additional Weight Total weight Figure 27 Abdomen Certification Instrumentation The only instrumentation necessary to perform this test is a tape measure or calliper rule to measure the distance between the two plates Additional weight me Q1 amp Q1 5 peser Abdomen test weight Additional weight 5 60 0 050 kg Total weight 7 65 0 050 kg Abdomen support part no TE 036 9910 Test Procedure Place the abdomen on the appropriate Q abdomen certification support Ensure a good fit and orientation of the abdomen over the block Lower the top plate with a weight of 2 05 0 05 kg on the abdomen Determine this point as zero for the displacement measurement 2 Place the additional weight on the top plate this weight differs for the Ol 5 and Q6 dummies Let the force exerted by this mass apply as indicated in The figure above 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 10 sec Read the measurement 5 Remove the mass and top plate
25. 57 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 Description Parts Q1 Q1 5 Qty Lumbar Spine Moulding 036 6001 1 Lumbar Spine Cable 020 6100 1 Nyloc Nut 50000093 1 Plain Washer 5000094 1 Set up 1 Remove the lumbar spine assembly from the dummy Disassemble the disks of the head form and mount them in the correct position for lumbar spine testing Use part TE 2650 13 as the central mounting block 2 Slide the head form over the lumbar spine thorax interface bracket Insert and tighten the two M6 countersunk screws 1 Attach 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 2 Attach the head spine system to the part 572 pendulum The front of the head form should point in the direction of motion of the pendulum 3 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 Insert the rod connecting the axes of the potentiometers and tighten the screw on
26. 6 5 Mounting Bracket 1 020 1010 ATA Structural Replacement 3 9000208 Screw 10 32 FHCS x 1 2 9 23 5000679 Screw 45 SHCS o 3 2 7 Certification Equipment 7 Requirements The frequency of the QI 5 certification and the number of tests that can be performed between certifications is strongly depends on the type and severity of the tests in which the dummy is used as well the test frequency Which certification tests have to be carried out depends on the dummy application ECE R44 EuroNCAP Airbag NPACS performed 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 requirements for both are listed in table which also lists the appropriate paragraph in this document that describes the certification test 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 a temperature of 20 2 degrees Celsius a relative humidity of 40 30 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
27. Assembly Disassembly 4 1 General Overview The Q dummy consists of the following main components head neck thorax lumbar spine abdomen pelvis arms legs The dummy is clothed in a tight fitting suit This suit is an integral part of the dummy and should be worn in all testing A full description of the instrumentation capabilities is given in section 3 The tools needed for assembly and disassembly of the Q1 5 dummy e screwdrivers e metric hex keys 4 2 Head Construction The components that constitute the standard head are Description Part No Qty in Assembly Head Assembly 048 1000 1 head front assembly 048 1020 1 head rear assembly 048 1010 1 accelerometer mounting base standard 020 1013 1 screws SHCS M3x40 5000649 1 screws SHCS M3x10 5000119 2 screws BHCS 5 12 5000565 4 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 5 12 button head cap screws located at the rear of the head The head skin and skull are moulded together and cannot be separated The picture in the Figure of head assembly is shown that inside the head there is a large cavity which may be used to mount various types of instrumentation The standard arrangement is to have the head mounting base bolted in the head which will accept a mount block for 3 uni axial accelerometers
28. Hcs gt 5000649 0202007 Load Cell Structural replacement 1 O DX I EE RR 048 3004 Neck Torso Interface Pias 0202100 _ Neck Assembly Tested Certified 0202101 Neck Moulding pretese 1 1 020 2200 5000118 5000297 5000084 ScewMexofHcs pui se I 4 048 3000 Torso Assembly Tested Ceried 045 3001 Rib Cage Assembly tested 1 0483010 045 3011 Shoulder Spine Interface Assy RH rubber 1 048 3015 Shoulder Spine Interface Assy LH rubbe 1 48 3005 OevceRetime 863002 Shoulder Bali Retaining Ring gt 0563004 SouderBal 2 1 Fo4 amp 3101 0864002 SingPotCadjy 1 0864003 9003140 _ Shoulder Friction Washer e 1 103 206 ShoulderWasher 6e 048 4303 GsbeTay 1 5000005 SeewMaed28HcS 8 5000096 SeewM amp xizrHcs 5000662 SeewMbeFHcs 5000416 SeewMexieBHcS
