Home

AEROSP SURFACE VEHICLE RECOMMENDED PRACTICE

1. Item Number Quantity Part Number Description 1 2 A 1886 Modified SHSS 14 x 34 2 2 880995 1600 L 880995 1601 R Molded Foot L and R FIGURE 45 FEET AND ATTACHMENT BOLT 3 4 3 Non Instrumented and Optional Force Indicating Lower Legs Each Hybrid Ill Large Male lower leg assembly consists of the ball bearing sliding knee with an optional potentiometer to measure displacement a lower leg either standard or an optional instrumented one and a 45 degree foot The knees are attached so the potentiometer mounts inboard in order to provide easier access to the knee adjustment screw when seating the dummy Separate the lower leg from the machined knee by removing eight FHCS from the clevis This exposes the knee slider assembly The slider is detached by removing the SHSS that has a metal and a urethane washer Figure 42 The two parts of the slider assembly then can be taken off of the machined knee Disassemble the inboard and outboard stops by removing two BHCS from each stop assembly Figure 42 Inspect the rubber blocks of the slider and the rubber stops for damage Inspect the balls in the tracks of the slider to ensure they are in the track securely If damaged contact the manufacturer for guidance The instrumented lower leg option can measure knee tibia to femur shear knee clevis axial loads medial and lateral upper leg fore aft and lateral moments plus shear and axial forces and lower leg
2. N English Units Moment ft Ibf My ft Ibf 0 05833 ft Fx Ibf NOTE The formulae are based on the sign convention contained in the latest revision of SAE Recommended Practice J211 1 and SAE Information Report J1733 E Performance Specifications Neck Flexion The performance specifications for the Neck Flexion test are listed in Table 15 TABLE 15 NECK FLEXION TEST SPECIFICATIONS Temperature 20 6 22 2 C 69 1 72 0 oF 22 60 23 39 ft s 7 2 8 9 ft s 13 1 16 4 ft s 18 7 22 6 ft s D Plane Rotation 61 75 Deg Moment During Rotation Interval 110 130 N m 81 96 lbf ft Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 44 of 74 F Performance Specifications Neck Extension The performance specifications for the Neck Extension test are listed in Table 17 TABLE 16 NECK EXTENSION TEST SPECIFICATIONS Corridors Lower Upper Units emperature 20 6 22 2 PG Humidity RH 19 52 20 31 ft s Pendulum Pulse at 10 ms m s 5 9 7 2 ft s Pendulum Pulse at 20 ms m s 11 2 13 8 ft s Pendulum Pulse at 30 ms m s 15 7 19 0 ft s D Plane Rotation 81 98 deg Moment During Rotation Interval 66 84 N m 49 62 lbf ft Moment Decay to 10 N m ms Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 45 of 74 62 mm 3 i paa 4 8mm 3 16 in WallThickness Structural
3. The test environment should have the same temperature and humidity requirements as the soak environment Remove the knees and lower legs from the dummy if needed Clean and dry all component surfaces Disassemble the lumbar spine bracket from the pelvis separating the dummy Adjust the torque on the lumbar cable hex nut to 1 13 to 1 40 N m 10 0 to 12 4 in lbf Fasten a pelvic support bracket to the outside of the pelvic instrument cavity with four screws Reassemble the dummy by attaching the lumbar bracket to the pelvis Adjust all joint torques to 1 G as specified in Appendix C Mount the dummy rigidly onto the torso flexion test table using the pelvic support bracket The pelvic surface to which the lumbar spine mounts must be horizontal 2 degrees and the bottom surface of the pelvis is between 1 2 to 1 inches above the table surface The test set up appears in Figure 57 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 60 of 74 a 12 13 If the lower legs are removed use two hex nuts to attach a socket head cap screw with the head downward to the knee end of each femur load link Adjust each femur load link to horizontal within O to 6 degrees If the lower legs are attached rest them on the table surface Flex the elbow joints to 90 degrees and point the forearms laterally away from the dummy torso to clear the table Attach a torso pull bracket Figure 58
4. 0 N m 2 95 Ibf ft 33 degrees 2 degrees 4 0 N m 2 95 Ibf ft 22 degrees 1 degree 4 0 N m 2 95 Ibf ft 22 degrees 1 1 degree The moment in dorsiflexion up to 34 degrees must be less than 6 N m 4 42 Ibf ft 6 NOTES 6 1 Marginal Indicia A change bar 1 located in the left margin is for the convenience of the user in locating areas where technical revisions not editorial changes have been made to the previous issue of this document An R symbol to the left of the document title indicates a complete revision of the document including technical revisions Change bars and R are not used in original publications nor in documents that contain editorial changes only PREPARED BY THE HYBRID III 95TH LARGE MALE TASK GROUP OF THE DUMMY TEST EQUIPMENT COMMITTEE OF THE HUMAN BIOMECHANICS AND SIMULATION STANDARDS STEERING COMMITTEE Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 69 of 74 APPENDIX A ACCELEROMETER HANDLING GUIDELINES A 1 GENERAL The accelerometers used in anthropomorphic test dummies such as the Hybrid Ill Dummy Family are small low mass piezoresistive accelerometers Because of their design and inherent mechanics certain precautions must be observed when handling and mounting accelerometers to avoid damaging them When handling and mounting the accelerometer avoid dropping the accelerometer or striking the unit against hard surfaces Keep t
5. 9 Wait at least 30 minutes between successive tests on the same knee slider assembly a Performance Specifications The performance specifications for the Knee Slider test are listed in Table 20 TABLE 19 KNEE SLIDER TEST SPECIFICATIONS 18 9 25 6 C 66 02 78 08 F 10 0 70 0 10 0 70 0 Velocity 2 70 2 80 m s 6 04 6 26 mph Peak Deflection 15 0 18 3 mm 0 59 0 72 in S A E FEMUR LOAD CELL HORIZONTAL 20 5 RIGID FIXTURE Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 J2860 Issued SEP2012 ACCELEROMETER MOUNTED WITH SENSITIVE amp x S PARALLEL TO TEST PROBE LONGITUDINAL CENTERLINE MOUNTING BOLTS TORGUE TO 407 N m C30 Ib Ft HP zo TEST PROBE CENTERL HORIZONTAL D5 TEST PROBE MASS 12 0 0 14 ke 26 5 3 lbs TEST PROSE FACE DAKETER 76 2 0 25 an 3 0 2 Dl im 5 13 130 20 2 500 63 50 2475 62 37 DARN Ba a ASLE SIDE SUPPORT TOTAL ASSEMBLY WEIGHT PLATE 234 02 LES 1 08 01 Kg SGREW FHOS 10 32 X 1 2 on 3 281 7 14 THRU 6 50 12 7 C SINK X BZ ON 61 00 25 4 B CIRCLE IZI NO eg YV LP 1 750 4445 pozo 412 70 BALLAST WEIGHT CLEARANCE FOR SUDER STOP 1 4 20 X 75 LE SHCS OTY 4 FIGURE 54 KNEE SLIDER TEST SET UP SPECIFICATION Hardware for cable length adjustment should be located ENSOLTE m near the upper pivot and is not i
6. Inspect each yoke to make sure each one contains five alignment dowel pins and one rubber bumper Separate the lower arms from the upper arms and examine the elbow joints noting the condition and position of the various parts as for the shoulder joints Look to see that the two elbow rubber stops are in place Remove the elbow pivot nut and check that the nut slides freely in the hole Detach the hands from the lower arms and disconnect the wrist rotation joint The elbow and wrist rotation joints have no stops Lubricate these two rotation joints with an anti seize agent such as Molylube Anti Seize lubricant made by Bel Ray Co P O Box 526 Farmingdale NJ 07727 or an equivalent lubricant Examine all metal parts for burrs and sharp edges and remove them as necessary Inspect vinyl to foam adhesion cracked or cut vinyl skin cracked or damaged bushings and the condition of the threaded holes Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 40 of 74 3 5 1 Arms Special Care and Maintenance e Check the flesh for rips or tears Repair or remold e Check the elbow joint washers and replace if damaged 4 CERTIFICATION TEST PROCEDURES 4 1 Head Drop Test A This test measures the forehead response to frontal impact with a hard surface B lt The head assembly 880995 1100 consists of head assembly 6 channel neck transducer replacement head to neck
7. Instrumentation SAE J1733 Sign Convention for Vehicle Crash Testing SAE J2517 Hybrid Ill Family Chest Potentiometer Calibration Procedure SAE J2859 SAE Hybrid Ill Large Male Drawing Package 2 2 Related Publications The following publications are provided for information purposes only and are not a required part of this SAE Technical Report 2 2 1 SAE Publications Available from SAE International 400 Commonwealth Drive Warrendale PA 15096 0001 Tel 877 606 7323 inside USA and Canada or 724 776 4970 outside USA www sae org SAE J2570 Performance Specifications for Anthropomorphic Test Device Transducers Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 9 of 74 3 ASSEMBLY DISASSEMBLY 3 1 Head Neck TABLE 2 HEAD EXPLODED VIEW PART LIST Item Number Quantity Part Number Description 1 1 880995 105 Head skin 2 1 880995 095X Machined Skull 3 1 880995 1715 Accelerometer mount 4 4 9000224 SHCS 10 24 x 5 8 5 1 78051 383X Upper neck load cell replacement Upper neck load cell not shown 6 4 9000677 Washer Flat 2510 x 38 OD x 06 THR 7 4 9000453 SHCS 14 28 x 34 8 2 78051 253 Washer Nodding Joint 9 1 78051 339 Pivot pin Neck Transducer 10 2 9000452 SSCP 8 32 x YA 11 1 SA572 S80 Accelerometer cube 12 2 9000531 SHCS 2 56 x 5 8 13 4 78051 94 SHCS 1 20 x 5 8 14 1 78051 220 Machined skull cap 15 1 7805
8. Knee Impact Test A The components required for the knee impact test include knee cap 880995 1510 knee flesh 880995 508 knee insert 880995 51 1 knee slider assembly optional lower leg assembly optional femur load cell optional or structural replacement 7805 1 319 C The test fixture consists of a rigid test probe and a method of rigidly supporting the knee and lower leg assembly The probe mass is 5 0 kg 0 01 kg 11 0 Ib 0 02 Ib including instrumentation rigid attachments and the lower 1 3 of the suspension cable mass The diameter of the impacting face is 76 2 mm 0 25 mm 3 0 in 0 01 in with an edge radius of 0 5 mm 0 02 in Mount an accelerometer on the end opposite the impacting face with its sensitive axis collinear to the longitudinal centerline of the test probe C The data acquisition system including transducers must conform to the requirements of the latest revision of SAE Recommended Practice J211 1 Filter all data channels using Channel Class 600 phaseless filter Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 51 of 74 D Test Procedure 1 Inspect the knee flesh and insert for cracks cuts abrasions etc If the machined knee is cracked or broken replace it If the insert is cut replace the insert 2 Soak the knee assembly in a controlled environment with a temperature between 20 6 and 22 2 C 69 to 72
9. be used under the load cell attachment bolts Larger washers will interfere with load cell operation After the screws have been removed the transducer can then be removed by lifting it upward and out the back of the skull opening The transducer may have to be turned slightly sideways to do this The accelerometer mount and cube are shown as reference Figure 2 Item 3 amp 11 Accelerometer mounts and cubes can differ depending on the accelerometers being used and the manufacturer of the mount FIGURE 11 NECK TRANSDUCER REMOVAL Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 14 of 74 To remove the flesh from the skull hold the skull by the back of the skull opening Peel the skin forward starting at the top rear of the skull and skin assembly This should allow the skin to pull away from the skull and then slide off the chin area To remove the cap skin from the machined skullcap follow a similar procedure The skin should be inspected for nicks tears or other damage that may be present after testing If damaged the skin should be repaired or replaced see Special Care and Maintenance Inspect the skull for smoothness and freedom from flat spots and pits Examine the bond of the skull ballast If the ballast must be reinstalled or changed see drawing for instructions 3 1 3 Neck Figure 12 is an exploded view of the neck assembly Table 3 gives a general description o
10. fore aft and lateral moments plus shear Load cells with five channels to measure various combinations of forces and moments are available for the upper and lower tibias The standard lower leg Figure 43 is a welded assembly with a bolt on knee clevis that can be replaced with an optional instrumented leg The following section describes the assembly of the optional instrumented lower leg The upper part of the lower leg consists of the clevis that is bolted to the upper tibia load cell by four SHCS The optional upper and lower tibia load cells are separated by a heavy wall aluminum tube that protects the load cell connectors The upper and lower tibia load cells are each attached to the tube by four modified BHCS The lower load cell may be rotated 90 degrees if lateral shear and moment are preferred by using the second slot in the ankle to tibia adapter or this load cell may be purchased with both moment measurements built in No adjustments are possible except for a friction adjustment at the ankle ball Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 38 of 74 3 44 Legs Assembly Notes When assembling the knees with the standard non instrumented lower legs the shoulder bolt head is mounted on the outboard side of both knees The shoulder bolt for the machined knee acts as a control for the motion between the lower leg and knee 3 4 5 Legs Special Care and Maintenance e Ch
11. kahalalan 31 FIGURE 39 FEMUR ASSEMBLY ccccccescesceseesceccecceseecceceacceceaceecasseecascaesacsacsacsacsecusvsesasvacsassaececeassecasessscesaueseseeases 32 FIGURE 40 ASIS LOAD CELL REMOVAL c cescescessesceceecessesceececeeececceecescecsescacseceavseceaveesassacsaseaesetasseseseesteseseeates 32 FIGURE 41 UPPER LEG EXPLODED VIEW daanan AA AA AA AG 33 FIGURE 42 BALL SLIDER ASSEMBLY EXPLODED VIEW ccccccescescessesceceeccsceeceececesecessecsessacsessaceeceasssacereteaseseeaees 34 FIGURE 43 LOWER LEG EXPLODED VIEW Q ccccccessesceceecssceeccecescsececceccessacceseacseceaesecuaveesessacseseaececeaeeesasecusateaeeases 35 FIGURE 44 ANKLE ASSEMBLY EXPLODED VIEW c cccecccseesecceseesceceeecesceccsceaceececesecesveecassacsaseacessesssecevesstsseseeates 36 FIGURE 45 FEET AND ATTACHMENT BOLT waaa AKA GG GG Cassar ANAN 37 FIGURE 46 ARM ASSEMBLY EXPLODED VIEW c cecceccecessescecceseesceceescescecceccacsceceassecusveccassaccaseassecsasseceeessatsateseeaees 39 FIGURE 47 HEAD DROP TEST SET UP SPECIFICATIONS w w wawwawawawawamawawamamamamawawwawamamamam nawaza 41 FIGURE 48 NECK PENDULUM SPECIFICATIONS 111111111101 NN Kanan 45 FIGURE 49 NECK EXTENSION TEST SET UP SPECIFICATIONS ccccescecsccescesceceesceceessescecseseasceceaeessceesateaseseeaees 46 FIGURE 50 NECK FLEXION TEST SET UP SPECIFICATIONS 111111210001010 00m LAG mma 46 FIGURE 51 THORAX IMPACT TEST SET UP SPECIFICATIONS 1 1111111101010000 0
