Flex PLI GTR User Manual
Contents
1. 27 Figure 23 Fixing Messring Wire to Launcher 2 2 4 27 Figure 24 Right hand side of knee sensors not connected 2 2 2 28 Figure 25 right hand side of knee sensors connected 28 Figure 26 Bottom right hand side of knee sensors connected 29 Figure 27 left hand side of knee sensors 29 Figure 28 Bottom left hand side of knee sensors connected 30 Figure 29 Wiring diagram for 12 channel 440 80 91 Figure 30 Typical Slice wiring to knee with SLICE 31 Figure 31 Disconnect connector and clamp on 1 0 32 Figure 32 Left hand side of leg with knee covers fitted Leg wires are not shown secured 32 Figure 33 Right hand side of knee showing earth strap terminations and connectors 33 Figure 34 Leg with disconnect wire TDAS interface and power supply 33 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 442. 22 2 9 9 E 22 2 4 Dara Acguisiton Ee UU UU uu uu uu uuu b dpa IM UNIUS 23 2 5 ue E 23 2 6 Messring M BUS On Board Data Acquisition a 25 2 6 1 25 2 6 2 ASTIN EE 28 2 DTS Onboard SLICE Nano DAS 30 2 8 SLICE 24 Channel OPUON EE 34 Section 3 Assembly and R E 35 3 1 Femur IOC 2 a aE SiR 37 Femu r Upper LSC EE e EE 39 3 1 2 Femur after Calibration 42 3 19 DIS 42 9 2 Knee Exploded TE 43 KDA STD EE de 44 SS MEME 1 46 5 16 uuu uuu ull ETT 47 3 2 3 405 389 te EE 47 2 9 EXODO E 49 3321 Tibla Assembly TIT tac seen EE 51 G I 3 04 JoL EEN 53 3 3 3 Tibia Disassembly pA CE Ote 53 53 3 3 0 Log DisGsSsembyly uu Lu 56 Section 4 57 Section 5 Calibration and certification 58 5 1 S CU
3. 58 5 2 Femur and Tibia Bone Assembly Certification 59 o MEE cs 59 5 2 2 Femur and Tibia assembly EIER ege 59 9 9 Knee lee 62 5 4 Pendulum Dynamic lee EE 64 5 5 Preparation for Pendulum Dynamic Calibration 66 Section 6 Leg Preparation Tor Dynamic Inverse Test 69 6 1 MOGUC uuu u an DET PI 69 6 2 Leg Preparation for Dynamic Inverse 69 6 3 Inverse Test Calibration Description eu suo eus 71 PUN E 72 oS T S WEE 72 Do E 72 6 3 1 3 Impactor Pitch Roll and Yaw angle cordor a 72 6 3 1 4 Flex PLI Inverse Test 72 6 4 Gar Tee 3 Section 7 Impactor Guide setting distance on Launcher 74 Section 8 EE 76 3 04 Table of Figures Figure 1 Let 9 Figure 2 10 Figure 3 Ratchet offset wrench with hex bits kt 10 Figure 4 Leg wire setting tool 199 51 KEE 11 Figure 5 Knee spacer tool 133 5113 2 are used to hold string potentiometer attachment plate 11 Figure 6 Optional Instrumentation for FeMUTr TETTE 13 Figure 7 Detail
4. arar rrar ras rsrrssrsrssssssssssssssssrsssssssss 46 Attachment plate ready crimp wires in tension for knee femur block assembly 47 Cross wire feed through on BE 47 Tibia Assembly Exploded 49 Typical shim arrangement with 05 inside main shim 52 screws to be tightened to 8 Nm a 53 Assembly of first flesh 54 Assembly of flesh second layer 55 Rubber flesh assembly Velcro positions 55 Rubber flesh tied on with Velcro 55 Leg with outer cover uu uuu 56 Bone Assembly Fixture tibia shown 60 EE 62 Diagram of Dynamic Pendulum Fixture E 64 Release Latch Wire Position rr assrssssssssssa 65 Attaching Ballast VV IgRt 66 Step 3 Attaching Dynamic RIG Pivot Block EE 67 Screws to be torqued to 8 69 Stop cable clearance adjustment using setting tool 70 Diagram of Inverse guided impactor Certification
5. G 3 04 Section 3 Assembly Disassembly 4 5000770 4x 5000584 wi b 2 w Figure 37 Instrumented Leg Exploded View G 3 04 KNEE ASSEMBLY FLEXPU 3 1 133510 FEMURASSEMBLY FLEXPLI 4 1 1335020 BUFFER SHEET ASSEMBLY LEG SHOWN 6 5504 COVER OUTER FEMUR NOT SHOWN 8 1 1335016 COVER OUTER TIBIA NOTSHOWN 9 1 1335017 COVER FLEXPLIGTR NOTSHOWN 10 6 133 5019 VELCRO BUNDLE TIE 500mm LONG NOT SHOWN Table 6 Flex PLI Parts List G 3 04 3 1 Femur Exploded View Figure 38 Femur Assembly Exploded View G I 3 04 6 5 133 5505 7 1 133 5504 SHIM BONE CLAMP 4 THICK OPTIONAL 8 1 133 5510 RUBBERBUFFER FEMURITIBIAEND 9 5 1335507 CONTACT THN SHIM 0 4 THICK OPTIONAL 14 28 500465 SCREW BHCSM6X1X18 14 5000094 WASHER FLAT 6 6 7 ID X 12 5 OD X 1 0 5000604 SCREW SHCS M6 X 1 X 14 2 23 1 5000008 SCREW SHCS 6 X 1 X 30 24 1 133 5107 ROLLER 25 8 133 5521 WASHER CABLE 133 5110 CABLE ASSEMBLY FEMUR 27 5000522 HEX NUT M5 X 0 8 NYLOK 29 6 500072 SCREWBHCSMOX1X16 1 30 32 2 133 5002 SHIM BONE CLAMP T0 05 OPTIONAL NOT SHOWN 133 5003 SHIM BONE CLAMP
6. 63 Figure ACL and PCL e e 63 Draft GTR 9 Regulation Pendulum test corridors values are up to 250 ms after impact 67 Draft non injurious Pendulum test corridors values up to 250 ms after impact 68 Dynamic Inverse test corridors These peak values shall be within 50 ms after impact 72 ED MANTIS EE 78 G I 3 04 Section 1 Introduction 1 1 Overview Pedestrian Lower Legform Impactors are used to evaluate pedestrian protection afforded by passenger cars in case of vehicle collision with a pedestrian The current EEVC WG17 Pedestrian lower legform impactor is known to have certain limitations regarding the biofidelity and the repeatability of the test results Therefore Japan proposed to use a completely new legform the so called Flexible Pedestrian Legform Impactor FlexPLI In the year 2000 the Japan Automobile Manufacturers Association Inc JAMA and the Japan Automobile Research Institute JARI initiated development of the Flexible Pedestrian Leg form Impactor Flex PLI In 2002 an initial design was made available followed by the Flex GT version in 2006 The FLEX PLI features biomechanically based femur tibia and knee design with biofidelic bending characteristics In the knee the ligaments are represented according to human anthropometry A Technical Evaluation Group FLEX TEG consisting of governmental and industrial parties is evaluating the possibility to use the leg form i
7. 71 Optional catch rope bracket 133 5034 73 Impactor guide width setting T13MM EE 74 Location of impactor guide on pusher launch plate JARI pusher shown as example 75 Exploded VIEW Dynamo PI uuu u l 3 04 Table List Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Contents of the tool kit provided with the leg on delivery 11 12 Channel Instrumentation E 12 Example of Optional Instrumentation Parts 17 ISO MME Sensor Gode table E 20 Wire label codes for HE Ce 21 FETE Pane E 36 Femur EE 38 Knee Assembly PAINS LIST 44 Assembly Fans LISL uu uuu k u 50 EIE PELO TS DIOS M Eum awanu OMIM NND i UU 97 Sensor Mass FLEX PLI GTR certification steps 58 Femur assembly calibration corridor showing a typical 60 Tibia assembly calibration corridor showing a typical result 61 Figure MCL sensor elongation ee e
8. Q N gt cO Oo N O gt 37 11 FT O C2 NI N NI NIN NIN a ay a a gt Table 20 Dynamic Rig Part List G I 3 04 8 3 Assembly as shipped Fit the top cross member Item 8 and then tighten all the screws ensuring the top cross member is in line with the impact face Fit the pivot clearance block Fit the control release box this can be fitted either side depending on user requirement Fit the release latch and connect up to the control box tape or loop the wire to the frame The control box comes with a gate switch If a barrier is required around the fixture during testing this switch can be used in the barrier to ensure the barrier is in place during the testing When the leg is fitted adjust the impact face so that the bottom of the impactor face is 30 mm above the top of the plastic blue meniscus of the knee center of knee
9. AT 14 Figure 8 Wire routing for Detail Re ele ET ee 14 Figure 9 Wire routing out of segment for optional sensors Detail A in upper 15 Figure 10 Similar arrangement to Detail A but with 2 uniax Kyowa accels Assembly 133 7600 15 Figure 11 Sensor IES 3103 ARS for Knee upper and lower used with M BUS mount 133 7522 m 16 Figure 12 Kyowa accel 3 axis option for leg top and bottom locations mount 133 7530 16 Figure 13 Optional Instrumentation TOF TIGA eerie petite erem bue mer i 17 Figure 14 Leg Local Sign GonvefllolL E 21 Figure 15 Leg manipulations for positive output 22 Figure 16 Clamping Arrangement and Position for Off board Wires 23 Figure 17 Off Board DAS wiring left hand side of impact face 24 Figure 18 Off Board DAS wiring right hand side of impact face 24 Figure 19 Wiring Diagram for 12 channel M BUS 25 Figure 20 M BUS wiring arrangement in knee 26 Figure 21 Clamping of Messring Disconnect 26 Figure 22 Messring Terminator housing installation in upper
10. Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Figure 67 Figure 68 Figure 69 Figure 70 G 3 04 Optional SLICE unit 24 channel option right side 34 Left side wiring example of 24 channel 34 Instrumented Leg Exploded View 35 Femur Assembly Exploded View 37 Femur bone assembly aaa 39 Fitting end E Man ln EE 40 Passing segment over bone 40 Exit wire from Temur u sinio Ee 41 Exit cable restraint use cable ties tie not shown trimmed 42 Knee Assembly Exploded View 43 Meniscus string pot assembly wire feed 45 Meniscus with all string pots assembled String pots identified 45 Meniscus wire clamp
11. 25 meter roll 6002558 13 Double Sided Tape 50mm Wide 5000522 M5 Nyloc Nuts 6002565 Transport Case 133 5112 Wire Setting Tool 133 5113 Setting Tool Knee 133 5025 Double Sided Tape Impact Segment Table 1 Contents of the tool kit provided with the leg on delivery 9003192 Open Ended Wrench 1 8 5000819 A strong double sided tape supplied by Teraoke is used extensively on the Flex leg FTSS recommends the use of this tape or a tape with the same strength to maintain performance 133 9900 User Manual FLEX PLI GTR Rev C Page 11 of 79 2011 Humanetics Innovative Solutions G I 3 04 Section 2 Instrumentation 2 1 Standard 12 Channel instrumentation FLEX PLI GTR is offered with 12 channel standard instrumentation measuring tibia and femur bending moments and knee ligament elongations as well as tibia acceleration in impact direction The standard instrumentation channels are listed in Table 2 The channels intended for injury assessment are tibia bending moments and knee medial collateral ligament MCL elongation These channels are controlled by the certification procedures given in Section 5 Instrument Channels Standard Femur moment 1 2 3 J 3 Tibia moment 1 2 3 4 4 Assessment Tibia top acceleration ax TREE Standard Option MCL elongation njury abd Assessment iDummy ACL el ti mm PCL elongation LCL elongation put Table 2 12 Channe
12. Tibia Segment 4 Acceleration Y AY S10 Tibia Segment 5 Acceleration Y AY S11 Tibia Segment 6 Acceleration Y AY S12 G 3 04 Tibia Segment 7 Acceleration Y AY S13 OOTIBIO700PFACYC Tibia Segment 8 Acceleration Y AY S14 oo TIBIO800PFACYC Tibia Bottom Acceleration X AY TB Tibia Bottom Acceleration Y AY TB A TB Tibia Bottom Acceleration Z AZ TB Table 5 Wire label codes for all sensors 2 3 1 Co ordinate System Recommended local co ordinate system for standardization Figure 14 Leg Local Sign Convention G I 3 04 2 3 2 Signal Polarity Sensor function check The leg can be pushed manually as shown in Figure 15 below to test polarity and function for positive output A spacer can be placed under the leg to assist in the bending of the leg The positive outputs shown in Figure 15 below are preferred for standardization users can use their own polarity if required Impact face down Push femur MX tibia out MX femur out MCL out ACL out PCL Push tibia Push femur LCL out ACL out PCL out Figure 15 Leg manipulations for positive output 2 3 3 Filter Class The filter class to be used on the Flex PLI is 180 3 04 2 4 Data Acquisition Options The FLEX PLI can be used with various options for data acquisition systems The most basic version is a system with connection cables to a static laboratory Data Acquisition System DAS the so called o
13. 2 Middle Upper X standard TIBI 3 Middle 0 Lower A standard TIBI JS Ts 4 Lower X standard TIBI Knee Bottom Acceleration standard KNEE Femur Top Acceleration A additional FEMR Femur Top Acceleration Y additional FEMR Femur Top Acceleration Z additional FEMR Femur Segment 1 Acceleration Y additional FEMR Femur Segment 2 Acceleration Y additional FEMR Femur Segment 3 Acceleration Y additional FEMR 03 Femur Segment 4 Acceleration Y additional FEMR 04 Femur Segment 5 Acceleration Y additional FEMR 05 N 6 Segment 6 Acceleration additional Y Knee Upper Acceleration 22 X additional Knee Upper ABER 23 Y additional Knee Upper NE Z4 24 7 additional Knee Upper Angular Rate NM 25 WX additional Knee Upper Angular Rate 26 WY additional Knee Upper n Angular Rate NN 27 wZ additional Knee Lower Acceleration 28 X additional Knee Lower Acceleration 29 Y additional Knee Lower Acceleration 30 2 additional Knee Lower Angular Rate 31 WX additional Knee Lower Angular Rate 32 WY additional Knee Lower Angular Rate WZ additional Tibia Segment 1 Acceleration Y additional Tibia Segment 4 Acceleration Y additional Tibia Segment 5 Acceleration Y additional Tibia Segment 6 Acceleration Y additional Tibia Se
14. DB 12 x 40 SPRING 18 X 80 AMISTAR DB 18 x 80 SPRING CAP 8 1835311 CABLE WASHER 0 8 183 5350 CABLEASSEMBLY KNEEML G I 3 04 5000203 SCREW FHCS M3 X 0 5 X 10 2 COVER KNEE FEMUR RIGHT SIDE COVER KNEE COVER KNEE TIBIA LEFT SIDE SCREW FHCS M4 X 0 7 X 8 ZINC AP CABLE ASSEMBLY HEX NUT M5 X 0 8 NYLOK 1 1 1 1 SCREW MSSFP M8 X 30 SCREW BHCS 8 X 1 25 X 35 ZINC TAPE FRONT COVER COVER UPPER KNEE FLEX PLI COVER LOWER KNEE FLEX PLI Table 8 Knee Assembly Parts List 1 3 2 1 Knee Assembly Make a note of the string pot serial numbers and their ligament positions this is needed for off board and onboard DAS identification for sensitivity input Referring to Meniscus assembly Item 2 133 5313 feed the connector of one of the right hand RH pull string pots through the inner side of one of the central holes see Figure 45 The RH and the LH string pots can be identified from the serial number the RH has an R at the end of the number and the LH an L The two pull string pots are positioned closest to the main flange of the meniscus one is shown fitted in Figure 45 Attach the string pot with the 2 56 x 1 4 long cap head screws making sure the pull wire is directed towards the furthest away outer bronze bush Fit the other
15. Figure 12 Kyowa accel 3 axis option for leg top and bottom locations mount 133 7530 LS _ _ 133 9900 User Manual FLEX PLI GTR Rev C Page 16 of 79 2011 Humanetics Innovative Solutions G 3 04 Figure 13 Optional Instrumentation for Tibia ITEM PART NO DESCRIPTION 133 7508 ACCEL INSTRUMENTED OPTION LEG amp BOTTOM 133 7514 IMPACT SEGMENT INSTRUMENTED ASSEMBLY FEMUR 2 8 133 7514 IMPACT SEGMENT INSTRUMENTED ASSEMBLY TIBIA 8 1 133 7507 ACCEL 8 ARS INSTRUMENTED OPTION FOR KNEE 4 1 133 7502 KNEE END ACCEL MOUNT 5 1 133756 TAPE DOUBLE SIDED 6 1 5000164 _ SCREWSHCSM2XO4X18 MS 68C ACCELEROMETER LINEAR TRIAXIAL MEASUREMENT SPECIALTIES MS 68C 133 7506 SPECIAL M2 ACCEL FIXING Table 3 Example of Optional Instrumentation Parts List G I 3 04 23 ISO MME Codes For the identification of sensor channels and for computer processing of signals the following codes have been established for ISO MME Transd Fine Fine Fine Description L Dimension Class ocation Femur Moment 3 Upper X standard FEMR Femur Moment 2 Middle X standard FEMR Femur Moment 1 Lower X standard FEMR Lo Kaap Elongation standard KNEE Los FE Elongation standard KNEE Elongation standard KNEE e Le Elongation standard KNEE e Le 1 Upper X standard Tibia Moment
16. RH pull string pot in the same way on the opposite side Pass the pull wires through their designated bushes Carry out the same procedure with the Left hand pull string pots the pull wires are directly in line with the two inner bushes Feed the pull wires through the bushes Make sure electrical wires are inside the cavity as much as possible then run cables through channels both sides and clamp with retaining plate see Figure 4 Fit assembly to knee block bottom and retain with four M5x10 low head cap screws ensure wires are in their grooves before clamping down If the Messring on board DAS system is to be installed a terminator has to be fitted at this stage For details of onboard DAS installation see Sections 2 6 and 2 7 G 3 04 OUT LIGIMENT BUSHES WIDER NON IMPACT SIDE Figure 46 Meniscus with all string pots assembled String pots identified _ _ 133 9900 User Manual FLEX PLI GTR Rev C Page 45 of 79 2011 Humanetics Innovative Solutions G 3 04 Figure 47 Meniscus wire clamp Pass all four ball crimps through attachment plate Item 5 133 5302 and place two spacers below it the pot wires will then be in tension see Figure 48 Two tubular soft plastic spacers are shown in the photo to show attachment clearly there are special spacers in the tool kit for this purpose 133 5113 Place four of the 212 x 40 long springs Item 6 into the knee block femur and place washer Item 9 133 5311