29. IH 170 EM H 170 Not included with EN dummy purchase Ali gt 9000791 Figure9 String pot Side impact bracket 048 9900 User Manual Q1 5 Rev D Page 25 of 63 2012 Humanetics Innovative Solutions Note A spring is used to keep tension on the string potentiometer cable When dismounting the string potentiometer from the rib gently let the cable be reeled in by the spring Releasing the cable while it is pulled out will cause serious damage the string potentiometer Side Impacts UI To use the string potentiometer for side impact remove the string potentiometer caddy from the cavity in the thoracic spine Remove the string potentiometer from its caddy The string potentiometer can be used for left and right sided impacts by mounting the potentiometer on the right of left side Fasten the string potentiometer on the side impact caddy 048 3103 using the two imperial 2 56 screws Note that the 2 56 x 3 8 screws are used at the top while a shorter 2 56 x 5 16 screw is used at the bottom hole Attach the caddy to the thoracic spine using the two M3 x 20 SHCS screws Pull out the string towards the rib and put the ball in the socket of the string potentiometer attachment Insert the screw though the rib and fasten the string potentiometer attachment to the rib cage assembly To remove the string potentiometer perform steps 2 4 in reverse order and fasten the string
30. at longitudinal axis of the neck is in the direction of movement of the pendulum arm 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 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 minimum time interval to observe between tests on the neck is 30 minutes Performing the Test 1 Attach honeycomb material to arrest the pendulum 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 Data Processing Filter the pendulum acceleration at 8
31. atches the internal elbow joint Instrumentation No instrumentation is used in the arms 4 9 Abdomen Construction The abdomen 036 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 Abdomen Assembly and Disassembly Disassembly To properly remove the abdomen from the dummy the following steps should be taken 1 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 020 9902 from the lumbar spine thorax interface 2 abdomen can then easily be taken from the dummy Note t 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 greatly enhances the durability of the abdomen Assembly The dummy should be divided into the upper and lower half by unscrewing the two M6x43 screws 020 9902 at the lumbar spine 2 Insert the abdomen into the pelvis 3 Putthe 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 clothed in a tight fitting neoprene suit part no 048 8000 This suit is an integral part of
32. ct 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 if cracks are present Spring plungers Check the spring plungers in the elbows See paragraph 4 2 for instructions 5 2 Click Stops and Arm adjustment Arm Adjustment The correct arm shoulder friction can be set by tightening or loosening the M3 screws in the upper arm Rubber Friction washers 9003140 have been placed between the upper arm and retaining ring to ensure a certain amount of pressure at all times This will prevent the shoulder screws from loosening in normal use To set the correct 1 2 setting of the shoulder joint tighten the M3 screws evenly until the correct setting has been found 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 accelerations are experienced To verify this push against the arm to force the arm out of the click stop position If the spring plungers are screwed in too far the body of the spring plunger will dig into the plastic elbow of the lower arm This will cause excess friction and over t
33. d connecting the axes of the potentiometers and tighten the screw on the bottom most axis to secure the rod to that potentiometer 6 The minimum time interval to observe between tests on the lumbar spine is 30 minutes 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 Ibs cu ft with a nominal length of 76 2 mm 3 inches Optional length 152 4 mm of Hexcel may be used 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 4 Release the pendulum Data Processing The data processing procedures of the lateral test is equal to the procedure mentioned in the frontal test Figure 26 Lumbar Spine Lateral Requirements 1 The impact velocity should be 4 4 0 1 m s 2 The pendulum velocity decrease should be as indicated in the table below Lower limit m s Upper limit m s To meet the requirements of the lateral lumbar spine certification test 3 The maximum head angle first maximum should be between 42 degrees and 52 degrees This value should lie between 45 ms and 65 ms from the time zero point The first minimum head angle should occur at a time between 130 ms
34. e Any of these ARS sensor blanks be replaced with an 0 or ARS 06 flanged version sensor The Angular Velocity Mount block will accept the same mount block as the standard accelerometer mounting for the head I AD or Note that the arrangement of the accelerometers on the block should be different as shown in the Head Assembly in the figure below The ARS sensor blanks should not be removed if there is no sensor to replace it 6 Figure 2 Head Instrumentation both accelerometer bracket arrangements 020 1013 standard and 020 1014 optional ARS version shown 3 5 Cable Routing and Protection The QI 5 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 QI 5 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 cover is mounted on the back of the thoracic spine This cover will protect the cables and provide a fixed contour of the back of the dummy 4