12. medial lateral centerline of the ankle shell should be perpendicular to the centerline of the foot within 1 degree The centerline of the foot is 26 4 degrees from a centerline through the two standoffs Time zero is defined as the point at which the initial angles meet the requirements specified in item 6 All data channels should be at the zero level at this time Dorsiflexion Test apply a moment through the standoffs that rotates the toe towards the ankle shell about the ankle s medial lateral axis until a moment of at least 40 N m 29 5 Ibf ft is reached at a rate not to exceed 5 degrees per second Plantar flexion test apply a moment through the standoffs that rotates the toe away from the ankle shell about the ankle s medial lateral axis until a moment of at least 4 N m 2 95 Ibf ft is reached at a rate not to exceed 5 degrees per second Inversion test apply a moment through the standoffs that rotates the foot inward relative the ankle shell about the ankle s anterior posterior axis until a moment of at least 4 N m 2 95 Ibf ft is reached at a rate not to exceed 5 degrees per second Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 66 of 74 LINE CONNECTING KNEE PIVOT AND ANKLE PIVOT Hi l TIBIA IS OPTIONAL N FOR THIS TES FIGURE 61 LEG REFERENCE PLANES S A E Downloaded from SAE Internationa
13. must conform to the specifications of the latest revision of SAE Recommended Practice J211 1 Using phaseless filters filter the force and displacement channels using Channel Class 60 D Test Procedure 1 Soak the foot assembly in a controlled environment at a temperature between 20 6 to 22 2 C 69 0 to 72 0 F and a relative humidity from 10 to 70 for at least 4 hours prior to a test The test environment should have the same temperature and humidity requirements as the soak environment Inspect the foot assembly for cracks cuts and separation of the rubber from the metal segment Inspect the heel pad foam for signs of deterioration Attach the standoffs on the foot Install the ankle adaptor bracket to the foot and attach it to the compression testing machine Lower the foot until it first contacts the base of the test fixture Using an angle measurement device positioned on the standoffs position the foot so it is level relative to the test fixture in the transverse and longitudinal directions within 1 degree Wait at least 30 minutes between tests on the same foot Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 64 of 74 E Performance Specifications The performance specifications for the Foot Test are listed in Table 10 TABLE 22 FOOT TEST SPECIFICATIONS Foot Load 15 mm min 1 mm min 0 59 in min 0 04 in min Peak Deflection 8 9 mm 0 3
14. on the same knee Tm Performance Specifications The performance specifications for the Knee Impact test are listed in Table 19 TABLE 18 KNEE IMPACT TEST SPECIFICATIONS 18 9 25 6 C 66 02 78 08 F Humidity 10 0 70 0 10 0 70 0 2 07 2 13 m s_ 4 63 4 77 mph Knee Impact Force 4 9 7 3 KN 1101 56 1641 11 Ibf Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 52 of 74 Hardware for length adjustment should be located near ACCELEROMETER MOUNTED WITH the upper pivot and is not included in the cable weight SENSITIVE MATS PARALLEL T Wie aan Ces TEST PROBE GITUDINAL CENTE E HORIZONTAL 0 5 G BOLTS TO 40 7 N m C30 lh Ft RIGID FIXTURE E E CENTERLIM HORIZONTAL 0 5 MASS 5 0 0 01 kg 11 0 0 02 Ibf ADJUST KNEE PIV JOINT TO 1 2 G F D e ee L TEST PROBE FACE TEST DIAMETER 76 2t2 5 mm 3 0401 ind ANKI F PIVOT FIGURE 53 KNEE IMPACT TEST SET UP SPECIFICATIONS 4 5 Knee Slider Test A The components required for th
15. pin Figure 6 Neck Transducer Condyle Pin FIGURE 6 NECK TRANSDUCER There are several neck compression tools in existence Figure 7 is a representative model of such a tool available to assist in the separation of the head and neck FIGURE 7 NECK COMPRESSION TOOL Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 12 of 74 For this design the compression tool is mounted to the head by fastening the flat plate to the back of the skull Then slip the round end of the tool over the cable and turn the knob until the neck begins to compress Figure 8 FIGURE 8 NECK REMOVAL Slowly increase the compression on the neck until the pivot pin can be pushed or lightly tapped out with a minimal amount of effort Reduce the compression on the head and neck allowing the head and neck to separate at the nodding joint Figure 9 Two brass washers and the two rubber nodding blocks may fall out in the disassembly process To assemble the head and neck be sure the nodding blocks washers and nodding joint are in place before compressing the neck using the compression tool Once compressed slide the pivot pin into place while orienting the flats on the pin toward the set screw locations Tighten the set screws to finish the assembly With the head and neck disassembled inspect the neck cable for imperfections No evidence of the cable pulling through the end fittings s
16. seat surface N Compare measured dimensions to dimensions in Table 20 to determine conformance to specifications Y AXIS 1 wee 4 H POINT TO i ph C t X AXIS Y AXIS Wa b M X AKIS Z AXIS SIDE VIEW FRONT VIEW FIGURE 56 EXTERNAL DIMENSION MEASUREMENT Downloaded from SAE International by Yos SAE J2860 Issued SEP2012 Page 58 of 74 5 3 External Dimensions TABLE 20 EXTERNAL MEASUREMENTS Test Parameter Designation in mm Total Sitting Height A 36 20 0 6 919 48 15 2 Shoulder Pivot Height B 21 10 0 6 535 94 15 2 Hip Pivot Height Set up dimension C 4 00 0 2 101 64 5 1 Hip Pivot from Backline Set up dimension D 6 1040 2 154 94 45 1 Shoulder Pivot from Backline without Jacket E 3 60 0 2 91 44 5 1 Thigh Clearance at the highest point of the thigh F 6 60 0 3 167 64 7 6 flesh Back of Elbow to Wrist Pivot G 12 20 0 3 309 88 7 6 Head Back From Backline set up dimension H 3 50 0 1 88 9 2 5 Top of the shoulder yoke to elbow length I 14 30 0 4 363 22 10 2 Elbow Rest Height J 8 40 0 4 213 36 10 2 Backline to knee length K 25 50 0 5 647 7 12 7 Bottom of seating surface to bottom of foot L 18 50 0 5 469 9 12 7 Knee Pivot Height M 21 00 0 5 533 4 12 7 Chest Depth without jacket O 9 70 0 3 246
17. to the instrument cavity mating surface at the back of the spine box using four screws Position the upper torso of the dummy so that the instrument cavity mating surface at the back of the thoracic spine is 0 to 27 degrees forward of vertical initial angle If the test set up does not result in 0 to 27 degree initial angle check the possibility of replacing the lumbar and or abdomen Apply a forward pull force to the pull bracket through a cable attached at the occipital condyle location to flex the dummy forward at any rate between 0 5 and 1 5 degrees per second Flex the dummy forward until the instrument cavity mating surface at the back of the spine box is at 45 degrees Apply the force so that it is perpendicular to the undeformed neck centerline at 45 degrees this will be a pull angle of 59 degrees from horizontal Record the highest force required to flex the dummy to the 45 degree angle Wait at least 30 minutes between successive tests on the same components Performance Specifications The dummy will flex forward to an angle reading of 45 degrees from vertical as measured on the instrument cavity mating surface at the back of the thoracic spine The force required to flex the dummy to this angle shall be not less than 475 N 107 Ibf and not more than 550 N 124 Ibf The dummy s torso should return to within 12 degrees return angle of the initial angle see Step 10 in the test procedure Downloaded from SAE Internation
18. 0 NLA kman 49 FIGURE 52 HYSTERESIS DEFINITION 0 cccecccceccesceceesceceecceseecccceccsececcescessecsacacseceaesesusvessescaeseesateeceasesssvereatereseeaees 50 FIGURE 53 KNEE IMPACT TEST SET UP SPECIFICATIONS ccccccecsescessececceecescecesececeescescecseteateecasatceeesateateaeeaees 52 FIGURE 54 KNEE SLIDER TEST SET UP SPECIFICATION cecccccecsescesceccsceecescecesecucvecsesceeseceaceeceasaseeeesucateaeeases 54 FIGURE 55 CHEST DEPTH MEASUREMENT TOOL s cssescescessesceceescosceccecesececeaesecesvessescaesacsaccacesesseaveesassaseateasens 55 FIGURE 56 EXTERNAL DIMENSION MEASUREMENT cecceccescescecescesccececcesceceescescecseseacceceaseeceasessaceesatsaseseeaees 57 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 3 of 74 FIGURE 57 TORSO FLEXION TEST SETUP ccccccessesceceecessessecceceesceceeccescecseecacsaceassecesveesassacsassarsesassesesessteateseeares 61 FIGURE 58 TORSO FLEXION PULL BRACKET SPECIFICATIONS c ccccecscsescecceseesceceeccesseccsseaececeseeseeersteteseeeres 62 FIGURE 59 COMPRESSION TEST SETUP vvcsccscccssssscscscercseveinssnsevecesescesonsnesnusndustasuesdueucavacetosendtiannsedocsuaunadevensuinsdesensens 63 FIGURE 60 FOOT TEST SPECIFICATIONS sisciniseccccsscvsvseniseverseianesecncvecoosscnuvasdvicnsnaasiancaesnavovanabsansuaveseusidsntedeuenddavantesnas 64 FIGURE 61 LEG REFERENCE PLANES 0 scccscescesceseesceceeccsses
19. 07 BHCS 72 20 x 12 2 1 3000051 Washer 3 1 880995 324 Chest Deflection Transducer Assembly 4 4 9000005 SHCS 14 20 x 5 8 5 1 880995 1022 Upper Accelerometer Mount 6 6 9000528 SHCS 4 40 x Ya 7 2 880995 1021 Lower Mid Accelerometer Mount 8 1 880995 1000 Spine Box Assembly 9 4 78051 9 Rubber Sternum Stop 10 2 880995 1024 2 L 880995 1025 2 R Upper Rib Guide L and R 11 4 9000009 SHCS 1 4 20 x 34 12 4 9000022 Washer 13 1 78051 303 Lower Neck Bracket 14 4 900433 SHCS 5 16 24 x 7 8 15 1 880995 329 CG Accelerometer Mount 16 4 9000540 SHCS 8 32 x 3 8 17 1 880995 328 Load Cell Structural Replacement 18 6 900476 SHCS 5 16 18 x 7 8 19 4 9000559 SHCS 5 16 18 x 34 20 2 78051 85 Rubber Bumpers Torso flexion stop 21 1 880995 325 Spine Mounting Assembly FIGURE 31 THORACIC SPINE ASSEMBLY EXPLODED Remove the four SHCS that attach the lumbar spine to the thoracic spine assembly and lift off the thoracic spine Figure 32 Next remove the six SHCS from the side of the spine box and slide the thoracic insert out of the thoracic spine cavity The insert holds the chest accelerometer adapter assembly and chest displacement pot assembly to the bottom of the thoracic spine Slide the assembly out of the bottom of the thoracic spine Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 27 of 74 FIGURE 32 THORACIC SPINE REMOVAL Install the accelerometer block package an
20. 1 229 Skull cap skin FIGURE 2 HEAD EKPLODED VIEW Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 10 of 74 3 1 1 Chest Jacket Remove the chest jacket to permit easier access to the base of the neck bracket For easy removal of the jacket remove the arms first Figure 17 Remove the SHCS Figure 3 that holds the upper neck bracket to the lower portion of the neck bracket and permits adjustment of the neck angle Check the condition of the curved steel washer and note how it fits on the neck bracket FIGURE 3 NECK ADJUSTMENT SHCS AND WASHER Tilt the head and neck forward and remove the neck cable nut and four SHCS that hold the upper neck bracket to the base of the neck Figure 4 Check for the presence of four steel washers between these four SHCS and upper neck bracket upon reassembly If they are missing replace them upon reassembly The neck and head assembly is now disconnected from the plastic sternum to rib cage bib assembly FIGURE 4 UPPER NECK BRACKET AND BIB Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 11 of 74 Remove four SHCS from the rear skull cap once the head and neck have been separated from the dummy Figure 5 FIGURE 5 SKULL CAP For the six channel neck transducer or its structural replacement loosen two SSCP that secure the head to neck pivot
21. 16 x 1 2 11 1 A 1672 Stop Pin Retainer FIGURE 44 ANKLE ASSEMBLY EKPLODED VIEW Separate the 45 degree foot and ball joint ankle assembly by removing the modified SHSS at the ankle lower leg intersection Figure 43 item 3 Figure 44 is the exploded view of the ankle The ankle assembly and foot can be separated by removing the modified SHSS from the ankle shaft Figure 45 item 1 Remove the four BHCS from the ankle bumper This will remove the bumper and expose the lower ankle shell Two SSCP will be inset to hold in the pin retainer Two BHCS will hold the lower shell to the upper shell Remove the two BHCS and SSCP to remove the ankle shaft The pin retainer and dowel pin can now be removed easily from the assembly A single SSCP and Delrin friction pad can be found opposite the pin and pin retainer on the ankle shell When assembled the SSCP can be tightened onto the friction pad This will push against the ball of the ankle shaft and control the movement of the ankle joint Remove the heel insert and inspect for deterioration Inspect the flesh for tears or damage Make sure that the ankle bumper is in place and inspect for deterioration NOTE The ankle bumper needs to be installed with the thicker rubber section to the front for proper ROM control Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 37 of 74 TABLE 12 FOOT ASSEMBLY EXPLODED VIEW PART LIST
22. 4 7 6 Foot Length P 10 40 0 3 264 16 7 6 Backline to Knee Pivot Length R 22 80 0 5 579 12 12 7 Hip Breadth at H Point U 15 90 0 4 403 9 10 2 Shoulder Breadth V 18 70 0 4 475 0 10 2 Foot Breadth W 3 90 0 3 99 1 7 6 Chest Circumference Y 44 70 0 8 1135 4 20 3 Waist Circumference Z 39 70 0 8 1008 38 20 3 Reference Location for Chest Circumference Ref AA 19 00 0 2 482 6 5 1 Reference Location for Waist Circumference Ref BB 8 00 0 2 279 4 5 1 5 4 Mass Measurements A Check the masses of the various dummy segment assemblies on initial inspection masses specified in Table 21 They should conform to the B After replacing parts or accelerometers recheck the mass of the pertinent segment SAE J2860 Issued SEP2012 Page 59 of 74 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 TABLE 21 SEGMENT MASS Included in Mass Assembly Measurement Ib kg Head Assembly Figure 2 Items 1 15 10 90 0 1 4 94 0 05 Neck Assembly Figure 12 Items 3 18 3 70 0 1 1 68 0 05 Bib Simulator not shown Upper Torso Assembly with Torso Figures 14 15 8 29 all items 49 10 0 8 22 27 0 36 Jacket includes from lower neck shown plus the chest jacket bracket to bottom of spine box for further description of the items in this assembly see print 880995 0000 pg 6 of 6 Lower Torso Assembly includes Fi