17. T0 5 OPTIONAL NOT SHOWN 10 6 39 40 4 42 43 44 45 SHIM T0 6 OPTIONAL NOT SHOWN 5 SHIM 05 OPTIONAL NOT SHOWN Table 7 Femur Assembly Parts List Q DW W W CO CO gt O gt G I 3 04 3 1 1 Upper Leg Assembly Before assembly check all rubber buffers are bonded to segments If for any reason a buffer should become dislodged damaged or lost it will need re bonding When bonding the segment buffers ensure surfaces of both parts are prepped before bonding prepare plastic with 240 grit paper and rubber with 80 grit degrease then bond with Loctite 401 or similar Fit thick bone clamp Item 5 133 5502 to Segment Top Item 16 133 5108 fit to impact side using two 6 x 16 BHCS Black button head cap screw The difference between thick and thin spacer is 0 5mm 12 75 thick 12 25 thin Place this assembly onto a flat work surface and place the rubber buffer Item 8 133 5510 under Place the bone assembly Item 1 inside the assembly with the PCB board upper most on the non impact side and fit the thin bone clamp Item 3 133 5503 see Figure 39 Measure the gap clearance between the thin clamp and the segment wall with metric feeler gauges or use the shims This gap must be filled with the shims so that the parts fit as tight as possible See Figure 40 note that by screwing in two screws the shim will say in place while sizing the gap Shim thicknesses are 0 05 0 4 0 5 a
18. any would be necessary The PCB cable will have to be passed though each segment when slid down the bone Be careful not to pull too heavily on the wire as it is not fully restrained at this time G 3 04 Figure 51 Typical shim arrangement with 05 inside main shim The last blue segment to be fitted will have rubber buffers on both sides and the thin spacer and shims will have to be assembled from the underside of the segment due to the position of the PCB on the bone The PCB cable can exit on either side to impact direction at this point as this will depend on DAS configuration Lay the thin bone clamp Item 8 133 5508 with groove over the PCB Fit the clamp Item 6 133 5506 to knee segment Item 14 133 5514 using two M6 x 16 BHCS then lower over bone fit two M8x16 set screws to the rear just touching the clamp Pass the connector through a link 133 5515 then assemble all the links and washers with shoulder screws as shown in exploded view both sides The segments may need adjusting slightly to align holes for shoulder bolts If off board DAS or Messring DAS is being used fit the wire clamps Items 40 and 41 under the shoulder bolts closest to the knee see Figure 16 The two washers 16 will have to be removed to fit these clamps The wire clamps are only used for off board wires or when one clamp is fitted one side for the Messring disconnect wire Note that if fitted and not used to clamp a wire the clamp screw can interfere
19. either side of the knee three M3 FHCS fix the units to the knee The sensor connection is made by either 7 pin or 16 pin miniature round connector with locking latch For M BUS left hand side of leg see Figure 20 For detailed use and specifications please refer to the suppliers user instructions ToSensors Leg Form Launcher ToSensors Terminator Quick Disconnect Gateway Coax cable To PC Figure 19 Wiring Diagram for 12 channel M BUS For leg wire routing please refer to Figure 20 below this is typical for both sides G 3 04 disconnect wire is blue coax cable the brass end fitting is clamped to one of the off board cable clamps just below the knee see Figure 21 This direct clamping avoids any damage to the connector Be careful not to crush the connector when clamping Only one cable clamp requires fitting for Messring installation A hole also has to be cut in the outer cover to allow exit of the cable After the test the disconnect is reconnected and data can be downloaded to a PC Inside the femur block there is a terminator housing to complete the coax wiring see Figure 22 two M3 SHCS retain the part The terminator can only be accessed when the knee is disassembled If the knee is stripped down for access it is recommended the knee is recalibrated The loggers are programmed to specific sensors for sensitivity range and software recognition Loggers cannot change location and con
20. is an option to use a weak thread lock like loctite on these to prevent them coming loose For the specifications and requirements of the test refer to ECE TRANS WP 2 9 GSRP 2009 21 WARNING VIOLENT REBOUND After impact with the car the leg can be thrown high into the air or can be deflected some distance therefore it will be important to protect anyone exposed in the test lab Laboratory staff must be clear of the test site and they must be behind Barriers during the launch A catch rope attachment bracket is available to attach at each end of the leg allowing a 4 point rope attachment The protective covers are removed and replaced with a high strength aluminum Catch Rope Bracket see Figure 67 This allows the leg to be tied into a frame preventing any damage or injury from rebound The ropes are quickly retracted after impact to keep the leg inside the frame Figure 67 Optional catch rope bracket 133 5034 h 133 9900 User Manual FLEX PLI GTR Rev C Page 73 of 79 92011 Humanetics Innovative Solutions G 3 04 Section 7 Impactor Guide setting distance on Launcher Impactor guide must be set to 113mm as shown in Figure 68 below Figure 68 Impactor guide width setting 113mm _ mmm 133 9900 User Manual FLEX PLI GTR Rev C Page 74 of 79 2011 Humanetics Innovative Solutions G 3 04 Figure 69 Location of impactor guide on pusher launch plate JARI pusher shown as example LS 13
21. on top of springs insert wires Item 16 133 5360 through springs Lower this block assembly carefully over the tibia Knee block guiding the wires across to their designated holes and locating over the attachment plate see Figure 49 Double check the knee femur block is the right way round ref exploded view and the wires are in their aligned holes Carefully turn the whole assembly over and locate the remaining 212 springs over the wires Fit all four washers nuts tighten nuts down until the washers are exactly flush with the Femur block Two wrenches 8mm and 1 8 are required to tighten nuts Once removed FTSS recommends that the Nyloc nuts are only used twice after that new nuts should be fitted Fix the attachment plate with M3x8 countersunk screws Place eight 218 springs into the femur block counter bores and place washer Item 8 133 5310 on top feed through the 8 wires Item 10 133 5350 Turn knee joint over and fit remaining 8 springs into their counter bores fit washers Item 8 and M5 Nyloc nuts tighten until washers are flush with Tibia block this can be checked with a flat edge As a double check the spring protrusion on the Femur block should be 3mm In this condition the knee is now ready for calibration Keep remaining parts together for final assembly 133 9900 User Manual FLEX PLI GTR Rev C Page 46 of 1 2 2011 Humanetics Innovative Soluti
22. required Remove front blue covers on knee and remove M8 screws and set screws holding on the femur and tibia The leg parts can then be pulled out of the knee 133 9900 User Manual FLEX Rev 56 of 79 92011 Humanetics Innovative Solutions G 3 04 Section 4 Weight Specification Leg Part Weight kg Weight Tol kg Femur 133 5100 0 12 133 5300 Tibia 133 5500 Femur Knee amp Tibia Flesh System Leg Total Table 10 Flex PLI GTR Mass If off board DAS is used knee has 0 1 kg allocated for cables Includes tape and Velcro straps Mass without Wiring String Pot series ISO subminiature Kyowa ASE 500 AS7 3 DTS ARS optional 3 7 2 Model 68C Measurement Specialties optional 22202748000 9 9 g Table 11 Sensor Mass Breakdown G 3 04 Section 5 Calibration and certification testing 5 1 Overview Certification of the FLEX PLI GTR requires nine different procedures to ensure certified performance of all components All steps that may be performed by the users are discussed in this section Calibration of string potentiometers accelerometer and bending moment strain gauges are not presented in this user manual as this requires operations only to be carried out by experienced and trained lab personnel The subsequent steps of certifying the FLEX PLI GTR is given in Table 12 Table 12 FLEX PLI GTR certification steps Step Des