35. e The angle between the feet should be between 40 and 60 degrees Make sure the dummy does not move Place the upper arms vertically alongside the body and let the lower arms rotate downwards to let the hands touch the seating surface 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 Align the Impactor Let the Impactor hang in its lowest position Check that the Impactor is in a horizontal position within 0 2 degrees e The Impactor front surface should be within 5 mm distance of the most lateral rib surface e 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 surface of the rib e The centre line of the Impactor should be in line with the vertical plane through the IR tracc String potentiometer attachment at the side of the rib Make sure that the string of the string potentiometer is not mounted for frontal impact as the side impact test can cause damage to the string potentiometer when it is set up for frontal impacts Impact the dummy sternum with an Impactor velocity of 4 3 0 1 m s The impact velocity must be measured and recorded The minimum time interval to observe between tests on the thorax is 30 minutes Data Processing 2 3 data channels should be filtered at CFC600 Se
36. e knee joint 2 Remove the shoulder screw 036 9901 connecting the two parts of the leg Assembly l Check that the rubber end stops are in the correct position inside the upper knee joint before assembly of the lower leg 2 Align upper and lower leg at shoulder screw holes and screw in shoulder screw 3 Before inserting the motion stop screw place upper and lower leg in a 90 angle with respect to each other 4 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 048 9201 Qu p 048 9202 048 9202 048 9102 Leg Assembly Right Leg Assembly Left Figure 16 Leg Assemblies Instrumentation No instrumentation is used in the legs 048 9900 User Manual Q1 5 Rev D Page 34 of 63 2012 Humanetics Innovative Solutions 4 8 Arms Construction wo 5000558 036 3005 rubber washer 036 3006 49 steel washer 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 The figure shows all the parts used in the arm assembly The 1 2 setting
37. ents of the dummy The masses given include accelerometer mounts the string potentiometer and all screws and fixings Q1 5 Tolerance Head neck incl acc mount Torso incl acc Mounts string pot meter Upper legs 11 10 27 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 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 Applied Technologies Associates type 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 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 A 6 channel load cell FTSS model IF 217 or IF 218 can be placed in the upper neck and lumbar spine location 3 2 Transducers The QI 5 dummy can be fitted to measure of the following parameters Head Standard 3 uni axial accelerometers in head Ax Ay Az Optional 3 angular veloc
38. essnseesscenseessesonseesseesueeecesonsessessuseecesonseeseennseesseenseess 56 8 4 Certification Of the Abdomen RR SERRE tes E 59 8 5 Certification Of the Thorax so RD RR IRR RE RR DRIN 60 Figures Figure l exon 6 Figure 2 Head Instrumentation both accelerometer bracket arrangements 020 1013 standard and 020 1014 optional ARS version SHOWN nans oni 14 Figure 3 Head Assemb yannin in aa hann sn 16 Figure 4 Head Assembly with ARS mounts combination with accelerometer possible 18 Figure 5 Neck Assembly 19 Figure 6 Head and Neck Assembly n 21 Figure 7 Thorax 23 Figure 8 String 25 Figure 9 String pot Side impact 25 Figure 10 5 282 Ee UNSER NH 28 Figure 11 Tighten nut down to the lumbar ou sssssssssssssssssssesssssssscesessesssssssesessssssssssssssesssesssesssesssesoes 28 Figure 12 Abdomen and Lumbar Assembly eese tee ttententoa ttes ttn tta ntonton tonto nons 29 Figure 3 Pelvis Assembly ttti rue va eee piede 30 Fig re P4 Ip LOU a i 3l Figure 5 Hip
39. he 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 24 Instrumentation options 01 5 dummy The complete list of instrumentation options include Head Ax Ay Az linear acceleration Head Wx Wy Wz angular velocity 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 1 5 dummy series are described below Nr Q1 5 Tolerance Description Dimension mm sitting height head tilted forward 9 9 2 shoulder height 59 7 3 Stature 0 0 0 0 0 80 9 5 shouderwdth 7 9 6 hippwith 244 7 7 butocktofron knee 25 9 8 Buttock to popliteus sitting 45 The Chest depth is measured at the centre line of the string attachment of the displacement transducer The measurements are valid for the dummy without suit 5 The Chest Depth dimension 111 mm is taken from the dummy design computer model 2 6 Mass Distribution The table below shows the masses of the various compon