23. 4 of 74 TABLE 9 BALL SLIDER ASSEMBLY EXPLODED VIEW PART LIST Item Number Quantity Part Number Description 1 1 79051 32 Washer 2 2 9005045 BHCS FHCS 2 56 x 3 16 3 1 880995 1645 Rubber Stop 4 1 9006038 SHSS 187 Dia X 25 5 1 880995 1636 Ball Stop 6 1 880995 1633 Travel Stop 7 1 880995 1650 2 L 880995 1650 2 R String Pot Holder Assembly 8 1 880995 1646 Rubber Stop 9 2 9005078 BHCS SHCS 8 32 x 3 8 10 1 880995 1631 1 L 880995 1631 2 R Inboard Slider Assembly 11 1 SA572 S90 String Potentiometer 12 1 880995 1632 Outboard Slider 13 1 9006035 SHSS 3 8 x 12 14 1 79051 33 Compression Washer 15 1 880995 1637 Knee Stop Pin FIGURE 42 BALL SLIDER ASSEMBLY EXPLODED VIEW Separate the knee and upper leg sections by removing the two SHCS that secure the load cell or the femur load cell simulator upper leg weldment and knee cap Detach the lower leg from the knee cap by removing eight FHCS Figure 43 Inspect the knee skin and rubber knee insert by first removing the machined knee shown in Figure 41 Examine these flesh parts for cuts and tears Clean the inside and outside of the insert and adjoining knee skin with isopropyl alcohol or equivalent A pair of six channel femur load cells are available for use in place of the single axis femur load cells Either type of load cell directly replaces the femur load cell simulator in each leg The six channel lo
24. 5 in Time zero 4 45 kg 1 Ibf Foot Compression Test Performance Specifications 700 667 667 600 500 498 pa 445 Z 400 o 2 o 300 L 200 100 49 0 0 0 2 0 4 0 6 0 8 0 10 0 Deflection mm FIGURE 60 FOOT TEST SPECIFICATIONS 5 7 Ankle Motion Test A The test monitors the range of motion and resistance to motion of the ankle joint in dorsiflexion plantar flexion eversion and inversion B The parts required for testing are ankle assembly B 1889 Foot Attachment Bolt A 1886 Molded Foot Left or Right 880995 1600 1601 and the Ankle Bumper 78051 610 C The test device consists of a rigid fixture that will hold the ankle shell Two standoffs are mounted into the foot Attached to the standoffs is a plate or bar that will allow a reference for angle measurement and a means for transmitting moment to the ankle joint D The Data Acquisition System including transducers must conform to the requirements of the latest version of SAE Recommended Practice J211 1 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 65 of 74 E Test Procedure 1 Inspect the ankle bumper for uneven wear tears or other damage Replace if necessary Ensure that the ankle bumper is installed correctly with the front part visibly thicker than the rear part Adjust the ankle ball joint set screw so it applies
25. AE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 73 of 74 APPENDIX D AXIAL INTEGRITY OF THE NECK If the axial integrity of the neck is in question the neck without its cable can be pull tested to 7 kN 1575 Ibf No separation should occur Replace as required Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 74 of 74 APPENDIX E BOLT TORQUE VALUES TABLE E1 TORQUE SPECIFICATIONS Thread Size Torque in Ib Torque N m 0 80 1 00 0 113 2 56 2 50 0 283 4 40 12 0 1 36 6 32 23 0 2 60 8 32 41 0 4 63 10 24 60 0 6 78 10 32 68 0 7 68 1 4 20 144 16 3 1 4 28 168 19 0 5 16 18 300 33 9 5 16 24 300 33 9 3 8 16 540 61 0 3 8 24 600 67 8 NOTES 1 This applies to clean and dry parts A lubricated screw requires less torque 15 to 25 less to attain the same clamping force as a non lubricated screw
26. D SHOULDER YOKE EXPLODED VIEW The right and left shoulder clavicle and link assemblies consist of three main sections the clavicle clavicle link and shoulder yoke which bolt to each other and then to the thoracic spine These three sections permit arm rotation up down motion at the shoulder forward rear excursion hunching and up down motion of the entire shoulder clavicle unit See Figure 16 for the assembled view of the shoulder clavicle link Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 19 of 74 Shoulder Clavicle Link FIGURE 16 CLAVICLE LINK To begin disassembling the clavicles it is optional to first remove each arm at the shoulder yoke by unscrewing the SHSS Figure 17 If necessary clean the clavicle bushing and washers with isopropyl alcohol Never lubricate any of the plastic bushings FIGURE 17 ARM REMOVAL Detach the shoulder clavicle unit from the thoracic spine assembly by reaching through a hole in the plastic chest bib and removing the SHSS at the extreme top of the thoracic spine Figure 18 Pull the clavicle unit straight up Check for the urethane washer at the rear of the cavity in the thoracic spine and for two clavicle washers isolating the clavicle from the spine Make sure the pivot nut slides out freely A clavicle bushing should also be present in the hole through the clavicle link Downloaded from SAE Interna
27. Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SURFACE pa VEHICLE J2860 SEP2012 CAE i SAE International EDEN YA EET P RACTIC E Superseding EA 26 OCT2003 User s Manual for the Hybrid Ill Large Male Test Dummy RATIONALE This Surface Vehicle Report describes the assembly disassembly and certification procedures for the Hybrid Ill Large Male Test Dummy Storage and handling measurement procedures for external dimensions clothing specifications and part numbers are additions to this Surface Vehicle Report TABLE OF CONTENTS 1 NG AA 8 2 REEERENG AA PP 8 2 1 Applicable Documents wa a NAAN hina kaakaa Kia aaa dee aa 8 2 2 Related PUA OM Siha 8 3 ASSEMBLY DISASSEMBLY 0 c ccccccceceececccececeeeeeeceeececeaueeeeseceeseuauauuesecseeeueeauaasseeesseuauausaeeeeeeuaeaneaeeeeess 9 3 1 HENA nA Gn nd G 9 3 2 Upper T OFS aaa a BINAN AN eee eee AN ANA Ln AA NADA 16 3 3 Lower TOSA AA AA APA AAP PN taah 28 3 4 AI E AAA AA AAA AA AA AA AA AAA 33 3 5 AS AA AA OE EES 38 4 CERTIFICATION TEST PROCEDURES w wawamwamanwawawwwwanwamawu aa 40 4 1 Head Drop Kasama AA AA AA AA NAA si peweed sue 40 4 2 Neck Villa 42 4 3 Thorax Impact TeSti aa aaa 47 4 4 KASESE AA 50 4 5 KneaSlider TC Stic daa NGALANG AA NA NLNG 52 5 INSPECTION PROCEDURES AND TEST S 011111111111 aa 55 5 1 Chest Depth Measurement c ccccecceseneeeeneeeeeneeceeeeeeaaeeeaeecaeeeceaesseaaesaeee
28. F and a relative humidity from 10 to 70 for at least 4 hours prior to a test The test environment should have the same temperature and humidity requirements as the soak environment 3 Mount the knee lower leg assembly to the fixture using a femur load cell or load cell simulator Torque the load cell simulator bolts to 40 7 N m 30 ft Ibf to prevent slippage of the assembly during the impact When using the lower leg assembly adjust the lower leg so the line between the knee and ankle pivots is at an angle of 24 degrees 1 degree rearward of vertical Do not let the foot contact any exterior surface The test setup appears in Figure 53 4 Align the longitudinal centerline of the test probe so it is collinear within 2 degrees with the longitudinal centerline of the load cell simulator at the time of impact 5 Guide the probe so no significant lateral vertical or rotational motion occurs at the time of contact between the test probe face and the load distribution bracket 6 Time zero is defined as the time of initial contact between the test probe face and the knee skin All data channels should be at the zero level at this time 7 Impact the knee so the longitudinal centerline of the test probe is within 0 5 degree of a horizontal line parallel to the load cell simulator at time zero 8 The test probe velocity at the time of the impact is 2 10 m s 0 03 m s 4 70 mph 0 07 mph 9 Wait at least 30 minutes between successive tests
29. LE SPACERS i cvsviniiciscssccccavsasnasonsavecoavasseeiensasedanvnearedaraiedesdvanseotannaiiedaivesavadeunducaveayeduodavaddddumuswaionnd 22 FIGURE 25 ila Mag kaa AA AA 23 FIGURE 26 FRONT RIB STIFFENER GANA NAAN GA AGANG GN 24 FIGURE 27 CHEST CAVITY STERNUM SLIDER 111111710020020200200 kkk 24 FIGURE 28 STERNUM SLIDER AND BIB na GAGANA man LA GA BANAAG 24 FIGURE 29 RIB AND RIB STIFFENER REMOVAL 0 csssescessesceceescecceccsceecseceacesceseeecessecsessacceseassecseseseceesatsateaeeaees 25 FIGURE 30 RIB AND DAMPING MATERIAL sma Aa atone AA AA AA 25 FIGURE 31 THORACIC SPINE ASSEMBLY EXPLODED 1 11 71700000000 mkaka 26 FIGURE 32 THORACIC SPINE REMOVAL ceccescecsesceccecesceecesceceeececeescasceececeacsaceavsecesveesassaesassacsacassesaseestsateseeates 27 FIGURE 33 CHEST POTENTIOMETER 0 cccccccessesceceeccescecceceecsececeescesvescasceesessacseceaesesusveesessacsaesassaseasssseeseeseteareseeaseees 27 FIGURE 34 LOWER TORSO EXPLODED VIEW cccesceceescseecescescescecceecescecceceaceceacsecussessascacsetsaceecasataavrststeseeases 29 FIGURE 35 LEG REMOVAL na a NG ALAN EN naa cae maa 29 FIGURE 36 LOWER TORSO ASSEMBLY ABDOMEN NOT SHOWNJ ww wwswmnvanwamunwamuni mawaa waamua 30 FIGURE 37 ABDOMEN w w w wwamavavamawwawamawamamawa nan nwamamamn wawa kakata tnaa neatsssrecnssatsilucvnuasteastinsdlanstAn means DADEA AAA Eanna nanana 31 FIGURE 38 FEMUR REMOVAL w w wwavavavawwawawawamamama naa alangan laan
30. NECK ADJUSTING UPPER PAN 880995 1270 NECK ASSY P N 880995 1250 PLANE D PERPENDICULAR TO PENDULUM CENTERLINE 1DEG REF DWG 78051 095X a PENDULUM CENTERLINE ACCELEROMETER gt 1346205 mm 0 53 0 02 in tai MOUNTING SCREW C L BIB SIMULATOR P N 78051 84 NECK TRANSDUCER REF DWG 83 5001 008 OR C 1709 gt OCCIPITAL CONDYLES HEAD ASSY P N 880995 1100 FIGURE 50 NECK FLEXION TEST SET UP SPECIFICATIONS Page 46 of 7 4 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 47 of 74 4 3 Thorax Impact Test A The complete dummy assembly 880995 0000 is reguired including the clothing but without the shoes B The fixture consists of a smooth clean dry steel seating surface and a test probe The test probe is a 152 4 mm 0 25 mm 6 0 in 0 01 in diameter rigid cylinder with a mass of 23 36 kg 0 02 kg 51 5 Ib 0 05 Ib including instrumentation rigid attachments and the lower 1 3 of the suspension cable mass The impacting surface has a flat right angle face with an edge radius of 12 7 mm 0 3 mm 0 5 in 0 01 in Mount an accelerometer to the probe with its sensitive axis in line with the longitudinal centerline of the test probe C The data acquisition system including transducers must conform to the specifications of the latest revision of SAE Recommended Practice J211 1 Filter the p
31. OTION SPECIFICATIONS c0 ccsceccccescecceseescecceccecceccecacseceacsecesvescascacsassacseceassassaveecassatsaesareeeees 68 TABLE E1 TORQUE SPECIFICATIONS w w w wwwamamawamawuwwawawamawa LGA AG UA KANA 74 INTRODUCTION FOREWORD The Hybrid Ill Large Male dummy was developed under a grant awarded by the Center for Disease Control CDC to the Ohio State University in 1997 A task force of experts from the SAE International Mechanical Human Simulation Subcommittee of the Human Biomechanics and Simulation Standards Committee supported the development activity The design incorporated the same level of biofidelity and measurement capacity as the Hybrid Ill mid size adult male Therefore the certification procedures are based on the test procedures that were developed for the Hybrid Ill mid size adult male dummy The basic test fixtures are the same The Hybrid Ill Large Male Dummy is based on the characteristic size and weight measurements taken from anthropometry studies of the large adult male Its impact response requirements for the head neck chest hip knee and ankle were scaled from the biofidelity requirements of the Hybrid Ill mid size male dummy See Mertz H J Irwin A L Melvin J W Stalnaker R L Beebe M S Size Weight and Biomechanical Impact Response Requirements for Adult Size Small Female and Large Male Dummies SAE 890756 SP 782 1989 The Hybrid Ill Large Male dummy is designed to represent the
32. R can aang aaa a wamama wanaamua 11 FIGURE 7 NECK COMPRESSION TOOL 1 csssssescsseesceseesessescseceacsecesceecesssecasacseceassecuevescessaesessaseeceassssveeteseaeeates 11 FIGURE 8 NECK TIO Peis cilacivestiticocninchlaceerctastes La DA AA NAE GANA PAA adn 12 FIGURE 9 NODDINGJOI Gace ee NANANA kA AA Bae waste tno aa nice asa pnd ati 12 FIGURE 10 NODDING BLOCK ORIENTATION s cctsvicuccssncasscsinsaaneusnataasdavcanedsancdaessinsiatsasassaactinkdwatssadiaatansdvctaxanbaccsinetans 13 FIGURE 11 NECK TRANSDUCER REMOVAL ssssesceseecessescescescsececcescescsccessacsececesecusveesetcaessesaecsceaeesceeersteseaeeases 13 FIGURE 12 NECK EKPLODED VIEW ua AA GA BA AKA 15 FIGURE 13 NODDING JOINT BRACKET REMOVAL 011210121010 nA NA KK mma 16 FIGURE 14 CLAVICLE LINK EXPLODED VIEW JJ saa AG GG KAKA 17 FIGURE 15 CLAVICLE AND SHOULDER YOKE EXPLODED VIEW 211211110101000 Nka 18 FIGURE 16 CLAVICLE LINK w w wawawawwawanavawamamwa wawa GA panahanan nalaki Gab a 19 FIGURE 17 7 ARMREMOVAL ww wavavawunwawawamamawa LNG LALALALA BLG LALA LALALALA BAKA nkununununuuna 19 FIGURE 18 CLAVICLE a BING 0 a 20 FIGURE 19 BUMPER STOP A 20 FIGURE 20 SHOULDER YOKE ROTATION STOP ulan AN ALAK kaman 21 FIGURE 21 UPPER ARM STOP cash Aa la AG aa 21 FIGURE 22 CLAVICEE SHS AA AA 21 FIGURE 23 URETHANE SPRING STOP viscasccccssisicsocsavccsavasaresdvnasdaessivsadupsiasedevouaseieiaviatedaneeerapeinandadowseaedacacdddanistedanautdes 22 FIGURE 24 lt GLAVIC
33. RDER Tel 877 606 7323 inside USA and Canada SAE values your input To provide feedback Tel 41 724 776 4970 outside USA on this Technical Report please visit BAR eA 16 0790 http www sae org technical standards J2860 201209 Email CustomerService sae org NUP WWW S2C OrgHeCnNICaLsSiangardSiv egou u taus SAE WEB ADDRESS http www sae org Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 2 of 74 APPENDIX C JOINT ADJUSTMENT PROCEDURES 111121110110000 0 kk 73 APPENDIX D AXIAL INTEGRITY OF THE NECK e cescessesceseecessesecsceceeeceseescessaccecsacsceceacsesascecsassacsaceassaceaseecaseacsaeeaseaeess 73 APPENDIX E BOLT TORQUE VALUES c ceccecsosescesceseesceceeccescscceseacscececesscescsecessacsecsaccesuacsecaaveesausacsaceatsecassecaseesaeeateaeess 74 FIGURE 1 ACCELEROMETER LOCATIONS sescesssssecessessesceseescuseeecessecseseacseseassecusveesasceesatsatcaseaseacassessvceteteaeesees 7 FIGURE 2 HEAD EXPLODED VIEW cccccsceccccescesceceescesceccecseccecsacsecesceecesseesassacsacsacsecuavessassacsatsarceteaseectseesaseteseeteees 9 FIGURE 3 NECK ADJUSTMENT SHCS AND WASHER cccccescescceecceceeccscesceececececeseescesceeseeeaseecaesacaeeeesaucareaeeases 10 FIGURE 4 UPPER NECK BRACKET AND BIB sssessosessessesceccecesececeescecesccessacseceaesecusvessascaesessaseecasasaversteaseseeaees 10 FIGURE 5 IA UA AP AA AAO KAA 11 FIGURE 6 NECK TRANSDUCE