23. the flat surface of the launcher plate Wrap the rubber buffer assembly tightly around the leg using the six Velcro straps see Figures 55 and 56 there are markers on the rubber showing the exact position for the Velcro It is important that the fluffy side of the Velcro is to the outside otherwise the outer cover cannot be stretched over due to grip from the eye side of the strap To get a tight fit with the Velcro it is easier to get someone to pull the rubber sheet around the leg while you are locking the Velcro Finally pass any off board wires through the holes in the outer cover and wrap around the leg The outer cover must be zipped up from the bottom of the leg to make zipper fitting easier and to ensure wire exit holes are in the correct place if cut If Messring onboard DAS is being used just one wire will exit the leg just below the knee It may be necessary to cut a hole for this wire Lay the zipper tag back on itself to lock it and cover over with the Velcro tab to protect Zipper and to prevent undoing G I 3 04 Figure 54 Assembly of flesh second layer Figure 55 Rubber flesh assembly Velcro positions Figure 56 Rubber flesh tied on with Velcro 2 133 9900 User Manual FLEX PLI GTR Rev C Page 55 of 79 2011 Humanetics Innovative Solutions G 3 04 222 Leg Disassembly Remove outer covers and flesh rubber Unclamp off board wires if fitted and remove side covers from knee Disconnect wires as
24. the rig and tape up so that they do not interfere with the free swing motion of the leg when tested If using onboard DAS route the disconnect to allow detachment and fix with tape to the top cross member The impact bar must be positioned so that the top of the blue meniscus of the knee is 30 mm below the bottom of the inclined impact plate Adjust the impact bar if not Note The leg sensors are zeroed in the vertical impact position Check all sensors are working and polarity is correct by flexing the leg The leg is lifted back to the release mechanism and secured using a steel wire rope The has been made so that the angle of the leg before release is 15 from the horizontal this should be checked with a digital angle block laid on the back of the knee The steel rope is tied to the ballast weight via an eye bolt which can be used for fine height adjustment When ready the leg is armed ready for release The leg is released from a switch on the control box if there is a problem with the switch there is a manual release button on the latch ensure no one is inside the drop zone during release to prevent any injury This can be ensured with the use of barriers etc The wire must be fitted to the inside of the release latch as shown in Figure 61 otherwise the latch will not function A trigger for data collection can be from the accelerometer on the leg started manually or from a speed gate All 12 channels on the standard leg are recorde
25. with the stopper cables and reduce free bending of the tibia Place washer 133 5521 over each stainless steel cable 133 5530 and feed through the holes in the leg segments Place another 133 5521 washer over threaded fitting end and fit four M5 Nyloc nuts Set the gap between nut and washer to 10 3 mm using 4 and 8mm wrenches Check gap with spacer tool 133 5112 If the Nyloc nuts are removed FTSS recommends they are only used twice Ensure bone clamps are flush with end of bones and tighten all screws except M8 SSFP socket set flat point Be careful not to over tighten If fitting new double sided tape unpeel cover material on one side Item 26 and fit on the forth plastic segment from the knee Fit an impact segment Item 31 locating over two BHCS Where the wire comes out through the link tightly tie on two cable ties as shown in Figure 43 to provide restraint to the wire The assembly is now ready for calibration Note If recalibrating a few of the links washers and shoulder screws will need to be removed and replaced to allow fitting to the calibration fixture Keep all parts together ready for final assembly G I 3 04 3 3 2 After Calibration Fit four M3x6 SHCS Item 24 into front inner segment knee and segment top Fit all the double sided tape profiles and attach impact segments as shown in Tibia exploded view The end cover item 22 should be fitted after dynamic calibration with M5 button head cap screws Also fit any o
26. 2 6 3 1 4 Flex PLI Inverse Test Corridor Calibration Results Peak Moment Tibia Peak Moment Tibia Peak Moment Tibia Peak Moment Tibia Peak ACL Elongation Peak MCL Elongation Peak PCL Elongation 2 gt e gt Table 19 Dynamic Inverse test corridors These peak values shall be within 50 ms after impact For further details of the test requirements refer to document ECE TRANS WP 2 9 GSRP 2009 21 G I 3 04 6 4 Car Test For the car test a special launch plate or pusher is required which is attached to a firing ram or launch system for an example see Figure 69 The design of the guide and push stroke length is important to maintain stable release conditions when the leg leaves the launcher The leg is fired at the car at 40 kph or 11 1 m s 0 2 The loading level of impactor during free flight for tibia bending moments are recommended to be less than 10 Nm and knee ligament MCL ACL PCL elongations are recommended to be less than 1mm If it is difficult to achieve the loading level we recommend to refine a propelling system by changing pushing surface profile by changing the spacing between knee and legs The leg step preparation steps described above in 6 2 also apply to the car test The launch guide at the top of the femur is tilted back about 15 degrees and locked for launch The side link shoulder screws on the aluminium segments can become loose in testing It
27. 2 5003 5004 and 5504 When a good fit has been achieved align holes and fit two 6 16 BHCS Warning When fitting the bone clamps and spacers take care not to damage any strain gage wires or gages laid down the center of the bone Select one of the plastic segments which has the best tight fit over the bone clamp Rubber buffers must interface with the part already fitted be careful not to damage the shims then fit four M6x18 BHCS Item 14 as shown in exploded view Note the connector will have to pass through each of the segments as they are assembled Stand the assembly on the bench and slide a plastic segment over the bone with the buffers facing down Fit the thick bone spacer to the impact side of the assembly apply pressure to the segment to hold the bone spacer in position against the bone to allow fitting of screws fit two M6 x18 BHCS Slide in the thin bone contact spacer Item 7 133 5507 in the rear side of the segment with radius against the bone Measure and shim the parts to get the same tight slide fit as mentioned above Use shims 133 5001 5005 5509 and 5012 to achieve the required fit Note that the inner 0 05 0 1 or 0 2 thick shims locate inside the other shims see Figure 51 Align holes and fit two M6x18 BHCS as shown Repeat this procedure for the next six plastic segments Once a spacer has been shimmed start the next segment with the same shim arrangement to save time measuring the clearance only fine adjustment if
28. 2 Refit all front and side covers Figure 52 Screws to be tightened to 8 Nm G 3 04 On the day of the test for certification the flesh covers are fitted over the leg To simplify the fitting of the flesh system all the covers should be laid on the bench in reverse order of assembly Place the large outer cover on the bench with lettering face down Lay 6 strips of Velcro tape over with fluffy side down then place the rubber buffer sheet assembly 133 5020 over the strips The large rubber part goes to the top of the leg this is the opposite end to where the zipper on the outer cover starts Adjust the tape so that all the Velcro strips line up with the six markers on the rubber Lay Thigh 2 and Leg 2 covers over with the two knee end inside arrows pointing towards each other allowing a gap for the knee area then do the same with Thigh 1 and leg 1 covers Place the leg assembly onto the laid out flesh covers with thigh femur section over thigh covers and leg tibia over leg covers with the leg assembly on its side Fit the black plastic protective end covers to the ends of the leg with 4x M5 BHCS Figure 53 Assembly of first flesh layer Do up the zippers on Thigh 1 and Leg 1 making sure each zipper is positioned on the side of the leg Turn the leg over and do up the Thigh 2 and Leg 2 zippers making sure these zippers are on the opposite side to the first No zipper should be at the back of the leg or it will interfere with