40. he thoracic spine lumbar spine interface as shown above 2 Remove the four 5 2 countersunk head screws which are used to fasten the load cell or structural replacement to the pelvis 3 Remove the load cell or load cell structural replacement From the lumbar spine by removing the four 5 12 socket head cap screws 4 The cable assembly should not need to be removed under normal circumstances Should it become 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 spanner Assembly Perform steps 1 3 or 4 under disassembly in reverse order Figure Tighten nut down to the lumbar 048 9900 User Manual Q1 5 Rev D 2012 Humanetics Innovative Solutions Page 28 of 63 Instrumentation Load cell An FTSS IF 217 or IF 218 6 Axis Load cell may be mounted between the lumbar spine and pelvis This load cell replaces the 020 2007 load cell replacement as shown in the figure below To do so first remove the upper torso from the lumbar spine by removing the two M6x43 screws 020 9902 2 Then unscrew the four 5 12 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 5 12 screws to remove the structural replacement from the lumbar spine 4 Now replace the structural replacement by the actual load
41. ime may damage the elbow material 5 3 Time Interval between Tests When 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 Special Attention Always provide sufficient slack in the sensor 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 so snag behind some other object in the test set up and which can result in damage of the head instrumentation It is strongly recommended to include a strong guide cable in the cable bundle especially when head instrumentation is used This cable can be attached to the rear hole of the structural replacement or load cell and attached to the transducer cables with tape or tie wraps 6 Dummy Parts list ar 048 0000 Q1 5 DUMMY TESTED CERTIFIED UNINSTRUMENTED pie ee 0481000 HeadAssemby 0481020 _ Head Front Assemby 0481010 HeadRearCapAssy 50008565 ScewM amp xinBHcS 020 1013A _ Head accel mounting bass 1 o 1020 1013 3 500019 SwewMsdos
42. 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 allows certification of both the neck and the lumbar spine The head orientation 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 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 J21 1 version March 1995 All data channels should be filtered using a hardware filter prior to A D conversion according to SAE 2 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 Neck Test Set up Assemble the complete neck as described above 2 Attach the IF 217 6 AXIS LOAD CELL and 2650 11 SPACER FLEXION HEAD FORM to the head form Slide the head form over the neck and attach with 4 m5 x I2SHCS 3 Attach the neck to the pendulum interface plate Place the modified 020 2015 TE 2650 9 intermediate plate between the neck and pendulum interface Align the neck and the interface making sure th
43. ity Applied Technologies Associates type ARS 01 or ARS 06 flanged version angular velocity DTS IT 100 type 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 Thorax Standard 3 uni axial accelerometers or tri axial accelerometer in upper spine Ax Ay Az string potentiometer to measure chest deformation frontal or lateral Dx or Dy Optional additional accelerometers may be installed on the thorax and the rib cage see notes below Ax Ay 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 Pelvis Standard 3 uni axial accelerometers or tri axial accelerometer on pelvis skeletal structure Ax Ay Az Notes l The string potentiometer may be mounted in two ways either to measure frontal or lateral deformations The string potentiometer must not be used in deformations with expected rib deformation speeds exceeding 5 m s 2 Information on the installation of the instrumentation be found 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
44. k is used when testing the QI and QI 5 lumbar spine TE 2650 13 CENTRAL BLOCK QI QI 5 The potentiometer and balance weight are mounted on the side of the central block in line with the movement of the pendulum This can be seen in figure Lumbar Spine Frontal Both configurations use three screws for fixing the discs to the central block and the positions frontal and lateral of the angle transducer and balance weight remain the same Both potentiometers have their centre lines parallel to the axis of the pendulum The angle transducer and the balance weight of the head form must be repositioned when changing from frontal to lateral testing and vice versa Abdomen Test Rig The abdomen test compresses the abdominal insert between a Ql amp QI 5 abdomen certification support TE 036 99 0 and a flat plate The support s 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 2 050 0 05 kg Additional masses that are required for the certification are mentioned in the certification section of this manual 7 3 Equipment Parts List 020 1050 Head Certification Mass Q Dummies Head Drop Test TE 2650 Q Head Form Neck amp Lumbar Spine Test TE 036 9910 1