34. ROMETER LOCATIONS SPECIAL TOOLS The following special tools will allow assembly disassembly and certification of the Hybrid Ill large male dummy For information concerning tool availability contact the dummy manufacturers Neck compression tool Ball hex wrench set Lumbar cable nut wrench Pelvis angle measurement tool Head skin thickness gauge Chest depth gauge Clavicle washer alignment tool lliac bolt removal tool Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 8 of 74 1 SCOPE This SAE Surface Vehicle Information Report identifies and defines the assembly disassembly and certification procedures relating to the use of the Hybrid III Large Male Test Dummy 2 REFERENCES 2 1 Applicable Documents The following publications form a part of this specification to the extent specified herein Unless otherwise indicated the latest issue of SAE publications shall apply 2 1 1 SAE Publications Available from SAE International 400 Commonwealth Drive Warrendale PA 15096 0001 Tel 877 606 7323 inside USA and Canada or 724 776 4970 outside USA www sae org Mertz H J Irwin A L Melvin J W Stalnaker R L Beebe M S Size Weight and Biomechanical Impact Response Requirements for Adult Size Small Female and Large Male Dummies SAE 890756 SP 782 1989 SAE J211 1 Instrumentation for Impact Test Part 1 Electronic
35. SH 8 TO 80 MICRDINCHES IMPACT SURFACE TO BE CLEAN AND DRY NAI CENTERLINE OF 1 6 mm 0 062 ind k Ng I DIAMETER HOLES IN SKULL A 3 DISTANCE A DISTANCE B FIGURE 47 HEAD DROP TEST SET UP SPECIFICATIONS Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 42 of 74 4 2 Neck Tests A The components required for the neck tests are head assembly 880995 1100 neck assembly 880995 1250 upper neck bracket 880995 1270 lower neck bracket 78051 303 bib simulator 7805 1 84 six channel neck transducer to measure the X axis force and the Y axis moment transducers to measure the rotation of the D plane horizontal plane through the base of the skull with respect to the pendulum s longitudinal centerline three actual or simulated accelerometers in the head to maintain the proper weight and center of gravity location data from the accelerometers are not required C The test fixture pendulum arm with specifications appears in Figure 48 The aluminum honeycomb material is commercial grade 28 8kg mm 1 8 ft Ib per cubic ft with 19 mm 0 75 in diameter cells Mount the accelerometer with its sensitive axis aligned with the arc formed at a radius 1657 4 mm 65 25 in from the pivot point C The data acquisition system including transducers must conform to the specifications of the lates
36. SteelTube Ngong mm 4 in j ol mm 1 25 in 91 1 mm 7 80 in LIA mm 1 5 in 469 9 mm 18 5 in te Pivot 50 8mm 2 in 828 0 mm 32 6 in 61 0 mm 2 40 in Inertial Properties of PendulumMounting Plate and MountingHardware Weight 29 6 kg 65 2 Ib Moment of Inertia 33 2 Nms 2 24 5 lbs CG of Pendulum Aluminum HoneycombHexcell 28 8 kgimete 1 8 Iba 1657 4 mm 401 6 mm 4 in 65 25 in i Radius i Ky Ng oe Rigid Impact Surface Accelerometer i 152 4 mm 6 in 16 2mm x 152 4mm x 9 5mm 3 in x 6 in x 48 in Striker Plater Sharp Edges FIGURE 48 NECK PENDULUM SPECIFICATIONS S A E Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 J2860 Issued SEP2012 PENDULUM CENTERLINE 89 PENDULUM STRIKER PLATE 37 34 0 5 mm 1 47 4 0 02 in MOUNTING SCREW C L Ni BIB SIMULATOR PAN 78051 84 NECK TRANSDUCER CREF DWG 83 5001 008 OR C 1709 OCCIPITAL CONDYLE HEAD ASSY P N 880995 1100 FIGURE 49 NECK EXTENSION TEST SET UP SPECIFICATIONS PENDULUM STRIKER PLATE BRACKET NECK ADJUSTING LOWER P N 78051 84 BRACKET NECK lt ADJUSTING UPPER P N 880995 1270 NECK ASSY P N 880995 1250 PLANE D PERPENDICULAR TO PENDULUM CENTERLINE 1DEG REF DWG 78051 095X ACCELEROMETER BRACKET NECK ADJUSTING LOWER P N 78051 84 BRACKET
37. TABLE 4 CLAVICLE LINK EXPLODED VIEW PARTS LIST Item Number Quantity Part Number Part Description 1 1 9006001 SHSS 2 1 880995 358 Clavicle Link Pivot Bushing 3 2 78051 236 Clavicle Link Pivot Washer 4 1 880995 334 left 880995 335 right Clavicle Link 5 1 78051 243 Washer 6 1 9000043 SHSS x1 7 1 880995 338 Clavicle Spring Stop 8 2 880995 339 Clavicle Spacer 9 1 880995 336 left 880995 337 right Clavicle FIGURE 14 CLAVICLE LINK EKPLODED VIEW Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 18 of 74 TABLE 5 CLAVICLE AND SHOULDER YOKE EXPLODED VIEW PART LIST Item Number Quantity Part Number Part Description 1 1 78051 250 Washer Shoulder Yoke Retaining 2 1 78051 249 Washer Spring 3 1 78051 248 Washer Steel Shoulder Yoke 4 2 9000047 SHCS 5 1 880995 346 Steel Stop 6 1 78051 245 Shoulder Stop Assembly 7 1 78051 202 Nut Elbow Pivot 8 1 880995 351 Washer Spring 9 1 880995 709 Bushing Upper Arm and Elbow Pivot 10 1 880995 708 Washer Upper arm and Elbow Pivot 11 1 880995 711 Washer 12 1 9000055 SHSS 13 1 880995 343 Shoulder Yoke Assembly 14 1 880995 348 Bushing Shoulder Yoke Pivot 15 1 880995 349 Washer Yoke Pivot 16 1 880995 336 left 880995 337 right Clavicle 17 1 9000800 Locknut Thin FIGURE 15 CLAVICLE AN
38. The accelerometer mounts can be removed by removing the two SHCS from the front face of the thoracic spine Figure 31 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 28 of 74 The lower neck adjustment bracket can be disassembled from the thoracic spine by removing four SHCS and washers from the top of the spine box Two rib guides mount to the side of the spine box and can be removed by removing two SHCS from each side of the spine box Figure 31 Inspect the Teflon sheets on the underside of the rib guides for damage Replace if necessary 3 2 5 Upper Torso Assembly Notes e Attach the ribs and rear rib supports to the thoracic spine assembly Do not tighten the screws Attach the bib to the ribs using the rib stiffeners Install the aluminum sternum to the inside surface of the bib and attach the Delrin track Ensure that the chest displacement rod ball engages the Delrin track properly Figure 27 Check the spacing and alignment of the ribs and then tighten the screws A 3 8 diameter rod can be used as a spacer control for the space between the ribs 3 2 6 Upper Torso Special Care and Maintenance e Check for rib deformation using the chest depth gauge described in Inspection Procedures and Test section e Check the ribs and rib damping material for warping or cracks Replace damaged ribs and re certify e Sternum stops should be periodically checked for looseness If th
39. ad cells measure axial and shear loads and moment in three axes while the single axis load cells measure axial load only Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 35 of 74 3 4 2 Lower Legs and Ankle Figure 43 represents the exploded view of the lower leg Table 10 lists the general part descriptions identified in Figure 43 Figure 44 shows the exploded view of the ankle assembly Table 11 lists the general part descriptions identified in Figure 44 TABLE 10 LOWER LEG EXPLODED VIEW PART LIST Item Part Number Number Quantity Description 1 1 880995 1614 Lower Leg Flesh 2 1 B 1889 Ankle Assembly 3 1 A 1886 Modified SHSS 4 1 880995 622 Lower Leg Bone 5 8 900313 FHCS 14 28 x 3 8 6 4 9000115 SHCS 14 28 x V2 7 1 880995 605 Knee Clevis FIGURE 43 LOWER LEG EKPLODED VIEW Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 36 of 74 TABLE 11 ANKLE ASSEMBLY EXPLODED VIEW PART LIST Item Number Quantity Part Number Description 1 4 9000076 BHCS 2 1 78051 610 Ankle Bumper 3 1 A 1590 Ankle Shaft 4 1 A 1888 Ankle Friction Pad 5 1 A 1897 1 SSCP 5 16 18 x 3 8 6 2 A 1897 2 SSCP 10 32 x 1 4 7 2 9000076 BHCS 8 32 x 2 8 1 C 1885 Ankle Lower Shell 9 1 C 1884 Ankle Upper Shell 10 1 A 1896 Dowel Pin 3
40. al by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 61 of 74 TORSO PULL BRACKET ANGLE MEASUREMENT DEVICE MEASURES RELATIVE PULL CABLE ATTACHED TO SPINE BOX INSTRUMENT AT OCCIPITAL CONDYLE CAVITY MATING SURFACE LOCATION OF UNDEFORMED NECK FIGURE 57 TORSO FLEXION TEST SETUP Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 62 of 74 D HIII 95N FIGURE 58 TORSO FLEXION PULL BRACKET SPECIFICATIONS 5 6 Foot Test A The components required for the foot tests are foot assembly 880995 1600 or 880995 1601 including the heel pad foam 7805 1 608 B The test fixture consists of a compression testing machine equipped with a load cell and displacement gage An example set up appears in Figure 59 An ankle adaptor bracket is needed to attach the foot to the compression testing machine To allow adjustment of the foot angle two standoffs are inserted into the bolt holes in the foot weldment provided for this purpose SAE Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 J2860 Issued SEP2012 Page 63 of 74 COMPRESSION TESTING MACHINE ANKLE ADAPTER BRACK FIGURE 59 COMPRESSION TEST SETUP C The data acquisition system including transducers
41. assembly so it points forward and is horizontal Twist the arm so the elbow cannot rotate downward Adjust the shoulder yoke rotation hex nut so the arm is suspended at 1 G Bend the elbow 90 degrees so the hand moves toward the chest Adjust the elbow rotation bolt through access in the upper arm to hold the lower arm horizontally suspended at 1 G Reposition the arm so it points forward and is horizontal Twist the lower arm at the elbow so the lower arm can pivot downward to vertical Adjust the elbow pivot bolt through access holes in the lower arm flesh at the elbow to hold the lower arm suspended at 1 G Extend the arm and twist the palm so it faces down Adjust the wrist pivot bolt at the base of the hand so it is suspended at 1 G Adjust the wrist rotation bolt through access in the wrist flesh to hold it suspended at 1 G Repeat procedure for other hand and arm LEGS AND FEET Remove abdominal insert With the lower leg at 90 degrees to the upper leg and the dummy in a seated position lift the upper leg assembly above horizontal Adjust the femur ball set screw so the upper leg is held suspended at 1 G Rotate the lower leg assembly so it is horizontal Adjust the knee clevis bolt so the lower leg is held suspended at 1 G Adjust the ankle ball joint set screw so the foot is held suspended at 1 G The ankle adjustment is not critical and is determined by individual feel Repeat procedure on other leg and foot Downloaded from S
42. be measured last NOTE At this point inspect the thorax for damage If required remove the thorax displacement transducer for calibration Use extreme caution to avoid damaging the instrumentation cables SAE J2517 D Remove the four socket head cap screws which attach the lumbar spine to the thoracic spine Torque the two lumbar spine cables to 1 13 1 40 Nm 10 0 12 4 in Ibf Refer to page 27 Reassemble the lumbar spine to the thoracic spine E Place the dummy on a flat rigid smooth clean dry horizontal surface Seating surface must be at least 406 mm 16 in wide and 406 mm 16 in deep with a vertical section at least 406 mm 16 in wide and 914 mm 36 in high attached to the rear of the seating fixture F Secure the dummy to the test fixture so the rear surfaces of the spine box ribs are tangent to the rear vertical surface of the fixture The dummy s midsagittal plane should be vertical G The Hip Pivot Height C and Hip Pivot from Backline D should be the set up dimensions Insert the H point gages at left and right first measure the dimensions C and D Adjust the dummy so that left and right measurements are within 2 5 mm 1 inch Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 56 of 74 H Constrain the head so that the distance from the back of the skull cap to the seat back is 3 5 0 1 inch I Position the upper and lower legs paral
43. caaeeeeaaeseeaeessaneesaeeseaaesseneesaas 55 5 2 External Measurements sarreren E E E E AOE E E AG LA 55 5 3 External DIMENSIONS ii 58 5 4 Mass Measurement Sisera nienia NN A A A A E a a a Am 58 5 5 Torso Flexion ad cae a aa a aae aeaa 59 5 6 Foot TEST AA AA AAP waw 62 5 7 Ankle Motion Test ia 64 6 NO ES PA AA AAA a PE Anh na AA AN a PAWA 68 6 1 Marginal UU AI 68 APPENDIX A ACCELEROMETER HANDLING GUIDELINES wwwwwwananwawwnwwnananwawwanunanwa www nanukuu 69 APPENDIX B GUIDELINES FOR REPAIRING FLESH w wwwamawwnwanaawawwwwanaa waw w ww wananwa inaw wa naumwa naanza wwa 71 SAE Technical Standards Board Rules provide that This report is published by SAE to advance the state of technical and engineering sciences The use of this report is entirely voluntary and its applicability and suitability for any particular use including any patent infringement arising therefrom is the sole responsibility of the user SAE reviews each technical report at least every five years at which time it may be revised reaffirmed stabilized or cancelled SAE invites your written comments and suggestions Copyright 2012 SAE International All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of SAE TO PLACE A DOCUMENT O
44. cable This will prevent the unit from slapping the mounting surface during installation Place the unit on the mounting surface and align the mounting holes Correct torque is important to ensure correct mounting and performance When mounting the accelerometer use only the materials and parts which are supplied with the accelerometer Always use the proper mounting torque recommended by the accelerometer manufacturer If applicable use the supplied mounting washers and screws or mounting stud Using the supplied wrench turn the screws into the mounting holes using the recommended torque Usually this is roughly equivalent to finger tight with the supplied wrench Installation of the unit with higher torque values dry threads or thread adhesives is not recommended as excessive torque will be required to break the screw loose when the accelerometer is dismounted EXCESSIVE TORQUE CAN CREATE AN OVERRANGE TRANSIENT SHOCK PULSE UPON REMOVAL OF THE UNIT WITH SUFFICIENT HIGH FREQUENCY CONTENT TO DAMAGE OR DESTROY THE UNIT Do not over torque the screws Do not use snap type torque wrenches Do not cement the unit to the mounting structure Where practical tie down the cable within 4 to 6 cm 1 6 to 2 4 in of the unit Whipping of the cable during vibration and shock will strain the cable unnecessarily at the unit Connect the unit to the signal conditioner and check for proper functioning through the use of standard techniques such as shunt calibrati
45. cceceacsececsescessacsassacsaceaesacusvecsassaesatsasceseassasaversateaseaeeases 66 FIGURE 62 ANKLE FOOT REFERENCE PLANES c ceccecscsececceseesceceescesceccaccacceceaesecessecsassaesaseascecacecaueeesateateseeares 67 TABLE 1 INSTRUMENTA HON aNG RA AG GA la Bis Ph donc GA aa 6 TABLE 2 HEAD EXPLODED VIEW PART LIST c cescescecccseecesceseesceceecceccecsescacceceacsecesveecessacsatsarceseaseseseessetesesseres 9 TABLE 3 NECK EXPLODED VIEW PART LIST cccccceccecscssececcescescecseccecceccecsacseceassesusveesassacsaesaccecavsasaeersatsareseeases 14 TABLE 4 CLAVICLE LINK EXPLODED VIEW PARTS LIST cc cessescoscececsescesceceeececvecsescecsessacceceaeseseasecsaseateateateas 17 TABLE 5 CLAVICLE AND SHOULDER YOKE EXPLODED VIEW PART LIST cscceccesceceeceecesceceesceesesseseeseseeeteees 18 TABLE 6 SPINE BOX EXPLODED PART LIST siiscisscssasscccevescvsccanssenceanssecdevencsecsanateusunaseveseaneduessiassacsaanneeadsnaetueseanedane 26 TABLE 7 LOWER TORSO EXPLODED PART LIST 224i NGANGA AKA nnaiararinna ranana 28 TABLE 8 UPPER LEG EXPLODED VIEW PART LIST 111211111100000 Kana 33 TABLE 9 BALL SLIDER ASSEMBLY EXPLODED VIEW PART LIST cc cccsscecceceesceceescecceccseeecesceseesseseeseteaseseeaees 34 TABLE 10 LOWER LEG EXPLODED VIEW PART LIST wawawuwwawawawawamawanwamamatamawwwwawamawamm nawaza 35 TABLE 11 ANKLE ASSEMBLY EXPLODED VIEW PART LIST ccceccessececcescesceceesceceeccescecceseaccecesesaseceeecassersateareee