29. 3 9900 User Manual FLEX PLI GTR Rev C Page 75 of 79 2011 Humanetics Innovative Solutions G I 3 04 Section 8 Dynamic Rig 8 1 Dynamic Rig Assembly Instructions If the assembly has been stripped down use the following steps to assemble the rig Normally when shipped the rig is mostly assembled Please follow assembly instructions from assembly as shipped 8 2 Assembly after Complete Strip Down Stand the Left and Right support weldments Items 1 and 3 opposite each other and about 400mm apart ensure the tapped hole flanges are facing inwards Fit the cross bars Item 2 and tighten this will bring the side supports together Now loosen the screws on the cross bars and fit Impact Bar Item 5 and pivot cross bar Item 4 tighten the screws this will pull the support weldments square with the Impact and pivot cross bars The Cross Bar screws can now be tightened The top A frame assembly can be assembled on the ground and lifted on to the base or assembled directly on to the base Note it will be important to keep all the screws loose while the parts are being fitted Fit the two A Frames Item 6 then fit two side supports making sure diagonals go in the opposite direction Do up all the bolts so there is no slack but the parts can still move Assembly continues as per assembly as shipped G I 3 04 N 99 6 9 9 2 L 4 a Figure 70 Exploded view Dyn
30. G 3 04 Flex User Manual G 3 04 AN Ino IA AA rire WU IVI MING gt Innovative Solutions For information on Humanetics products please visit our web site at www humaneticsatd com or contact Humanetics Innovative Solutions 47460 Galleon Drive Plymouth MI 48170 USA Telephone 734 451 7878 Fax 734 451 9549 No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic photocopying recording mechanical or otherwise without the express written consent of Humanetics Innovative Solutions Copyright 2011 Humanetics Innovative Solutions All rights reserved The information in this manual is furnished for informational use only and is subject to change without notice Humanetics Innovative Solutions assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual G I 3 04 Table of Contents Section 1 III ODC TK 8 1 1 a Hn 8 1 2 uuu Emm 9 Section 2 IP lili e EE 12 2 1 Standard 12 Channel 12 22 Optnal Si UMC VAN UU 12 2 9 E MME OS ee 18 2 9 1 21 2 3 2 Signal Polarity Sensor function check
31. W M5 X 8 X 12 OQ O O G O I OO N a a 2 2 42 2 QTY 18 EE XN 20 8 29 8 WC WE 2 Table 9 Tibia Assembly Parts List G 3 04 3 3 1 Tibia Assembly Before assembly check all rubber buffers Item are bonded to segments If for any reason buffer should become dislodged lost or damaged it will need replacing or re bonding When bonding the buffer ensure surfaces of both parts are prepared before bonding prepare plastic with 240 grit paper and rubber with 80 grit degrease then bond with Loctite 401 or similar Place rubber buffer 133 5510 centrally inside segment bottom tibia Item 11 133 5511 Place the thick bone spacer Item 2 133 5502 into the impact front side of the segment bottom and attach the two M6x16 BHCS Fit the bone assembly Item 1 into the segment bottom with the PCB on the non impact side and at the top then place the thin bone clamp Item 3 133 5503 on the other side of the bone There is a difference between the thin and thick spacers of 0 5mm 12 25 and 12 75 Measure the gap clearance between the thin clamp and the segment wall with a metric feeler gauge or use shims This gap must be filled with shims so that the shims create a tight fit so that there is no clearance against the bone Shim thicknesses are 0 05 0 4 0 5 and 0 6 use any combination to achieve this fit Shim part numbers here are 133 500
32. amic Rig G I 3 04 ITEM QTY PART NO 133 8401 133 8412 133 8402 133 8415 133 8420 133 8424 133 8429 133 8431 133 8432 5000267 5000587 5000441 DESCRIPTION LEFT BASE SUPPORT WELDMENT BASE CROSS BAR WELDMENT RIGHT BASE SUPPORT WELDMENT PIVOT CROSS BAR WELDMENT IMPACT BAR WELDMENT A FRAME SUPPORT A FRAME SIDE SUPPORT TOP CROSS MEMBER NUT PLATE WASHER FLAT M12 13 0 ID X 24 0 OD X 2 5 THK SCREW SHCS 8 X 1 25 X 70 SCREW SHCS M12 X 1 5 X 30 5000314 SCREW SHCS M10 X 1 5 X 16 5000444 SCREW SHCS M10 X 1 5 X 30 5000552 WASHER FLAT M8 8 4 ID X 16 0 OD X 1 6 THK 5000486 HEX NUT M8 NYLOK 133 8419 PIVOT CLEARANCE BLOCK 5000785 SCREW SHCS M10 X 1 5 X 120 133 8418 PIVOT HINGE 5000786 SCREW SHSS M12 X 50 133 8423 IMPACT BLOCK 5000028 SCREW SHCS 8 X 1 25 X 50 9000244 WASHER FLAT 4 133 8438 BRACKET RELEASE MECH 6002571 RELEASE SYSTEM TENNEN 099 005 5000499 SCREW SHCS X 1 25 X 60 133 8436 CALIBRATION BALLAST FEMUR 5000105 WASHER FLAT M10 10 85 ID X 20 0D X 2 5 THK 5000797 EYEBOLT M6 X 1 12 ZINC PLATED 3107 41 6002575 RELEASE SYSTEM CONTROL BOX TENNEN BV TE RSCB 100 5000001 SCREW SHCS M6 X 1 X 20 5000030 SCREW SHCS X 1 25 X 25 6001587 CONNECTOR SOCKET SHOWN 6001588 SOCKET TERMINAL SHOWN 6001737 TERMINAL 60618 1 NEWARK 6001738 CONNECTOR MATE N LOCK NOT SHOWN 6003042 SERVICE CORD 16AWG 2 CONDUCTOR NOT SHOWN N 0 To 4
33. covers with three holes one of these covers part 133 5314 must be fitted over the SLICE unit for screw head clearance as shown in Figure 32 the other cover 133 5315 is necessary for 24 channel DAS when two SLICE units are fitted If 24 channels are not being used this cover can go to any of the other three locations Figure 32 Left hand side of leg with knee covers fitted Leg wires are not shown secured NN rm em rte Fa IS L L x LA era P L Li J IN IN GV U eil Y S ali itinne Solutions G 3 04 Figure 33 Right hand side of knee showing connectors Figure 34 Leg with disconnect wire TDAS interface and power supply NN 133 9900 User Manual FLEX PLI GTR Rev C Page 33 of 79 2011 Humanetics Innovative Solutions G I 3 04 2 8 SLICE 24 Channel Option To complete the DAS system to 24 channels on board DAS for optional instrumentation an additional 12 channel SLICE unit is packaged on the opposite side to the standard 12 channel unit in the upper knee for balance and for access to upper leg sensors to reduce the number of wires crossing the joint See below The arrangement of SLICE bridge units and wiring will vary depending on the optional sensors selected Figure 35 Optional SLICE unit 24 channel option right side Figure 36 Left side wiring example of 24 channel SLICE
34. cription When Required Pass Fail Requirement Femur Gauge Calibration 1 Annually recommended 1 1 0 linearity full scale 2 After exceeding injury 2 2 0 hysteresis full Tibia Gauge Calibration thresholds for FLEX GTR in scale application test recommended all gauges Calibration nl VEL Calibration 1 Annually recommended 1 Femur centre bending Bending Test 2 After exceeding injury moment deflection corridor thresholds recommended 2 Tibia centre bending 4b Tibia Assembly Bending 3 After maintenance and or moment deflection corridor Test component exchange recommended 1 Annually recommended 1 Bending moment MCL 2 After exceeding injury elongation corridor Knee Assembly Bending thresholds recommended 2 ACL and PCL elongation 2 Test 3 After maintenance and or force corridors component exchange recommended 1 Annually 1 Peak bending moment 2 After 10 vehicle tests max tibia 1 tibia 2 tibia 3 and 3 Dynamic Pendulum 3 After exceeding injury tibia 4 Impact thresholds 2 peak elongation MCL 4 After maintenance and or PCL ACL component exchange 1 Annually 1 Peak bending moment 2 After 30 vehicle tests tibia 1 tibia 2 tibia 3 and 4 Dynamic Linear Guided 3 Prior to homologation tests tibia 4 Impact 4 After exceeding injury 2 Peak elongation MCL thresholds 5 After maintenance PCL ACL and or component exchange http www veci vrci com VRCI P 100A pdf Indus
35. d See draft corridors Tables 17 and 18 Table 17 channels are mandatory After initial impact the leg will continue to bounce where possible the leg should be caught or stopped to prevent this This action must be done from the side of the rig under no circumstances should anyone be behind the leg or in its swing plane during testing The springs in the knee and the elastic response from the rubber flesh create a strong rebound It is highly recommended that a barrier is erected in the swing rebound area to avoid any injury If there is any doubt about safety allow the leg to bounce If a test is to be repeated the leg should rest for 45 minutes minimum before repeating Figure 61 Release Latch Wire Position G 3 04 5 5 Leg Preparation for Pendulum Dynamic Calibration Introduction After a maximum of 10 car test the leg must be calibrated using the pendulum test Step 1 Check the eight M8 set screws shown in Figure 65 are tightened to 8 Nm Step 2 Check the washers over the knee springs are flush inline with the tibia knee block Step 3 Check the four stop cable clearances passing through the femur is set to 9 1 mm and 10 3 on the tibia See Figure 65 and special tool 133 5112 is used for this Step 4 Check knee block alignment by using a straight edge check that the back faces of the 2 knee blocks are aligned checking the left and right outer areas Also with the same straight edge check on 1 side that the 2 knee bloc