45. later the Q6 1999 and the QI 2000 were added to the series Based on customer feedback and test results FTSS have received comments on the dummies performance and durability This has resulted in an update program that was started in 2004 this update aimed at a number of issues with the Q dummies in the shoulder and head neck area During this period the QO and 1 5 were added to the family based on Q series anthropometry and biofidelity data The European Enhanced Vehicle safety Committee has 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 44 test is expected in 2005 Results of the first evaluations have been published at the 19 Enhanced Safety of Vehicles conference 20057 2006 the New Programme for the Assessment of Child restraint Systems NPACS adopted the Q dummies for their test protocols 2 2 Application The 1 5 4 is a child dummy which is intended for both homologation 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 Sy
46. moved for proper access to the thorax assembly Remove the cable cover 048 4303 from the back of the Thoracic spine The upper part of the body can easily be separated from the lower part of the body by removing the two 6 43 counter sunk 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 M6x43 counter sunk screws The upper body can then be lifted from the lower part of the dummy when operating the upper torso section of the dummy for example when installing or removing 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 amp O 5000312 056 4002 s o m e 048 3015 048 3103 Figure 7 Thorax Assembly The parts list for the torso assembly is shown on the previous page Note to prevent unnecessary wear the rib cage and shoulders should not be removed from the thoracic spine under normal circumstances 048 9900 User Manual Q1 5 Rev D Page 23 of 63 2012 Humanetics Innovative Solutions Arms l To remove the arms turn the dummy sideways and remove the three M3 button head
47. n this position for more than minute 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 3 9 0 1 m s 2 The pendulum velocity decrease should be as indicated in the table below Lower limit m s Upper limit m s To meet the requirements of the lateral neck certification test 3 The maximum head angle first maximum should be 60 0 6 5 degrees The peak moment shall be 20 75 2 25 Nm 8 3 Certification of the Lumbar Spine General The lumbar spine is tested with the same device as the neck To certify the lumbar spine separate tests are defined for side and frontal impact In each test the angle between the base and the test head is measured The certification head orientation is measured using two rotational potentiometers One is installed on the base of the spine pendulum interface The second one is attached to the test head The sum of the two angles measured on the potentiometers is the head relative to the pendulum angle The data acquisition system and all instrumentation must comply with the requirements of SAE J211 version March 1995 All data channels should be filtered using a hardware filter prior to A D conversion according to SAE J21 l version March 1995 The pendulum acceleration should be measured with an accelerometer which is located on the pendulum arm 16
48. ndevco 7264 and 7267A series e Entran EGAS Series and EGE3 73 Tri axial e Kyowa ASM Series e MSC 126M CM Uni axial accelerometers The tri axial accelerometers Endevco 7267A and Entran EGE3 073 cannot be fitted to the head The head will only accept uni axial accelerometers Thorax and Pelvis locations will ONLY accept tri axial transducers with a side entry cable The following accelerometers and mounts can be used for the QI 5 dummy Only uni axial accelerometers Location Accelerometer Type Head Mount Head Mount only uni for ATA Sensors Thorax Pelvis accels optional ENTRAN EGAS FS 50 AD 020 1014 ASM 200BA 020 1014 ILAN LAN ENDEVCO 7264 2000 020 1014 LAN LAN 7264C 2000 ENDEVCO 7264A 2000 AD 020 1014 IAO 7264 2000 MSC 126M CM 020 1014 ILAN LAN Tri axial Location Accelerometer Type Head Mount Head Mount only uni for ATA Thorax Bave axial sensors accels optional ENDEVCO 7267A 1500 Triaxial amp Not possible Not possible 56 Endevco Use Endevco Mount base Mount base 3 4 Angular Velocity Sensor mounting Application of the ATA 01 or ARS 06 flanged version angular velocity sensors in the head requires an alternative mount block for the head part no 020 1014 This mount block 020 1014 consists of a base and three ARS sensor blanks of similar weight and siz
49. of the arm to shoulder joint can be changed by tightening or loosening the P M3 attachment screws The compression washers ensure a certain amount of pressure on the screws and prevent them from loosening Slots in the retaining ring have been provided to Arm Assembly indicate horizontal and vertical positions of the upper arm 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 Figure 17 Arm Assembly Left 036 9901 A click stop provides fixed position for the lower arm when setting up the dummy Description Part No Left Part No Right each Assembly Arm assembly L or R 048 9300 048 9400 1 Upper Arm Assembly L or R 048 9301 048 9401 1 Lower Arm Assembly L or R 048 9302 048 9402 1 Shoulder Screw modified 036 9901 1 Stop Screw 020 9901 1 Spring Plunger 5000328 1 Shoulder Ball Retaining Ring 036 3002 2 Shoulder Ball 036 3004 1 Screw SHCS M3 x 12 5000568 3 Steel Washer 036 3006 3 Rubber Washer 036 3005 3 Part is shown on Figure 7 Thorax Assembly Assembly Disassembly Disassembly l remove the arm assembly by removing the three M3 screws at the top of the upper arm It is recommended NOT to remove the shoulder ball from the clavicle 2 remove the spring plunger and motion sto