46. d make sure no interference with the accelerometers occurs Check the two larger rubber bumpers protecting the chest displacement pot for damage Figure 33 To remove the rubber bumpers remove the two SHCS per bumper from the back side of the spine mounting assembly Carefully remove the chest deflection transducer assembly by removing the BHCS and washer from the bearing The assembly should easily push out Check the bearing for smooth operation Chest Deflection FIGURE 33 CHEST POTENTIOMETER To remove the thoracic load cell or simulator remove the four SHCS from the bottom of the spine mounting assembly Four SHCS on the top of the thoracic load cell will allow for the removal of the T4 accelerometer mount Figure 31 The thoracic spine will have four rubber bumpers fixed to the front of the spine box to prevent metal to metal contact between the ribs and thoracic spine at max deflection of the ribs Inspect the bumpers for tears and ensure that they are fixed tightly to the spine box Replace any damaged bumpers and refasten the bumpers if they begin to tear away from the spine box Figure 31 The bumpers also prevent contact between the potentiometer arm and the accelerometers mounted on the three accelerometer mounts on the front of the thoracic spine The bottom two accelerometer mounts are the same The top accelerometer mount is distinguishable by a notch that aligns with a roll pin to prevent misorientation during assembly
47. day January 14 2015 SAE J2860 Issued SEP2012 Page 29 of 74 FIGURE 34 LOWER TORSO EKPLODED VIEW 3 3 1 Lumbar Spine The lumbar spine is more easily accessed if the legs are detached Remove the SHSS one per leg holding the rear of the upper leg to the brass femur These bolts are located through holes in the flesh at the side and front of the pelvis Figure 35 Detach the leg assemblies This will separate and isolate the lower torso FIGURE 35 LEG REMOVAL Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 30 of 74 Lumbar Spine Assembl Molded Pelvis With ASIS LCR Femur Assembl FIGURE 36 LOWER TORSO ASSEMBLY ABDOMEN NOT SHOWN Remove the four SHCS holding the pelvic instrument cavity cover in the rear of the molded pelvis Once the cover is removed remove the accelerometer block by removing one SHCS Separate the lumbar spine and its lumbar to pelvic adaptor from the pelvis by removing two SHCS from the front of the adaptor and two SHCS through the pelvic instrumentation cavity Figure 34 Separate the lumbar spine from the adaptor by removing three SHCS from the bottom of the lumbar adaptor Check the upper and lower surfaces of the lumbar adaptor Figure 34 The lower surface must be flat and smooth The upper surface for mounting the lumbar spine must be flat and smooth and have two hemispherical clearance depressions for the ends
48. de with the plane of motion of the pendulum s longitudinal centerline Install the transducers or other devices for measuring the D plane rotation with respect to the pendulum longitudinal centerline These measurement devices should be designed to minimize their influence on the performance of the head neck assembly Torque the jam nut on the neck cable with bushings to 1 36 N m 0 23 N m 12 0 in Ibf 2 2 in lbf before each test on the same neck Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 43 of 74 8 The number of cells in the honeycomb material required to produce the pendulum input pulse will be different for the flexion and extension tests The number of cells required may also vary for each sheet and or batch of material Prior to the test it is an option to pre crush the honeycomb material by lightly impacting it so 90 to 100 of the projected honeycomb surface contacts the pendulum strike plate 9 With the pendulum resting against the honeycomb material adjust the neck bracket until the longitudinal centerline of the pendulum is perpendicular within 1 degree to the D plane on the dummy s head 10 Wait at least 30 minutes between successive tests on the same neck 11 Calculate the moment about the occipital condyle for both flexion and extension tests using the formulae For a six channel neck transducer Metric Units Moment Nm My Nm 0 01778 m F
49. dummy responses which could affect dummy measurements that are used by government and safety engineers to assess occupant injury potential Certification tests are performed by the dummy manufacturer to assure that a new component or assembly meets the SAE specified response requirements The crash dummy user will periodically perform the certification tests to assure the dummy is maintained at the SAE specified performance levels Inspection Test Inspection tests are supplemental to the certification tests to insure that a component meets its design intent They are performed by the dummy manufacturer on new parts The dummy user may conduct inspection tests when a part is damaged or replaced Abbreviations ASIS Anterior Superior Iliac Spine LCR Load Cell Replacement Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 5 of 74 The following threaded fastener abbreviations are used in this manual SHCS Socket Head Cap Screw FHCS Flat Head Cap Screw BHCS Button Head Cap Screw SHSS Socket Head Shoulder Screw SSCP Socket Screw Cup Point RHMS Round Head Machine Screw CONSTRUCTION e The skull and skull cap are both one piece cast aluminum with a removable one piece vinyl head and skull cap skin The skull cap is removable for access to the head instrumentation The vinyl skin is tuned to give a human like response to forehead impacts e The neck has a biofidelic angle versu
50. e knee slider test are knee cap 880995 1510 knee flesh 880995 508 knee insert 880995 511 left and right knee slider assemblies 880995 1666 or equivalent displacement transducer femur load cell optional 78051 265 or structural replacement 78051 319 C The test fixture consists of a rigid test probe and a method of rigidly supporting the knee assembly The test probe mass is 12 0 kg 0 14 kg 26 5 Ib 0 3 Ib including instrumentation rigid attachments and the lower 1 3 of the suspension cable mass The diameter of the impacting face is 76 2 mm 0 25 mm 3 0 in 0 01 in with an edge radius of 0 5 mm 0 02 in A load distribution bracket is required to transmit the impact energy into the slider assembly as seen in Figure 54 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 53 of 74 C The data acquisition system including transducers must conform to the specifications of the latest revision of SAE Recommended Practice J211 1 Filter all data channels using Channel Class 180 phaseless filter D Test Procedure 1 Inspect the knee insert and flesh for damage Pay particular attention to the left and right side assemblies to ensure the ball tracks are clean and free from damage that could affect the operation Inspect the rubber for separation and the travel stops and ball retainers for damage 2 Soak the knee assembly in a controlled e
51. e top of each femur A small amount of talcum powder can be used on the bumpers to reduce friction Femur Assembly Removed Femur Removal FIGURE 38 FEMUR REMOVAL Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 32 of 74 Remove the two BHCS holding the bumpers in place Figure 39 Inspect the bumpers for tears or cracks and replace if necessary The bumper is designed to prevent metal to metal contact between the femur and the flange screws that hold the femur when the femur is rotated towards the pelvis This holds true when the femur is parallel to the midsagittal plane as well as 7 degrees inboard and outboard of this plane Check the femur sockets and femur ball for galling Confirm that the nylon tipped femur friction adjusting screws are not damaged see Figure 39 FIGURE 39 FEMUR ASSEMBLY The pelvic bone houses two ASIS load cells or simulators To disassemble from the pelvis remove four SHCS from the access holes in the rear of the pelvis Figure 40 FIGURE 40 ASIS LOAD CELL REMOVAL Examine the pelvis for flesh tears and or cuts and the skin for foam separation If the pelvis cavity for the femur shows signs of deterioration such as these it will affect the pelvis range of motion and the pelvis should be remolded 3 3 4 Lower Torso Assembly Notes Torque the lumbar cables to 1 13 to 1 40 N m 10 0 to 12 4 in Ibf Install t
52. eck the leg flesh for rips and tears Repair or remold e Check the machined knee for bent rotation stops and improper assembly e Check the ankle bumper for damage e Check the ankle ball for damage 3 5 Arms Figure 46 shows the exploded view of the arm assembly Table 13 lists the general part descriptions identified in Figure 46 TABLE 13 ARM ASSEMBLY EXPLODED VIEW PART LIST Item Number Quantity Part Number Description 1 2 880995 709 Bushing Upper Arm 2 2 78051 202 Nut Elbow Pivot 3 2 880995 351 Spring Washer 4 1 9006004 SHSS 3 8 x 13 4 LG 5 1 880995 700 Molded Upper arm 6 1 9000496 SHSS 12x 1 3 8 LG 7 2 9008021 Washer Flat 8 2 880995 708 Washer Upper Arm 9 1 9000074 SHSS 3 8 x1 10 1 880995 718 Wrist Pivot 11 1 9000055 SHSS x1 12 1 880995 705 Lower Part Upper Arm 13 1 880995 732 Lower Arm Flesh 14 1 78051 214 Screw Wrist Pivot 15 1 78051 208 78051 209 Hand Molded Assembly Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 39 of 74 FIGURE 46 ARM ASSEMBLY EKPLODED VIEW Remove each arm at the shoulder by unscrewing the SHSS Figure 17 If necessary clean the upper arm bushing and washers with a chlorinated solvent Never lubricate any of the plastic bushings Push out the steel pivot nut in each shoulder yoke Figure 46 Item 2 Make sure the nut slides freely in its hole
53. ee and adjust the pelvis angle to 13 degrees 2 degrees Use the special tool that inserts into the pelvic structure and extends outward beyond the pelvic skin surface The tool permits the use of an angle measurement device to determine the pelvis angle The midsagittal plane of the dummy is vertical 1 degree and within 2 degrees of being parallel to the centerline of the test probes The longitudinal centerline of the test probe is centered on the midsagittal plane of the dummy within 3 mm 0 25 mm 0 12 in 0 01 in Align the test probe so its longitudinal centerline is 12 7 mm 1 mm 0 5 in 0 04 in below the horizontal centerline of the No 3 rib and is within 0 5 degree of a horizontal line in the dummy s midsagittal plane After completing the initial setup record reference measurements from locations such as the rear surfaces of the thoracic spine and the lower neck bracket These reference measurements are necessary to ensure that the dummy remains in the same position after installing the chest jacket When using a cable supported test probe the dummy must be moved rearward from the test probe to account for the thickness of the chest jacket so the probe will impact at the lowest point on its arc of travel The test setup appears in Figure 51 Install the chest jacket and reposition the dummy as described in the preceding paragraph using the recorded reference measurements The reference locations must be accessible after installa
54. er mounts for the head chest and pelvis The following is an instrumentation list currently available for the Hybrid Ill Large Male dummy TABLE 1 INSTRUMENTATION HYBRID Ill LARGE MALE DUMMY INSTRUMENTATON Location Measurement Number of Channels Head C G Acceleration 3 Head Angular Acceleration 9 or 12 Head Angular Rate 3 Head Neck Interface Forces amp Moments 3 Head Neck Interface Forces amp Moments 6 Neck Thorax Interface Forces amp Moments 6 Thorax C G Acceleration 3 Thoracic Spine Forces amp Moments 5 Sternum Acceleration 3 Thoracic Spine Front Acceleration 3 Sternum Displacement 1 Lumbar Spine Forces amp Moments 3or6 Pelvis C G Acceleration 3 Anterior Superior lliac Spine Load 2 each side Femur Forces amp Moments 6 each femur Femur Force 1 each femur Knee Tibia Displacement 1 each knee Knee Clevis Force 2 each knee Upper Tibia Forces amp Moments 5 each leg Lower Tibia Forces amp Moments 5 each leg Foot Acceleration 3 each foot Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 7 of 74 oN bo nena Pa C VIEW 78051 13 REMOVED SCR S ACCELERC 72 PELVIS A METER AS CHEST ELEROMETER A HEAD ACCELEROMETER ASSEMBLY DESCRIPTION PARTS LIST FIGURE 1 ACCELE
55. ess 36 TABLE 12 FOOT ASSEMBLY EXPLODED VIEW PART LIST cccccescecsssescecceseesceceecceccecseseaccsesaseeceseessaeeeeeausaseseeases 37 TABLE 13 ARM ASSEMBLY EXPLODED VIEW PART LIST c ccccesccssececcescesceceeecesseccescecsescecceceaesececcessaseaneateareneees 38 TABLE 14 HEAD DROP TEST SPECIFICATIONG 2 cescessssescesceseescecceecesceccacaccececesecusceesassaeseesateeceasessesessteseseeates 41 TABLE 15 NECK FLEXION TEST SPECIFICATIONS ccccccseccccescesceceescecsecceceecsececcsecucveesersacsessaceeceassseeeesatsareseeaees 43 TABLE 16 NECK EXTENSION TEST SPECIFICATIONS ccccccescescecseccecceccsceaceececeseceseessescaeseeeatescessessusersteateaeeases 44 TABLE 17 THORAX IMPACT TEST SPECIFICATIONS cccccceccesceceescsceccscescescescsecesseccescsesassaccecassssaceessaueaecateasereees 48 TABLE 18 KNEE IMPACT TEST SPECIFICATIONS c cecccssececceseescecseccesceccaceacsececesececveesessacsaseaececeasstseeesaueseaeeases 51 TABLE 19 KNEE SLIDER TEST SPECIFICATIONS ccceccessececcescescecceccecsecceceacsececesecuseescassaesaesaececeasesseestsateaeeases 53 TABLE 20 EXTERNAL MEASUREMENTS 0 ccccecseseececcescesceceeccecceecescecceceacseceacsscesvsecasvacsassaeceseaseceaesssvaeeausseseeases 58 TABLE 21 SEGMENT MASS sicscsccciscsctecsscsvccsovecnnndssncecavusesvesevsaveussvusavedansceanisvidnavaduwnsdedesuatenssenatuduuoeieteadaaudedesinaneoseniere 59 TABLE 22 FOOT TEST SPECIFICATIONS a AN nd GAGA a 64 TABLE 23 ANKLE M
56. est Height The flesh below the elbow pivot bolt to the seat surface K Backline to Knee Length The most forward surface of the knee flesh to the seat rear vertical surface L Bottom of the Seating Surface to Bottom of Foot Seat surface to the horizontal plane at the bottom of the feet M Knee Pivot Height Knee pivot to the horizontal plane of the bottom of the feet in line with the knee and ankle pivots O Chest depth without jacket The rearmost surface of spine box assembly to the front of the sternum slider at the top of the third rib P Foot Length Tip of toe to rear of heel R Backline to Knee Pivot Length The seat rear vertical surface to the knee pivot bolt U Hip Breadth at H Point The width at H points V Shoulder Breadth Between outside edges of shoulder clevises in line with the shoulder pivot bolt W Foot Breadth The widest part of the foot Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 57 of 74 L Reinstall the chest jacket and abdominal insert Reposition the dummy on the test fixture You do not need to level the head as specified for the previous measurements M Mark the locations and record the chest and waist circumference dimensions Y Chest Circumference Measured 482 6 mm 19 0 in above the seat surface approximately at the top of the 5th rib Z Waist Circumference Measured 203 2 mm 8 0 in above the