36. d and replaced to fit onto the calibration fixture Keep parts together ready for final assembly Figure 43 Exit cable restraint use cable ties tie not shown trimmed 3 1 2 Femur after Calibration Fit four M3x6 SHCS Socket head cap screws into front inner segment knee and segment top Fit all the double sided tape profiles and fit impact segments Fit launch guide and roller as shown in exploded view Fit end cover Item 28 133 5516 after dynamic calibration with four M5 x 8 screws Also fit any optional sensors and mounts 3 1 3 Femur Disassembly Disassembly is the reverse of assembly except you can disassemble from either end care must be observed when removing bone spaces and shims not to damage bone wires and gages The double sided tape can be reused if still sticky and is not folded over It will also be important to check for any damaged parts that would need replacement eg 133 9900 User Manual FLEX PLI GTR Rev Dane 42 of 79 22 700 Vianual FLEA F LI GI IN rage 42 9 x 2 2214414 Lhhimanatine Innmuat 2011 Humanetics Innovative Solutions G I 3 04 3 2 Knee Exploded View 18 UN E 6 L v Figure 44 Knee Assembly Exploded View DESCRIPTION KNEE BLOCK TIBIA FLEX PLI MENISCUS ASSEMBLY SCREW SHCS M5 X 8 X 10 LOWHEAD KNEE BLOCK FEMUR ATTACHMENT PLATE STRING POT 8 90031559 SPRING 12 X40 AMISTAR
37. e at the top of the leg is locked vertically with the two 6 side screws The bone is shimmed tight at build to allow for wear on the bone however after a relatively high number of tests the blue segments will become lose as the interfacing parts wear Having some play is acceptable as long as the leg passes either pendulum or inverse test certification If the user is concerned with a high amount of play the bone can be re shimmed to remove it G 3 04 6 3 Inverse Test Calibration Description The inverse test is a dynamic calibration test where the fully assembled leg is stationary suspended vertically from a sprung hook which releases on impact The leg is struck with an 8 1 kg linear guided impactor with a honeycomb face fired at 11 1 m s 40 kph the same speed as the car test This procedure is carried out at build along with the pendulum test then after thirty car tests or before any homologation testing Hanging System Z axis release the FlexPLI within 10 ms after the moving ram impact Y axis X axis FlexPLI with Flesh cross sectional image Moving ram Total Mass 8 1 0 05 kg Depth d Impact speed 11 1 0 2 m s 60 5 mm Impact face Moving ram guide Honeycomb Width w 200 2 mm Length 1 160 2 mm Crash strength 75 1096 psi Figure 66 Diagram of Inverse guided impactor Certification G 3 04 6 3 1 Requirements 6 3 1 1 Im
38. em 9 133 5507 in the rear side of the segment with radius against the bone Shim the part on the rear side to get the same tight fit as mentioned above Use shims 133 5001 5005 5509 and 5012 to achieve the S V c 133 9900 User Manual FLEX PLI GTR Rev C Page 40 of 79 2011 Humanetics Innovative Solutions G 3 04 required fit Note only 0 4 0 5 0 6mm shim be assembled number of 0 05 0 1 0 2 shims be used inside the thicker shim to achieve this fit Align holes and fit the two 6 18 BHCS Repeat this procedure for the next five plastic segments Once a spacer has been shimmed start the next segment with the same shim arrangement as a starting point to save time The last blue segment Item 13 133 5535 to be fitted will have rubber buffers on both sides The thin spacer and shims will have to be assembled from the underside of the segment due to the position of the PCB on the bone The PCB cable can exit on either side with reference to the impact direction at this point depending on DAS configuration Lay the thin bone clamp Item 2 133 5508 over the PCB as shown in Figure 42 Lay up the other clamp Item 4 133 5506 to the other side and slide over segment knee Item 11 133 5514 Fit two M6x16 BHCS to the front and fit two M8x16 SSFP Socket set flat point to the rear so that they are just touching the clamp Ensure the buffer 133 5510 is fitted under and centralized this sh
39. est data has been obtained as the corridors were based on limited test results Additional Mass Suspension angle 15 1 deg 2 FlexPLI with Flesh cross sectional image 13 1 R 4 540 2 988 5 2 Released Free fall around i the pin joint Stopper bar Knee E e joint Additional Mass MI center Mass 5 0 kg 0 05 with screws line Inertia 0 0061 0 0006 kom 10 deg Impactor side 58 1 lt s 120 1 EG ALE Z Center of gravity of additional mass Dimension units mm Figure 60 Diagram of Dynamic Pendulum Fixture This test is carried out at build and mandatory after every 10 car tests this test can be carried out at any time if required to check the leg before testing The test must be carried out at a stabilized temperature of 20 2 and the temperature must be recorded The leg assembly is calibrated with the flesh cover parts fitted and the leg is inverted so that the leg pivots from the bottom of the tibia to increase the impact moment on the knee Remove the end rubber buffers if fitted 133 5516 and launch guide from the leg Then fit the 5 kg end weight to the top of the femur using two M8 x50 long cap head bolts see Figure 62 Fit the pivot hinge to the tibia base as per Figure 63 using four M6 x 18 SHCS G I 3 04 Fit the leg to the pivot block on the rig using the M10 SHSS Refer to rig assembly in Appendix A Route the off board wires if fitted onto
40. ff board DAS option As the FLEX PLI is a tool that is in free flight after launch the off board cables may affect the free flight trajectory accuracy and the cables are susceptible to damage when the tool lands after rebound from the vehicle Therefore the use of off board DAS is only recommended during calibration of the FLEX PLI To solve issues with free flight trajectory and cable damage the FLEX PLI GTR can be executed with on board DAS systems from various suppliers Currently FTSS is working in close co operation with and offering systems from Messring DTS Hentschel and Kayser Threde The Messring and DTS systems are described in 2 6 and 2 7 2 5 Off Board DAS For off board DAS umbilical cables of 10m long exit the leg just below the knee This position is close to the CG of the leg to minimize the mass affect from the cables in free flight The cables are clamped to the leg via the top shoulder link bolts of the tibia to provide restraint protection to the connectors see Figure 16 See Figure 17 for left hand side wiring arrangement The connectors at the off board DAS side are specified by the customer and fitted by FTSS as all users have different systems Figure 16 Clamping Arrangement and Position for Off board Wires G 3 04 Figure 17 Off Board DAS wiring left hand side of impact face Most of the wiring for the off board configuration is in the tibia block Only the femur bone wire bridges the knee joint see Figu
41. gment 7 Acceleration Y additional Tibia Segment 8 Acceleration Y additional Tibia Segment 2 Acceleration Y additional Tibia Segment 3 Acceleration Y additional 33 34 35 36 37 38 39 40 41 G 3 04 G 3 04 Tibia Acceleration additional 0 0 00 x X Tibia Bottom ELM 43 Y additional WELL Acceleration 44 Z additional Table 4 ISO MME Sensor Code table Wire Label TRIAX Sensor Location Description Code wire label ISOMMECODE code Femur Moment 3 Upper X Moment 2 Middle X F2 Femur Moment 1 Lower X Knee LCL Elongation LCL ACL CL CL 1 2 9 4 tg tr D di 1 x s P NENNEN M T T 00TIBILO00PFMOXC AY KB OOKNEEBOOOPFCAYC AX FT AY FT A FT AZ FT AY S1 0 1 Femur Segment 2 Acceleration Y 52 00FEMRO200PFACYC Femur Segment 3 Acceleration Y AY S3 00FEMRO300PFACYC Femur Segment 4 Acceleration Y 54 400 O0FEMROSOOPFACYC O0FEMROGOOPFACYC ARX KU ARY KU AR KU KL AY S5 AY S6 AX KU AY KU K AZ KU ARZ KU AX KL AY KL A AZ KL ARX KL ARY KL AR KL ARZ KL AY S7 OOTIBIO200PFACYC Tibia Segment 2 Acceleration Y AY S8 ww Tibia Segment 3 Acceleration Y AY SO OOTIBIO400PFACYC OOTIBIOSOOPFACYC OO0TIBI600PFACYC