50. of the neck The Neck cable assembly can now be pulled out from the top The neck cable assembly should NOT be disassembled Note Do not unscrew the screws at the bottom of the clamping plates 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 requested to replace the complete neck cable assembly 020 2200 Assembly Head amp Neck 1 Perform the steps described under disassembly in reverse order Instrumentation 1 To install a load cell first remove the load cell structural replacement To do so remove the head as shown above 2 Remove the four 5 10 FHCS screws that attach the load cell to the base of the head assembly 3 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 4 Fasten the load cell to the base of the head using the four M5x10 counter sunk head cap screws Assemble head and Load cell onto the top of the neck using the four M5 x 12 SHCS screws pn 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 top of the head 5000002 048 1000 Se a 020 2007 020 2100 5000291
51. ounting block onto head accelerometer block using the two socket head cap screws supplied with the mount Mount the mounting base inside the head front assembly 5 Replace the head rear assembly and tighten the four bolts UI To remove the accelerometers the procedure described above must be performed in the reverse order Alternative Instrumentation The cavity in a Q dummy head is large enough to accept an array of angular velocity sensors type ARS 0I or ARS 06 flanged version Applied Technologies ATA Sensors as be seen in the figure with ARS mounts below To mount these sensors the use of an alternative accelerometer mounting base is required part No 020 1014 The standard head accelerometer mounting base 020 1013 will not accept the 01 or ARS 06 sensors Refer to section 3 3 for additional information the mounting of these sensors 020 1014 5000649 5000654 048 1020 Head Assembly with 020 1014 mount Figure 4 Head Assembly with ARS mounts combination with accelerometer possible 048 9900 User Manual Q1 5 Rev D Page 18 of 63 2012 Humanetics Innovative Solutions 4 3 Neck Construction The neck assembly consists of the following parts from top to bottom Description Part No Qty in Assembly Neck Assembly Tested and Certified 020 2100 1 Neck Moulded pre tested 020 2101 1 Neck cable assembly 020 2200 1 Nut
52. p screw 3 remove the shoulder screw connecting upper and lower parts of the arm Assembly Perform steps 1 3 under assembly in reverse order Make sure that the retaining ring is in the right position with slot facing downward and the other facing rear ward 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 036 9901 4 Place upper and lower arm under a 90 angle with respect to each other 5 Turn the motion stop screw 020 9901 into the arm as far as it will go Then turn back half a turn and check that the motion of the lower arm is without significant friction The motion stop screw is Arm Assembly Right assembled on the inside of the arm 6 Screw in the spring plunger 5000328 in the hole next to the shoulder screw at the outside of the arm 7 Check the correct settings for 036 3005 rubber washer 50056 5000568 lt 036 3006 steel washer 048 9401 020 9901 5000328 gt the spring plungers see chapter 5 Figure 18 Assembly Right Note It is not possible to change the friction setting of the elbow joint The positioning is done by means of the fixed click stop positions in the joint Do not over tighten the spring plunger so the body of the plunger scr
53. rib cage assembly Use the 2 60 Kg test probe as described in section 7 2 The impact velocity must be measured and recorded Test procedure The 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 Place the dummy with its thoracic spine in a vertical orientation within 5 degrees with the vertical To stabilise 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 Make sure the dummy is motionless Place the upper arms vertically alongside the body and let the lower arms rotate downwards to let the hands touch the seating surface Align the Impactor Figure Let the Impactor hang in its lowest position Check that the probe is a horizontal position that is within 0 2 degrees Figure 2 The Impactor front surface should be directly in front of the dummy sternum within 5 mm Figure 3 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 aligns with the sternum halfway between the upper and lower surface of the rib This aligns the Impactor above the string potentiometer attachment point Figure 4 centre line of the Impactor should be in the mid sagittal plane Impact the dummy sternum with an Impactor velocity of 4 3 0 1 m s The impact veloci