57. ey become loose they can be glued back into place using an instant adhesive e Check the shoulder castings for compression damage from assembly Replace damaged castings e Check the rubber shoulder stop for damage and replace as necessary 3 3 Lower Torso Figure 34 represents the exploded view of the lower torso Table 7 is a list of general part descriptions identified in Figure 34 TABLE 7 LOWER TORSO EXPLODED PART LIST Item Number Quantity Part Number Description 1 4 9000345 BHCS 8 32 2 2 98051 498 1 Left 98051 498 2 Right Femur Bumper 3 2 880995 1410 L 880995 1411 R Femur Assembly L and R 4 1 78051 13 Cover Pelvic Cavity 5 4 9000624 SHCS 10 24 x 1 2 6 1 9000059 SHCS 3 8 16 x 3 4 7 4 9000348 SHCS 5 16 24 1 1 2 8 1 880995 1445 Molded Lumbar Spine 9 2 9000063 SHSS 5 8 x 1 3 4 10 1 78051 54 Accelerometer Mount 11 1 880995 1430 Molded Pelvis 12 6 9000009 SHCS 4 20 x 34 13 2 880995 1437 L 880995 1438 R ASIS Load Cell Replacement L and R 14 1 78051 53 Bracket Assembly 15 2 78051 69 Lumbar Cable 16 2 880995 1443 Lower Lumbar Bushing 17 2 9000018 Hex Jam Nut 72 20 18 2 9000018 Hex Nut 72 20 19 2 880995 1444 Upper Lumbar Bushing 20 2 9000059 SHCS 3 8 16 x 3 4 21 2 9000080 SHCS 3 8 16 x 3 4 22 3 9000005 SHCS 14 20 x 5 8 1 880995 1416 Abdomen not shown Downloaded from SAE International by Yoshihiro Ozawa Wednes
58. f each item in Figure 12 TABLE 3 NECK EXPLODED VIEW PART LIST Item Number Quantity Part Number Part Description 1 2 78051 253 Brass Washers 2 1 78051 339 Condyle Pin 3 1 180 2004 Upper Neck Bushing 4 1 880995 205 Cable 5 1 9000018 Nut Hex Jam 1 2 20 6 1 9001260 Washer 7 1 180 2005 Lower Neck Bushing 8 4 9008001 Washer 9 4 9000498 Screw SHCS 1 4 20 x 7 8 10 1 78051 305 Neck Adjustment Washer 11 1 9000021 Screw SHCS 3 8 16 x 1 12 1 880995 1270 Upper Neck Adjustment Bracket 13 1 880995 201 Lower Neck Spacer 14 1 880995 1260 Neck Molded Assembly 15 1 880995 203 Upper Neck Spacer 16 1 78051 297 Nodding Joint Neck Assembly 17 2 78051 351 Nodding Block 18 4 9000124 Screw FHCS 1 4 20 x 7 8 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 15 of 74 FIGURE 12 NECK EXPLODED VIEW Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 16 of 74 Remove the nodding blocks and set aside The pivot pin nodding joint washers SHCS and curved steel washer as well as the neck bushings washer and nut have been previously removed see Head Neck disassembly Remove four FHCS from the top of the nodding joint bracket Figure 13 FIGURE 13 NODDING JOINT BRACKET REMOVAL Upon removal of the four FHCS the neck disassembly is complete Fig
59. frequently damaged and is not expected to contribute significantly to dummy response duct tape can be placed on the flesh but under the clothing to help protect it Tape should not be used on any area which directly affects the test data such as head neck ribs or spine The engineer running the test should approve use of additional reinforcement such as tape before conducting tests Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 72 of 74 APPENDIX C JOINT ADJUSTMENT PROCEDURES The joints of the Hybrid Ill dummies are adjusted to a 1 G suspended setting This is defined as a torque level on the joint where the friction will allow an assembly to move toward the earth when a small force is applied to the unsupported end of the assembly For example when the dummy s arm is fully extended laterally so it is perpendicular to the body the shoulder yoke clevis bolt should be tight enough to support the weight of the arm but loose enough so when you tap the dummy s wrist the whole arm will slowly fall towards the dummy The following sections describe how to position the body parts and which joints to tighten to allow a 1 G setting C 1 1 C 2 HANDS AND ARMS Extend complete arm laterally outward to a horizontal position Twist the arm so the elbow cannot rotate downward Tighten the shoulder yoke clevis bolt so the arm is suspended at 1 G Rotate the complete arm
60. gures 34 amp 37 all items 66 80 0 8 30 30 0 36 femurs and their lower lumbar adapting plate Upper Leg Assembly Left Figure 41 all items 18 10 0 2 8 21 0 09 Upper Leg Assembly Right 18 10 0 2 8 21 0 09 Lower Leg Assembly Left Figures 42 amp 43 all items 12 68 0 2 5 75 0 09 Lower Leg Assembly Right 12 68 0 2 5 75 0 09 Upper Arm Assembly Left Figure 46 items 4 5 12 6 20 0 2 2 81 0 05 Upper Arm Assembly Right 6 20 0 2 2 81 0 05 Lower Arm Left Figure 46 items 9 10 13 14 as 4 55 0 1 2 06 0 09 Lower Arm Right shown items 1 2 3 6 7 quantity 4 55 0 1 2 06 0 09 1 each Hand Assembly Left Figure 46 item 15 1 25 0 1 0 57 0 05 Hand Assembly Right 1 25 0 1 0 57 0 05 Foot Assembly Left Figure 45 items 1 and 2 quantity 3 50 0 15 1 59 0 07 Foot Assembly Right 1 each 3 50 0 15 1 59 0 07 Total Dummy Weight 223 2 3 60 101 24 1 63 5 5 A This procedure tests the forward flexion of the torso of the dummy The fully assembled dummy with or without the Torso Flexion Test lower leg assemblies below the femur link can be used in this test B The test fixture consists of the torso flexion test table shown in Figure 57 and the torso pull bracket shown in Figure 58 C Test Procedure 1 Soak the dummy in a controlled environment with a temperature between 20 6 to 22 2 C 69 0 to 72 0 F anda relative humidity from 10 to 70 for at least 4 hours prior to a test
61. he lumbar adaptor assembly with the thorax weight and transducers into the bottom of the thoracic spine Install the thoracic spine with adaptor assembly to the lumbar spine Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 33 of 74 3 3 5 Lower Torso Special Care and Maintenance e Do not leave the lumbar spine cable torqued when storing the dummy This will cause permanent deformation of the spine e Check for cracks in the lumbar spine rubber e Check for tears in the pelvis vinyl e Check for chipped cracked or broken metal pieces or stripped screws and threads 34 Legs 3 4 1 Upper Legs and Knees Figure 41 represents the exploded view of the upper leg Table 8 lists the general part descriptions identified in Figure 41 Figure 42 represents the exploded view of the ball slider knee assembly Table 9 lists the general part descriptions identified in Figure 42 TABLE 8 UPPER LEG EXPLODED VIEW PART LIST Item Number Quantity Part Number Description 1 1 880995 1527 Upper Leg Flesh 2 1 880995 508 Knee Flesh 3 1 880995 502 Upper Leg Weldment 4 2 9000066 SHCS 3 8 16x2 5 1 78051 319 FEMUR LOAD CELL REPLACEMENT 6 1 880995 1510 Knee Cap 7 1 880995 511 Knee Insert FIGURE 41 UPPER LEG EXPLODED VIEW Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 3
62. he unit in its protective sleeve until the unit is installed A 2 PRELIMINARY CHECK OUT Before installing any accelerometer into the dummy check that it operates properly Three simple tests that require minimal test equipment should be conducted 1 Impedance Test Read the input impedance Red to Black and output impedance Green to White with an ohmmeter Compare the measured values to those on the accelerometer Calibration Data Sheet The measured impedance should be within 25 of the calibrated value 2 Insulation Resistance If the input and output impedances are within acceptable limits use a multimeter onmmeter or megohmmeter set at 50 volts maximum Measure the insulation resistance between 1 all leads connected together and the cable shield 2 all leads connected together and the accelerometer case 3 cable shield and the transducer case All three readings should be at least 100 megohms Be careful when connecting 50 V DC to eliminate the possibility of voltage spikes 3 Zero Measurand Output After the impedance and insulation resistance tests measure the output of the accelerometer with O G acceleration With the unit still in its sleeve turn the unit on its side so the accelerometer mounting surface is perpendicular to the table top sensitive axis horizontal and perpendicular to the gravity field Apply the specified excitation voltage to the accelerometer and measure its output with a DC millivolt meter Allow the unit
63. hihiro Ozawa Wednesday January 14 2015 J2860 Issued SEP2012 Page 49 of 7 O INDEX MARKS ALIGNED CREF DWG 880105 207 AND DWG 880105 208 Hardware for length adjustment should be located near the upper pivot and is not included in the cable weight f IMPACTOR FACE 152 4 t 0 25 mm 6 0 01 in DIA WITH EDGE RADIUS OF 12 7 mm 0 5 in ACCELEROMETER MOUNTED WITH SENSITIVE AXIS PARALLEL TO TEST PROBE LONGITUDINAL CENTERLINE CENTERLINE OF ARMS HORIZONTAL 2 TEST PROBE CENTERLINE HORIZONTAL 0 05 NO 3 RIB CENTERLINE HORIZONTAL 0 5 12 7 t 1 0mm 0 5020 04 in TEST PROBE 23 36 0 02 kg 51 54 0 05 PELVIC ANGLE MEASUREMEN REF SURFACE SEATING SURFACE HORIZONTAL 0 5 PELVIC ADAPTOR BLOCK FLAT SMOOTH RIGID CREF DWG 880105 406 CLEAN DRY HORIZONTAL STEEL SURFACE NOTE A NO EXTERNAL SUPPORT IS REQUIRED ON THE DUMMY TO MEET SETUP SPECIFICATIONS B gt THE MIDSAGITTAL PLANE OF THE DUMMY IS VERTICAL 1 AND WITHIN 2 OF THE CENTERLINE OF THE TEST PROBE C THE MIDSAGITTAL PLANE OF THE DUMMY IS CENTERED ON THE CENTERLINE OF THE TEST PROBE WITHIN 3 mm 0 12 ind FIGURE 51 THORAX IMPACT TEST SET UP SPECIFICATIONS 4 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 50 of 74 THORAX RESISTIVE FORCE CHEST DISPLACEMENT FIGURE 52 HYSTERESIS DEFINITION 4 4
64. hould exist Examine the machined metal parts and compare the rubber sections of the neck against the drawing pagana Nodding Blocks FIGURE 9 NODDING JOINT Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 13 of 74 Once separated check the condition of the two rubber neck nodding blocks on the top of the nodding joint The 90 degree surfaces of the nodding blocks fit opposite rather than inside the 90 degree grooves of the head to neck adaptor bracket Figure 10 Scole 2 5x NODDING BLOCKS ARE TO BE INSTALLED WITH THE 90 ANGLED CORNER TOWARD THE SKULL FIGURE 10 NODDING BLOCK ORIENTATION Upon re assembly assemble the two sections of the neck bracket with the adjustment set to 0 degree and measure the bracket angle The lug on the nodding joint must fit very tightly in the slot in the bottom of the neck load cell The tightness is controlled by a brass washer on each side of the yoke These washers must be lapped to produce a 0 000 to 0 025 mm 0 000 to 0 001 in interference fit at assembly Because the inside diameter of these washers is also critical validate this dimension against the drawing 3 1 2 Head Remove the four SHCS on the underside of the skull Figure 11 A steel washer under each of the cap screws helps to protect the aluminum from being galled by the steel screws Figure 2 Item 6 These are special washers and must
65. igure 23 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 22 of 74 Urethane pring Stop FIGURE 23 URETHANE SPRING STOP Top and bottom thin clavicle spacers Figure 24 should isolate the two sections FIGURE 24 CLAVICLE SPACERS The shoulder yoke connects the arm to the clavicle To remove the shoulder yoke use an open wrench or equivalent tool to remove the lock nut Figure 25 Once the nut is removed the shoulder yoke will slide out and the disassembly is complete Check for a steel stop on the rim of the shoulder yoke held by two SHCS Figure 20 The stop can be installed in two positions one for the right side and the other for the left Inspect clavicle aluminum parts for porosity and cracks This will complete the disassembly of the clavicle from the clavicle link Before assembly ensure the spring stop is in position Use a clamp or compression tool to squeeze the clavicle and clavicle link in order to compress the urethane spring stop until insertion of the clavicle SHSS is possible Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 23 of 74 FIGURE 25 CLAVICLE LOCK NUT 3 2 2 Shoulder Clavicles Assembly Notes When mounting the lower neck bracket to the top of the spine ensure that the cap screws have metal washers to protect the aluminum Assemble the shoulder yo
66. kes clavicles and clavicle links The long flat clavicle spacers are easily damaged during assembly An alignment tool will assist in this operation Assemble the clavicles to the thoracic spine assembly The flat spots on the flat clavicle washers are on the side nearest the centerline of the spine 3 2 3 Ribs and Sternum Remove the twelve BHCS holding the front of the ribs to the bib Figure 26 Inspect the thin steel strips under the bolt heads for cracks Check the thicker slightly angled strips behind the rib ends for cracks Note the way the strips fit the chest The bend is not symmetrical the upper portion is shorter than the lower Allow the chest displacement slider arm to slide out the bottom of the sternum slider slot Check that the open end of the sternum nut plate is at the bottom Figure 27 Remove the twelve BHCS screws holding the sternum slider assembly to the bib Figure 28 Examine the slider for damage and ensure that the slider ball moves freely in its track Inspect the aluminum plate to which the slider assembly bolts Inspect the bib for cracks tears and imperfections Compare the shape to the drawing Clean all parts with isopropyl alcohol or an equivalent Detach the six ribs and their rear rib supports by removing the twelve BHCS screws at the rear of the thoracic spine assembly Figure 29 Carefully examine each rib and the rib damping material for cracks Check for gaps or other failures of the epoxy bond betwee
67. l by Yoshihiro Ozawa Wednesday January 14 2015 J2860 Issued SEP2012 D Y sa LJ Bi E a Gro EI no o O tin ya T a Zu De Sooo Ww a BG z wor amp Z CF oH wa 5 LI D 1 Mm ir 0 Gou O LELO i I Li Z 5 a E O E Z E O oO Na Bi 5 r 3 Ed bs nL GIN O 67 8240 2 mm QN Oj hi 2 67 01 ro Page 67 of 7 YA OF ANKLE SHELL FIGURE 62 ANKLE FOOT REFERENCE PLANES Lu ze I jag Lo EH PA O ao R zZ sala H E3 So T HES ao 293 oo SI Lan 524 O 90 REF gt x go 1 oS i O 4 z5 9 REF 354 Sez p5 SJ d 4 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 68 of 74 11 Eversion test apply a moment through the standoffs that rotates the foot outward relative the ankle shell about the ankle s anterior posterior axis until a moment of at least 4 N m 2 95 Ibf ft is reached at a rate not to exceed 5 degrees per second 12 Testing should be performed on each ankle joint separately 13 Wait at least 5 minutes between successive tests on the same ankle F Performance Specifications The performance specifications for the Ankle Motion test are listed in Table 11 TABLE 23 ANKLE MOTION SPECIFICATIONS po Moment Age JJ 40 0 N m 29 5 Ibf ft 45 degrees 2 degrees Plantar Flexion 4