42. he left in femur knee block Figure 30 Figure 30 Typical Slice wiring to knee with SLICE eg 133 9900 User Manual FLEX PLI GTR Rev Page 31 of 79 2011 Humanetics Innovative Solutions G 3 04 Bi Figure 31 Disconnect connector clamp on leg To assemble the SLICE fit the SLICE unit with the higher stack part closest to the knee joint as shown in Figure 30 using four M3 Pozi type screws two 25mm and two 20mm long Then fit the super capacitor with the disconnect wire pointing downward towards the tibia using four M3 x 16 long screws All the connectors are identified so connect like for like MCL to MCL etc For the two string pot wires that pass across the knee tie wrap mounts are provided both sides to anchor the wires see Figure 33 showing connectors on the right hand side of the knee Route the wires as shown to provide adequate slack in the knee joint to prevent any disconnection or damage to the wires when the knee flexes The disconnect bracket is fixed to the launch guide as shown in Figure 31 using M2 5 screws and the 12 pin connector is mated with the connector coming out of the bottom of the base SLICE Most of the wires and connectors are behind the knee covers but the gage wires coming out of the leg must be properly restrained There should be two tie wraps fixing the bone gage wires coming out of each bone tibia and femur to the end link where it exits the leg Before fitting the covers note there are two
43. he spring pots from the attachment plate To remove the meniscus for access to spring pots remove the four M5 low head cap screws and pull it away from the tibia block If the string pots need servicing remove wire retaining clamps and unscrew the 2 56 cap screws fixing the pots Check all parts for damage and replace if necessary take note to check there has been no slippage on the crimps on the string pot mechanical wires The left hand and right hand pull wires should both be 61 5 mm from the stop at the potentiometer to the start of the ball fitting It is recommended that the Knee assembly is re calibrated after a strip down G 3 04 3 3 Tibia Exploded View Figure 50 Tibia Assembly Exploded View G I 3 04 ITEM QTY PART NO 133 5501 133 5502 133 5503 133 5504 133 5505 133 5506 133 5507 133 5508 133 5509 133 5510 133 5511 133 5534 133 5535 133 5514 133 5515 133 5104 133 5106 18 4 20 133 5521 133 5530 5000465 000522 33 5516 000814 4 32 NO NO NO NIN G 5000393 5000769 133 5025 133 5028 133 5027 133 5026 NINININ 133 5519 COVER END IMPACT KNEE END 133 5517 IMPACT SEGMENT 133 5518 COVER END IMPACT 133 5001 SHIM 0 5 OPTIONAL NOT SHOWN 133 5002 SHIM BONE CLAMP T0 05 OPTIONAL NOT SHOWN 133 5003 SHIM BONE CLAMP T0 5 OPTIONAL NOT SHOWN 133 5004 133 5005 133 5012 5000072 33 5522 33 5523 5000654 SCRE
44. ic Inverse Test Step 1 Check the eight M8 set screws shown below tightened to 8 Nm Figure 64 Screws to be torqued to 8 Nm Step 2 Check all the spring washers under the tibia block in the knee are flush inline with the housing Step 3 Check the four stop cables passing through the femur block are set to have a clearance of 9 1 mm and the four tibia cables have a clearance of 10 3 mm see femur example below A special setting tool 133 5112 is provided for this check G 3 04 Figure 65 Stop cable clearance adjustment using setting tool Step 4 Check knee block alignment by using a straight edge check that the back faces of the two knee blocks are aligned checking the left and right outer areas Also with the same straight edge check on one side that the two knee blocks are aligned by checking either side of the two side covers If there are any misalignments by hand push one of the knee blocks until there is alignment all the four alignment check positions Step 5 Check all segment screws and side aluminum shoulder screws are tightened between 2 3 to 2 5 Nm this can done by feel after torque wrench setting so a torque wrench is not mandatory for these screws Step 6 Fit the inner flesh system as described in 3 3 4 Step 7 All wires are correctly positioned to avoid damage and any exit wires are restrained in there clamps Step 8 Replace the outer cover skin and the leg is ready Step 9 The lunch guid
45. ks are aligned by checking either side of the 2 side covers If there are any misalignments by hand push one of the knee blocks until there is alignment in all the 4 alignment check positions Step 5 Check all segment screws and side aluminum shoulder screws are tightened between 2 3 to 2 5 Nm this can done by feel after torque wrench setting so a torque wrench is not mandatory for these screws Step 6 Remove the aluminum launch guide yoke fitted to the top of the leg along with the black protective cover Step 7 Attach the ballast weight as shown in Figure 62 below to the top of the femur using two M8 x 50 long cap head screws Figure 62 Attaching Ballast Weight _ _ lt _ 133 9900 User Manual FLEX PLI GTR Rev Page 66 of 79 2011 Humanetics Innovative Solutions G 3 04 Step 8 Remove the black protective cover from the tibia bottom and attach the pivot block as shown Figure 63 below using four M6 x 18 long screws Figure 63 Step 9 Attaching Dynamic Rig Pivot Block Step 9 Fit the suit as in section 3 3 4 allowing for onboard or off board wire exit For off board a hole may need cutting in the Knee area cut marks are provided The leg is now ready to be hung on the rig The bone is shimmed tight at build to allow for wear on the bone however after a relatively high number of tests the blue segments will become lose as
46. l Instrumentation 2 2 Optional instrumentation The FLEX PLI offers a range of optional instrumentation for research purpose When running regulatory tests with optional instrumentation it is recommended to check that the total mass of the tool including a certain amount of cable length does not exceed the regulatory requirement Each individual femur and tibia segment can be instrumented with an accelerometer in impact direction Tri axial accelerometers and or angular rate sensors are also offered at various locations It is recommended that damped accelerometers are used on the flex G 3 04 See Detail A Figure 6 Optional Instrumentation for Femur L 28 133 9900 User Manual FLEX PLI GTR Rev C Page 13 of 79 2011 Humanetics Innovative Solutions G 3 04 d de Figure 7 Detail Exploded View NU H SE Figure 8 Wire routing for Detail A optional sensors G 3 04 Figure 9 Wire routing out of segment for optional sensors Detail in upper knee Figure 10 Similar arrangement to Detail A but with 2 uniax Kyowa accels Assembly 133 7600 G I R9 3 04 Sensor 5 3103 ARS triax for Detail A position used with M BUS A single uniax accel either a Kyowa ASE 500 MSI model 64 or similar can also be used here with this sensor Assembly 133 7522 Figure 11 Figure 12 shows Kyowa accelerometer option for femur top and tibia bottom locations
47. ls of data As the FLEX PLI has limited space to package the SLICE stack a mounting board has been designed by DTS to link four bridges together allowing one base SLICE to be used The unit is fixed using four M3 pozi head screws Sensor connection to the DAS is via either 7 or 16 pin round miniature connectors see Figure 30 for 12 channel wiring arrangement After disconnect the SLICE is powered by a Super capacitor mounted on the same side of the knee as the standard 12 channel DAS See Figure 30 The super capacitor is quickly charged when reconnected The wire disconnect is a round 12 pin connector hard mounted to the launch guide bracket at the top of the femur see Figure 31 This disconnect position allows disconnect in the push phase from the launcher to avoid the connector affecting free flight stability On reconnect after the test data can be downloaded to If required there is provision to wire tape switch for 0 a wire is provided for this option out of the supercap housing G 3 04 Pendulum SLICE Connector Distributer interface Quick Disconnect at top of leg SLICE T Super cap e D 2 ch unit Power Supply Trigger from Tape switch Test option option Sensors 6 ch Sensors 6 ch Leg Form Launcher PC Figure 29 Wiring diagram for 12 channel SLICE Typical Slice wiring to knee with SLICE units on the right in tibia knee block and super cap on t