54. rizontal 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 Head Drop Test When released the head should impact the surface with the side of its head Figure 24 Head Drop Lateral Data Processing All three accelerations should be filtered 000 2 Determine the resultant head acceleration Requirement The maximum resultant head acceleration response should be between 100 g and 130 g The acceleration in X direction should not be between 20 and 20 g s The lowest point of the head should be 130 mm above the impact surface Release the head The minimum time interval to observe between tests on the head is 30 minutes 8 2 Certification of the Neck The neck of the dummy has been re designed Biofidelity targets have been set for frontal and lateral impact reference TNO and FTSS The lateral response corridors are based on TNO and FTSS biofidelity requirements and test results Note that the necks for the QI QI5 and are identical General The neck test is a component test which is performed using a pendulum as defined CFR49 part 572 The complete neck consists of the following parts Description Parts Q1 Q1 5 amp Q3 Qty Neck Moulding 020 2101 1 Neck Cable assembly 020 2200 1 Screw FHCS M3 x 8 5000119 2 The neck
55. screws in the arm see also section 4 8 Repeat this procedure for the other arm Note the position of the steel and rubber washers for the arm friction setting See Right and Left hand arm assemblies Clavicle 2 The clavicle is attached to the shoulder spine interface with three M5 x 8 countersunk screws on each side Remove these screws by turning the aluminum retaining ring until the screws become visible 3 Remove the 5 12 countersunk head screw at the front of the rib cage which is used to mount the clavicle retainer 048 3005 and clamps the clavicle to the rib cage Remove the screw and the clavicle retainer on the inside of the rib Rib 4 Remove the rib by unscrewing the six M5xl6 button head cap screws on each side of the thoracic spine Shoulders 5 Finally the shoulder spine interfaces 048 301 amp 048 3015 can be removed by unscrewing the three 4 12 button head cap screws of each shoulder spine interface Assembly To assemble the thorax perform the operation described above in reverse order 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 3 x
56. should be 4 4 0 1 m s 2 The pendulum velocity decrease should be as indicated in the table below Lower limit ae Upper limit m s To meet the requirements of the frontal lumbar spine certification test maximum head angle first maximum should be between 40 degrees and 50 degrees This value should occur at a time between 42 ms and 62 ms from the time zero point The first minimum head angle should occur at a time between 126 ms and 146 ms with a value between 17 degrees and 27 degrees Lateral 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 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 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 on the head form s central block Mount the balance weight for the potentiometer on the side of the head form s central block This ensures that the inertial properties of the head are symmetrical in the impact direction Refer to Figure Lumbar Spine Lateral to indicate the proper position and orientation of the potentiometers Insert the ro
57. stems NPACS protocols calls up the Q series for their frontal and side impact consumer test procedures for CRS performance rating 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 anthropometry of the dummy has been 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 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 Tejera ApplustIDIADA Spain Jean Philippe Lepretre UTAC France Paper no 05 0157 4 Progress Report and Results From the NPACS Research Project Lowne Third International Conference on the Protection of Children in Cars Munich December 2005 Special attention has been paid to the handling characteristics of the dummy ensuring the dummy be assembled and disassembled quickly and installing the dummy in the test configuration is simple and repeatable The influence of transducers
58. sure that lateral axis of the head is in the direction of movement of the pendulum arm 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 6 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 7 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 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 8 The minimum time interval to observe between tests on the neck is 30 minutes Performing the Test 1 Attach honeycomb material to arrest the pendulum 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 i
59. t the time zero at the g deceleration level in the Impactor signal filtered at CFC600 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 maximum impact force should be between 0 80 kN and 1 10 kN Manual Update Log Rev B July 2009 Pg 22 23 35 and 40 Remove LH from 036 2002 and add QTY 2 remove 036 3003 Rev C Sept 2011 Manual changed from FTSS to Humanetics Rev D Feb 2012 Pg 35 036 3005 was 9003140 036 3006 was 020 3006