68. lel to the midsagittal plane Vertically align the centerline between the knee pivot and the screw attaching the ankle to the lower tibia Position the feet parallel to the dummy s midsagittal plane with the bottoms horizontal and parallel to the seating surface J Position the upper arms vertically so the centerline between the shoulder and elbow pivots is parallel to the rear vertical surface of the fixture Position the lower arms horizontally so the centerline between the elbow and wrist pivots is parallel to the seat surface K Record the following dimensions The symbols and description for each measurement are indicated in Figure 55 and Table 21 A Sitting Height Seat Surface to highest point on top of the head B Shoulder Pivot Height Centerline of shoulder pivot bolt to the seat surface C H point height above seat surface Set up dimension D H point from seat s rear vertical surface Set up dimension E Shoulder Pivot from Backline Center of the shoulder clevis to the fixture s rear vertical surface F Thigh Clearance Seat surface to highest point on the upper femur segment G Back of Elbow to Wrist Pivot The back of the elbow flesh to the finger tip H Skull cap skin to seat rear vertical surface Set up dimension Top of the Shoulder Yoke to Elbow Length The highest point on top of the shoulder clevis to the lowest part of the flesh on the elbow in line with the elbow pivot bolt J Elbow R
69. m 0 062 in diameter holes located on either side of the head may be used to ensure that the head is level with respect to the impact surface 6 Drop the head assembly from a height of 376 mm 1 mm 14 8 in 0 04 in by a means that ensures a smooth clean release onto the impact surface 7 Wait at least 2 hours between successive tests on the same head assembly 8 Time zero is defined as the point of contact between the head and the impact surface All data channels should be at the zero level at this time F Performance Specifications The performance specifications for the head drop test are listed in Table 14 TABLE 14 HEAD DROP TEST SPECIFICATIONS 18 9 25 6 C 10 0 70 0 Peak Resultant 220 265 G Peak Lateral 15 0 15 0 G The resultant acceleration versus time history curve shall be unimodal to the extent that oscillations occurring after the main acceleration pulse are less than 10 zero to peak of the main pulse RIGID SUPPORTED FIXTURE AUICK RELEASE MECHANIS lt ACCELEROMETER CABLES Pa ROUTE CABLES SUCH THAT y THEY DO NOT INFLUENCE BUCKLE HEAD MOTION DURING THE DRO ADJUSTMENT ii AE NECK TRANSDUCER O HEAD SUPPORT pa STRUCTURAL REPLACEMENT CABLES YY ie LIGHTWEIGHT N NZ i THREADED INSERT x a 7 PLASTIC NYLON ETC V mm n FLAT HORIZONTAL STEEL PLATE DROP HEIGHT N 376210 mr N 14 80 04 ind 0 8mm X 610mm X 610mr in X 24 in x 24i ITH SURFACE FINI
70. mmy tool kit provided by the dummy manufacturers For best results a variable power supply should be used to control the heat output from the iron Without this control repairs will be more difficult and may be unsightly from black flakes of burnt flesh imbedded in the flesh These flakes are caused by overheating the flesh which happens when an iron is too hot or remains in one position too long Another cause of black residue in the flesh is improper or infrequent cleaning of the iron tip The tip should be cleaned frequently during the repair job between each melting of flesh if possible The best method for doing this is to tap the iron quickly on a buffing wheel Conduct all flesh preparations and repairs in a well ventilated area When patching first clear away any loose material which may be hanging from the damaged areas such as shredded vinyl or foam Clean the area with 99 solution isopropyl alcohol and let dry for 15 minutes Any residue from tape or chalk must be removed If it remains after the initial cleaning continue to clean with isopropyl alcohol until the area is completely clean Since isopropyl alcohol is flammable make sure the surface is dry before applying heat Do not use soldering flux or any other chemical on the flesh or repair iron After preparation a patch can be bonded to the flesh Cut a patch of adequate size from the material provided in the dummy tool kit The patch should be approximately 10 mm 0 5 in wider tha
71. n the damaged area on all sides To check that the iron is at a usable temperature test it on a small piece of patch material The flesh should easily melt but not instantly burn With the patch held over the damaged area slide the iron between the patch and dummy flesh Hold the iron in position until you see both materials melting When both the patch and the flesh look like a gel move the iron to a new point while holding the patch in place until they have both cooled Continue this all the way around the damaged area until the patch is completely bonded to the flesh For large areas or areas where the patch must bend to conform to the dummy part it may be easier to tack a few points around the edge of the patch to hold it in place then return to fill in the unbonded sections Once you bond the patch to the flesh you need to blend the patch into the flesh This will eliminate any protruding edges that may later snag and ruin the repair To blend the patch work the iron tip around the patch edges in a circular motion blending the patch material into the flesh as you work your way around the patch If the iron is too hot black flakes will appear if it is too cold the patch will not readily melt and the patch is probably not very well bonded to the flesh Continue working the patch into the flesh until the repair is fairly well hidden and let it cool After the area cools you can return to touch up any areas If a certain area of flesh is
72. n the rib damping material and the rib metal Figure 30 When reassembling make sure the rib supports are not bent or damaged and are mounted the correct way The tapered side of the stiffener should be oriented toward the ribs Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 24 of 74 Aluminum Plate Displacement Transducer Assy FIGURE 27 CHEST CAVITY STERNUM SLIDER FIGURE 28 STERNUM SLIDER AND BIB Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 25 of 74 qeesui Sta 06020158A 98030158A 08030156 FIGURE 29 RIB AND RIB STIFFENER REMOVAL Rib Damping Material Interface FIGURE 30 RIB AND DAMPING MATERIAL After assembling the ribs or when checking rib condition use the special tool V00278 to check for correct chest depth Refer to Chest Depth Measurements in the Inspection Procedures and Tests section 3 2 4 Thoracic Spine Figure 31 represents the exploded view of the thoracic spine Table 6 is a list of general part descriptions identified in Figure 31 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 26 of 74 TABLE 6 SPINE BOX EXPLODED PART LIST Item Number Quantity Part Number Description 1 1 90004
73. ncluded in the cable weight Page 54 of 7 4 Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 55 of 74 5 INSPECTION PROCEDURES AND TESTS 5 1 Chest Depth Measurements After assembling the ribs or when checking rib condition use the special tool V00278 to check for correct chest depth The gauge is used to check the chest cavity depth at number one and number six ribs Figure 55 The gauge should be pressed against the back edge of the spine box not the rear rib supports If the gauge probe contacts the front rib end threaded strip the condition is unacceptable and the ribs should be replaced The gauge has two separate calibrated surfaces for the number one and number six ribs The number one rib distance from the back of the rib stiffener to the back of the aluminum plate should be a minimum distance of 7 75 inches The number six rib distance from the back of the rib stiffener to the back of the nut plate should be a minimum distance of 8 10 inches am Rib 6 small notch FIGURE 55 CHEST DEPTH MEASUREMENT TOOL 5 2 External Measurements A Adjust the torques on all the joints to a 1 g setting Appendix C B Torque the neck cable to 1 36 0 23 Nm 12 0 2 2 in Ibf Make sure the zero marks on the upper and lower neck bracket 880995 1270 78051 303 are aligned C Allthe measurements are without jacket except the Chest Circumference Y It can
74. no friction to the ball joint Check for smooth rotation of the ankle shell on the ball If rotation is not smooth replace the ankle assembly The tests are run with the ankle set screw loose As seen in Figures 61 and 62 an ankle reference plane is defined as the plane parallel to the sole plate of the foot that passes through the ankle ball joint center This plane is 47 7 mm 0 2 mm 1 88 in 0 01 in above the bottom of the standoff holes Mount the ankle shell to a rigid fixture using the existing 19 mm hole intended for attaching the ankle to the tibia Insert the standoffs into the foot Attach a device to the standoffs for applying the moment and providing an angle measurement reference surface Soak the ankle assembly in a controlled environment with a temperature between 20 6 and 22 2 C 69 0 to 72 0 F and a relative humidity between 10 and 70 for at least 4 hours prior to a test The test environment should have the same temperature and humidity requirements as the soak environment Install the moment and angle transducers Angle and moment data should be measured continually throughout all tests Adjust the foot so the angle between an anterior posterior line on the ankle reference plane and the longitudinal centerline of the ankle shell is 81 degrees 1 degree In addition the foot should be adjusted so a lateral medial line on the ankle reference plane is perpendicular 1 degree to the ankle shell longitudinal centerline The
75. ntrolled environment with a temperature of 20 6 to 22 2 C 69 to 72 F anda relative humidity from 10 to 70 for at least 4 hours prior to a test The test environment should have the same temperature and humidity requirements as the soak environment 3 Mount the accelerometers in the head on the horizontal transverse bulkhead so the sensitive axes intersect at the center of gravity point as defined by Drawing 880995 1100 One accelerometer is aligned with the sensitive axis perpendicular to the horizontal bulkhead in the midsagittal plane Z axis The second accelerometer is aligned with the sensitive axis parallel to the horizontal bulkhead in the midsagittal plane X axis The third accelerometer is aligned with its sensitive axis parallel to the horizontal bulkhead and perpendicular to the midsagittal plane Y axis Ensure that all transducers are properly installed oriented and calibrated 4 Prior to the test clean the impact surface of the skin and the impact plate surface with isopropyl alcohol or an equivalent The impact surface and the skin must be clean and dry for testing Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 41 of 74 5 Suspend the head assembly in a manner similar to that shown in Figure 47 The lowest point on the forehead is 12 7 mm 1 mm 0 5 in 0 04 in below the lowest point of the dummy s nose when the midsagittal plane is vertical The 1 57 m
76. nvironment with a temperature between 18 9 and 25 6 C 66 to 78 F and a relative humidity from 10 to 70 for at least 4 hours prior to a test The test environment should have the same temperature and humidity requirements as the soak environment 3 Check that all transducers are properly installed oriented and calibrated 4 Mount the knee assembly to the fixture using a femur load cell Torque the two mounting bolts to 40 7 N m 30 ft lbf to prevent slippage of the assembly Attach the load distribution bracket to the slider assembly The bracket is attached to the inboard and outboard slider assemblies in the same manner as the knee clevis 5 Align the longitudinal centerline of the test probe so at the time of impact it is collinear within 2 degrees with the longitudinal centerline between the load cell and the load distribution bracket The test probe longitudinal centerline should be horizontal within 0 5 degree The test setup appears in Figure 54 6 Guide the probe so no significant lateral vertical or rotational motion occurs at the time of contact between the test probe face and the load distribution bracket 7 The test probe velocity at the time of impact is 2 75 m s 0 05 m s 9 02 ft s 0 18 ft s Conduct one break in test before the certification test 8 Time zero is defined as the time of initial contact between the test probe and the load distribution bracket All data channels should be at zero level at this time
77. of the lumbar cables Detach the two lumbar cables by removing the two hex and jam nuts on the top of each cable and pulling the cables through the spine Figure 34 These cables are not interchangeable with the neck cable Check the top and bottom end plates for flatness and for complete adhesion to the rubber Make sure sufficient clearance between the swaged balls and the hemispherical seats exists Each cable will have an upper and lower lumbar bushing Check the bushing for damage Clean with a chlorinated solvent if necessary These bushings are not interchangeable with the neck bushings 3 3 2 Abdomen Examine the abdominal insert Figure 37 for skin to foam separation for tears and or cuts in the vinyl skin and for air tightness When compressed no air should escape Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 31 of 74 FIGURE 37 ABDOMEN 3 3 3 Pelvis and Upper Femurs Remove the femur assembly shown in Figure 38 from each side of the pelvis by unscrewing three SHCS per side Access is gained through the three 1 2 inch diameter holes in each side of the pelvic flesh Figure 38 First remove the two rear screws and then rotate the femur assembly towards the pelvic center to allow access to the third screw A tool made to fit in place of the upper leg bone will simplify this task When removing the femurs be careful not to tear the urethane bumpers on th
78. on across the passive arms of the accelerometer A 4 RECALIBRATION Sensitivity and Zero Measurand Output calibrations should be performed at 6 to 12 month intervals depending on usage Usually 12 month intervals are sufficient if you know the accelerometer has not been used beyond its rated specifications If the unit is used under severe environments the shorter calibration interval may be desirable Cleaning Dirty units may be wiped clean using a damp cloth and a solvent such as acetone DO NOT SOAK OR IMMERSE the unit in any solvent or water Do not use any sharp tool such as a screwdriver to remove dirt or contaminants If tools such as pliers are needed to handle the accelerometer cover the jaws with masking tape to prevent unwanted metal to metal contact Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 71 of 74 APPENDIX B GUIDELINES FOR REPAIRING FLESH Dummy flesh is often damaged but can be repaired The most common types or flesh damage are punctures tears and scrapes Scrapes can be fixed by rubbing an iron at low temperature over the affected area several times Punctures and tears require patching To repair the flesh use an iron to bond the dummy s flesh to patches of repair materials The iron is similar to a standard electronic soldering iron Its output should range from 60 to 90 Watts The best tip is a broad flat paddle tip like the one in the du