60. t to keep the head in place The net allows easy adjustment of the head in any orientation 2 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 Head Drop Frontal The lowest point of the head should be 130 Imm above the impact surface Release the head 5 The minimum time interval to observe between tests on the head is 30 minutes A w 3 130 1 Figure 23 Head drop Frontal Data Processing All three accelerations should be filtered 000 2 Determine the resultant head acceleration Requirement The maximum resultant head acceleration response should be between 95 g and 125 2 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 7 2 Head Drop Table of this manual FTSS uses a thin wire net to contain 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 2 Position the head in such a way that the mid sagittal plane has an angle of 35 2 degrees with the ho
61. the bottom most axis to secure the rod to that potentiometer 4 The minimum time interval to observe between tests on the lumbar spine is 30 minutes 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 Ibs cu ft with a nominal length of 76 2 mm 3 inches Optional length of 152 4 mm Hexcel may be used 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 4 Release the pendulum Figure 25 Lumbar Spine Frontal Data Processing Filter the pendulum acceleration at CFC180 2 Filter the potentiometer readings at CFC600 3 Determine time zero of the impact by finding the g deceleration level in the pendulum signal after filtering 4 Software zero all transducer readings by averaging the part of the signal before time zero and subtracting this from the transducer reading 5 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 6 Sum the potentiometer signals to derive the total head relative to pendulum arm angle Requirements The impact velocity
62. ty must measured and recorded The minimum time interval to observe between tests on the thorax is 30 minutes Data Processing All data channels should be filtered at CFC600 2 Time zero is defined as the time of initial contact between the test probe and the sternum Set time 3 zero at the g deceleration 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 frontal thoracic impact The maximum thorax deflection should be between 22 5 mm and 27 5 mm 2 The force at the maximum deflection should be between 0 65 kN and 0 95 kN Side Impact Thorax Test Instrumentation The dummy must be equipped with the standard string potentiometer which is mounted on the front of the thoracic spine the string does not need to be attached to the ribcage for the certification test it The test probe is as described above The impact velocity must be measured and recorded Test procedure 4 5 The dummy should be seated on a flat horizontal clean dry surface consisting of two 0 60 x 0 65 m flat plates of 2 mm Teflon Place the dummy with its thoracic spine in a vertical orientation within 5 degrees of the vertical To stabilise the sitting position of the dummy rotate the upper legs outwards toes point outwards and place the legs in a v shap
63. 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 a low stretch neck cord in order to prevent excessive elongation The neck cord is also designed to act a safety in case of rubber failure A six channel load cell can be mounted at the neck head interface Thorax The thorax of the child is represented with a single rib cage The deformation can be measured with a string potentiometer The shoulders are connected with a flexible joint to the thorax allowing deformation forwards Accelerometers can be mounted on the spine to measure linear accelerations 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 t
64. w series was called the Q series As of September 2004 the series is available in four age groups representing a year 1 2 year 3 year and 6 year old child A new born dummy QO is also available In 2004 a major update of the Q dummy series has been performed resulting the completion of the series from till Q6 The QI 5 dummy and the 00 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 and CHILD 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 users manual if this is deemed necessary We will of course inform our customers of any changes or modifications as they occur Figure 4 Family 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 CT2002 00791 2002 2006 048 9900 User Manual Q1 5 Rev D Page 6 of 63 2012 Humanetics Innovative Solutions 2 General Description and Features 2 1 Design History In 1993 the international Child Dummy Working Group started with the development of a new series of child dummies as a successor to the P series This new series was called the Q series This development resulted in a dummy in 1998

Q1.5 (Advanced 1.5 year old child) User Manual

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