79. pivot pin three accelerometers NOTE The mass of the head assembly is 4 94 kg 0 05 kg 10 9 Ib 0 1 Ib C The test fixture consists of a structure to suspend the head assembly and a rigidly supported flat horizontal steel plate The square plate should be 50 8 mm 2 mm 2 0 in 0 08 in thick with a length and width of 610 mm 10 mm 24 in 0 4 in and have a smooth surface finish of 0 2032 to 2 032 um 8 to 80 micro inches inch rms A surface finish close to 0 2032 um 8 micro inches inch rms is preferred The suspension system and accelerometer cable masses should be as light as possible to minimize the external forces acting on the head Effective suspension cable and accelerometer cable masses are to be less than 25 g 0 05 Ib Effective mass can be estimated by multiplying the mass unit length of the cable by the length of cable between the head and the first support D The Data Acquisition System including transducers must conform to the specifications of the latest revision of SAE Recommended Practice J211 1 Filter all data channels using Channel Class 1000 phaseless filters E Test Procedure 1 Visually inspect the head skin for cracks cuts abrasions etc Replace or repair the head skin if abrasions or cuts to the frontal area are more than superficial Torque the 1 4 20 skull cap screws to 18 N m 160 in Ibf and the 10 24 accelerometer mount screws to 7 5 N m 66 in Ibf 2 Soak the head assembly in a co
80. robe acceleration data using Channel Filter Class 180 phaseless filter and filter the chest deflection using Channel Filter Class 600 phaseless filter D Test Procedure 1 Remove the chest jacket and visually inspect the thorax assembly for cracks cuts abrasions etc Pay particular attention to the rib damping material chest displacement transducer assembly and the rear rib supports Torque the lumbar spine cables to 1 13 to 1 4 N m 10 0 to 12 4 in Ibf Soak the test dummy in a controlled environment with a temperature of 20 6 to 22 2 C 69 to 72 F and a relative humidity from 10 to 70 for at least 4 hours prior to the test until the rib temperature has reached the soak temperature The test environment should have the same temperature and humidity requirements as the soak environment Check that all transducers are properly installed oriented and calibrated Seat the dummy without the chest jacket and shirt but with the pants on the test fixture surface The surface must be long enough to support the pelvis and outstretched legs Align the upper and lower neck bracket index marks to the zero position Place the arm assemblies horizontal 2 degrees and parallel to the midsagittal plane Secure the arms by tightening the adjustment nut that holds the arm yoke to the clavicle assembly If necessary prop the arms up with a rod that will fall away during the test Level the ribs both longitudinally and laterally 0 5 degr
81. s a seated pelvis construction A sit stand pelvis version is optional as are a neck covering for airbag testing a deformable face for steering wheel rim testing and a deformable abdomen for lap belt submarining and steering wheel rim evaluations Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 6 of 74 CLOTHING When used in testing the dummy should wear snug fitting cotton knit T shirt and pants The neckline should be small enough to prevent contact between a shoulder belt and the dummy s skin The pants should end above the dummy s knee The T shirt and pants should each weigh no more than 0 27 kg 0 6 Ib Garments similar to thermal underwear trimmed to be short sleeved and above the knee usually meet these requirements To improve the quality of high speed films taken of the dummy during testing by avoiding excessive glare the garments are usually dyed to a light pink A size large shirt L and double extra large pants XXL are suggested sizes for proper fit and weight The shoes used with the large male dummy are size 11XW shoe which meets the configuration size sole and heel thickness specifications of MIL S 13192 change P and whose weight is 1 25 0 2 pounds INSTRUMENTATION When ordering a new dummy inform the dummy manufacturer of the type and model of accelerometer you intend to use This will ensure that you obtain the correct acceleromet
82. s moment response in both dynamic flexion forward bending and extension rearward bending articulations e Aneck cable controls stretching responses and increases the neck s durability to high axial tension forces e The two piece aluminum clavicle and clavicle link assembly have cast integral scapulae with a lip along the superior medial edge to prevent the neck from interfacing with shoulder belts e Six spring steel ribs with polymer based damping material approximate the human chest force deflection response characteristics The sternum assembly connects to the front of the ribs and incorporates a slider for a chest deflection transducer to measure rib cage deflection relative to the thoracic spine e Acurved lumbar spine gives a sitting posture to simulate a person of larger stature in the driving position e The pelvis has a human shape and comes equipped with load cell replacements that can be replaced by transducers that indicate submarining of the pelvis e A knee slider mechanism is used that consists of steel ball sliders with energy absorbing molded rubber mounted on aluminum knees This allows for displacement of the tibia relative to the femur simulating ligament response e The leg assemblies are steel structures covered with vinyl The legs are interchangeable with instrumented versions e Constant friction movable joints are used that need few adjustments and provide consistent articulations e The standard model ha
83. t revision of SAE Recommended Practice J211 1 Filter the neck force data channel using Channel Class 1000 the neck moment data channel using Channel Class 600 the pendulum acceleration data channel using Channel Class 180 and the neck rotation data channels using Channel Class 60 All filters should be phaseless D Test Procedure 1 Soak the neck assembly in a controlled environment at a temperature between 20 6 to 22 2 69 to 72 F anda relative humidity from 10 to 70 for at least 4 hours prior to a test The test environment should have the same temperature and humidity requirements as the soak environment Check that internal neck temperature reaches the soak temperature by placing a thermo sensor into one of the holes in the neck Inspect the neck assembly for cracks cuts and separation of the rubber from the metal segment Inspect the nodding blocks 78051 351 for any deterioration and replace as necessary Replace the blocks if they are less than 80 of their original height The durometer should be 60 to 90 Shore A Ensure that the nodding blocks are installed correctly as shown in Figure 10 drawing 880995 1250 Inspect the nodding joint washers Drawing 78051 253 for an interference fit Adjust or replace as required Mount the head neck assembly on the pendulum so the midsagittal plane of the head is vertical As shown in Figure 49 for the Extension test and Figure 50 for the Flexion test the midsagittal plane should coinci
84. tion of the chest jacket so it may be necessary to leave the chest jacket unzipped until the references are checked and then fasten it just prior to the test Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 48 of 74 11 Impact the thorax with the test probe so the probe s longitudinal centerline is within 2 degrees of a horizontal line in the dummy s midsagittal plane at the moment of impact 12 Guide the probe so no significant lateral vertical or rotational motion takes place during the impact 13 The test probe velocity at the time of impact is 6 71 m s 0 12 m s 22 ft s 0 4 ft s 14 Time zero is defined as the time of initial contact between the test probe and the chest jacket All data channels should be at the zero level at this time 15 Wait at least 30 minutes between successive tests on the same thorax E Performance Specifications The performance specifications for the Thorax Impact test are listed in Table 17 Internal Hysteresis is illustrated in Figure 52 TABLE 17 THORAX IMPACT TEST SPECIFICATIONS Temperature 20 6 22 2 C 69 08 71 96 F Humidity 10 0 70 0 10 0 70 0 Velocit 6 59 6 83 m s 14 74 15 28 mph Maximum Force in Displacement Corridor 5 10 5 90 kN 1146 93 1326 37 lbf Peak Chest Displacement 66 0 76 0mm _ 2 60 2 99 in Internal Hysteresis 69 85 69 85 S A E Downloaded from SAE International by Yos
85. tional by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 20 of 74 SHSS AND WASHER FIGURE 18 CLAVICLE LINK BOLT At this time use a pair of needle nose pliers to remove the rubber bumper stop from the Thoracic Spine Figure 19 Inspect the shoulder yoke for damage The stop should be free from tears or permanent deformation and should be symmetrical in cross section FIGURE 19 BUMPER STOP The shoulder yoke assembly contains three stops One is a steel stop that contacts a rubber rear stop when the arm is extended Figure 20 There are four holes available for positioning the steel stop on the shoulder yoke The steel stop should be positioned in the two mounting holes furthest from the rear stop as shown in Figure 20 The third stop is the rubber shoulder pivot stop that prevents excessive arm abduction Figure 21 Upon disassembly all stops should be inspected for damage Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 21 of 74 FIGURE 20 SHOULDER YOKE ROTATION STOP Shoulder Pivot Stop FIGURE 21 UPPER ARM STOP Remove the SHSS Figure 22 and its steel washer that holds the two aluminum sections of the clavicle and its link together Clavicle SHSS FIGURE 22 CLAVICLE SHSS A urethane spring stop should be located at the back of the cavity in the inner clavicle link F
86. to warm up for 2 minutes The accelerometer should have a Zero Measurand Output ZMO within the manufacturer s specified limits If any of these initial checks do not give proper readings indicating a possible malfunction remove the excitation source immediately and take the following measurements 1 Check and record leg 1 leg 2 leg 3 and leg 4 resistances 2 Disconnect check and record excitation voltage from the source 3 Reconnect check and record excitation with the unit connected 4 Check and record ZMO again 5 Check and record static outputs 1 G and 1 G and compare to calibrated sensitivity 6 Check that the temperature and environment fall within accelerometer specification Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 70 of 74 7 Check to see if the accelerometer case is under stress 8 Check leads for abrasion or cuts If the reason for the erroneous reading cannot be found contact the accelerometer manufacturer A 3 INSTALLATION When mounting or removing the accelerometer you must use the proper techniques and tools The mounting surface should be clean and free of burrs A recommended surface roughness is 0 8128 um 32 microinch rms or less Make sure that no dirt or particles can be clamped between the unit and mounting surfaces Remove the unit from the protective sleeve With the sleeve absent handle the unit by the case not the
87. upper extreme of the United States adult population Much of the anthropometry and design is a scaled version of the Hybrid Ill midsize adult male dummy Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 4 of 74 MANUAL OVERVIEW Appendices Several guidelines and procedures apply to various parts throughout the dummy and are included in the appendices for easier reference e When handling an instrumented dummy improper techniques can damage instrumentation particularly accelerometers Appendix A contains guidelines for safe handling of instrumented dummies e The vinyl flesh of dummies can be damaged but is often repairable Appendix B contains instructions for repairing dummy flesh e Procedures for adjusting the joints throughout the dummy are included in Appendix C e The axial integrity of the neck is listed in Appendix D e A bolt torque value chart is Appendix E SAE Documents In addition to the attached appendices other SAE publications are particularly useful when working with the Hybrid III dummy SAE J211 1 provides the most recent guidelines and procedures for dummy instrumentation and filtering SAE Information Report J1733 illustrates the instrumentation available for the Hybrid Ill dummy family along with descriptions of how to apply the positive right hand rule sign convention SAE Test Definitions Certification Test Certification tests are specified for
88. ure 12 Note that the nodding joint bracket is separated from the upper neck by an upper neck spacer plate The lower neck adjustment bracket is separated from the lower neck plate by a lower neck spacer plate They are distinguishable by their hole patterns The upper neck spacer plate has a symmetrical hole pattern that matches the nodding joint bracket while the lower neck spacer plate has an offset hole pattern that matches the lower neck adjustment bracket to ensure proper assembly 3 1 4 Head Neck Special Care and Maintenance e Check for tears or breaks in the neck e Check the head skin for tears or cracks Repair the head skin as outlined in Appendix B e Damage to the head skin in the forehead region should not be repaired as this will affect test results Replace e Check the skull casting for dents or cracks Replace if damaged e Check the nodding blocks for wear and deformation Noise and improper loading of the nodding joint will occur with damaged blocks e Check the axial integrity of the neck see Appendix D e The neck cable should be torqued to 1 36 N m 0 23 N m 12 0 in Ibf 2 2 in Ibf 3 2 Upper Torso 3 2 1 Shoulder Clavicles Figures 14 and 15 show the clavicle and shoulder exploded views The corresponding table is the general part description that correlates with the adjacent item number Downloaded from SAE International by Yoshihiro Ozawa Wednesday January 14 2015 SAE J2860 Issued SEP2012 Page 17 of 74

AEROSP SURFACE VEHICLE RECOMMENDED PRACTICE

Contents

Download Pdf Manuals

Related Search

Related Contents