48. mpactor for Global Technical Regulation on Pedestrian Safety PS GTR FTSS is a member of this group as dummy manufacturer FTSS was asked to review the GT design and manufacture the leg This review highlighted a number of improvements and the proposed GTR design was accepted The performance of the leg was intended to remain the same to ensure existing test data was still valid The main improvements were centralising the deflection sensors to avoid impact direction sensitivity balancing the spring force load in the knee joint to prevent knee joint twist about vertical axis various improvements related to handling introduction of full bridge strain gauge configuration adding additional optional sensors and incorporating on board Data Acquisition System DAS to improve free flight motion FTSS also reviewed and updated the numerous quasi static calibration procedures for internal bones thigh knee and lower leg assemblies The dynamic calibration rig and procedure were also updated to provide more realistic loading An inverse linear guided impactor test will be required as an additional dynamic calibration method The standard leg instrumentation has 12 channels this includes 3 full bridge strain gage sensors in the thigh and 4 in the lower leg all measuring leg bending moment an accelerometer and 4 string potentiometers in the knee each one measures specific ligament elongation There are also options for a further 26 linear accelerometer cha
49. nd 0 6 use any combination to achieve this fit Shim part numbers are 133 5002 5003 5004 and 5504 When a good tight fit has been achieved align the holes and fit two M6x16 BHCS Item 35 The 16mm long button heads are black to distinguish them for this location from the 18 long ones Warning When fitting the bone clamps and spacers take care not to damage any gage wires or gages laid down the center of the bone Figure 39 Femur bone assembly G 3 04 Figure 40 Fitting end shims femur Select one of the plastic segments Item 12 133 5513 which has the best tight fit over the bone clamp rubber buffers must interface with the part already fitted take care not to damage the shims then fit four M6 x 18 BHCS Item 14 two each side diagonally spaced Note That the connector will have to pass through each of the segments as they are assembled over the bone Do not pull on this wire as the wire is not fully restrained at the PCB mounted on the bone at this stage See Figure 41 Figure 41 Passing segment over bone wire Stand the assembly on the bench again over the 2mm butter and slide a segment assembly over the bone with the buffers facing down Fit the thick spacer Item 6 133 5505 with radius against the bone to the front of the segment by pressing gently against the segment this will keep the holes aligned then fit two M6 x 18 BHCS diagonally as shown in exploded view Slide in the thin bone contact spacer It
50. nector labels must match to ensure connection to the sensor Figure 20 M BUS wiring arrangement in knee EE 4 Figure 21 Clamping of Messring Disconnect Connector G 3 04 Figure 22 Messring Terminator housing installation in upper knee Figure 23 shows the M BUS disconnect wire on the launcher and how the coax wire is routed and fixed to the launcher The disconnect design has a low release force however a strong tape is recommended to hold the wire in place see Figure 23 Figure 23 Fixing Messring Wire to Launcher 2 133 9900 User Manual FLEX PLI GTR Rev C Page 27 of 79 2011 Humanetics Innovative Solutions G 3 04 2 6 2 24 Channel M BUS Four six channel loggers be fitted to the leg to provide 24 channels of data recording See figures below for typical installation Wire connections can vary according to optional sensors installed Figure 25 right hand side of knee sensors connected G 3 04 Figure 26 Bottom right hand side of knee sensors connected Figure 27 Top left hand side of knee sensors connected G 3 04 Figure 28 Bottom left hand side of knee sensors connected 2 7 DTS Onboard SLICE Nano DAS For detailed use and specifications please refer to suppliers user instructions The SLICE is a modular system where a 3 channel bridge SLICE can be stacked onto a base SLICE in this case one base SLICE handles 12 channe
51. nnels and 6 Angular Rate Sensors ARS Flex GTR has symmetric design so can represent a right or left leg G 3 04 1 2 Tools Required Several types of standard tools used in the assembly and disassembly of the dummy T handle wrenches Figure 1 and hex wrenches Figure 2 can be used to access most of the fasteners in the dummy In some cases access to fasteners is easier if a ratchet offset wrench with hex bits is used Figure 3 Figure 1 T Handle Wrenches eg 133 9900 User Manual FLEX PLI GTR Rev Page 9 of 79 2011 Humanetics Innovative Solutions G 3 04 Figure 2 Hex Wrenches Figure 3 Ratchet offset wrench with hex bits kit 8 4 mm and 1 8 ended wrenches are required along with 8mm socket and ratchet Wire spacer tool 133 5112 is required see Figure 4 to help set bone assembly wires and there is another spacer tool to space the knee string potentiometer attachment part 133 5113 See Figure 5 All these tools are provided with the leg as part of the tool box EE 133 9900 User Manual FLEX PLI GTR Rev Page 10 of 79 2011 Humanetics Innovative Solutions G 3 04 Figure 4 Leg wire setting tool 133 5112 Figure 5 Knee spacer tool 133 5113 2 are used to hold string potentiometer attachment plate Note Apart from the string potentiometer 2 56 UNC cap head screws and the ARS optional angular rate sensors which use 0 80 cap heads all the leg screws are metric
52. ons G 3 04 3 2 2 After Calibration Fit the single channel accelerometer to impact side of tibia block Accelerometer will plug into a labelled matching connector if DAS is fitted The front covers should be fitted when the leg bones are being assembled to the knee see leg assembly 3 3 4 The side covers can be fitted at this stage as well for wiring or DAS attachment 3 2 3 Knee Disassembly Remove aluminum side and front blue covers if these have not already been removed to disassemble leg bones See section 3 3 4 for details Take off the accelerometer if not already removed then remove the 8 large springs from each end by unscrewing the eight 5 Nyloc nuts one end of the wires Hold the wire on its end with 1 8 open ended wrench to allow this Before removing the small cross ligament springs the attachment plate holding the string pot wires must be unscrewed otherwise string pots could be damaged when the two knee blocks are pulled apart Remove the two M3 Flat head screws fixing the attachment plate to the femur block Now unscrew the four M5 Nyloc nuts holding the cross wires and remove with the remaining eight smaller springs 133 9900 User Manual FLEX PLI GTR Rev C Page 47 of 79 2011 Humanetics Innovative Solutions G I 3 04 The fitting on the end of the cross wire can catch on the hole in the counter bore so the cables may require some alignment to free them Disconnect the crimped ends of t
53. ould be lightly bonded in place with super glue in case it is disassembled and falls out Fit the plate top Item 17 133 5102 with four M6x18 BHCS Pass the connector through a link Item 15 133 5515 then assemble all the links and washers using shoulder screws as shown on assembly both sides The segments may need adjusting slightly to fit the shoulder bolts Figure 42 Exit wire from femur Place washer Item 26 133 5521 over each of the four stainless steel cables Item 27 133 5110 and feed through the holes in the leg segments Place washer 133 5521 over threaded fitting and fit four M5 Nyloc nuts Set the gap between nut and washer to 9 1mm Check with spacer tool 133 5112 if nuts are removed FTSS recommends the Nyloc nuts should only be used twice Ensure bone clamps are flush with ends of bone and tighten all segment screws to recommended 2 3 2 5 Nm Do not over tighten Fit one double sided tape profile Item 34 133 5025 to the third plastic segment from the knee then fit one impact segment Item 40 133 5517 locating over two BHCS When fitting double sided tape it would be good policy to degrease the surfaces G I 3 04 Where the wire comes out through the link tie on two cable ties one on the link and one on wire attached to each other as shown in Figure 43 to provide restraint to the wire The assembly is now ready for calibration Note a few of the links washers and shoulder screws will need to be remove
54. pactor Mass 8 1 Kg 0 05 e Speed 11 1 m s 0 2 The impactor is covered with 5052 Aluminum honeycomb with a crush strength of 75 PSI 10 and covered with paper cloth less than 1mm thick and taped over honeycomb to prevent damage to the leg covers To ensure repeatability the honeycomb should be 3 16 cell size with a density of 3 1 or 2 0 pcf or 74 cell size with density of 2 3 pcf The top of the impactor plate must be in line with the honeycomb time of first contact and the upper edge of the honeycomb must be vertically in line with the knee joint top of blue tibia knee block 2 mm The size of the honeycomb is to be width 200 2 length 160 2 depth 60 5 On impact the leg is to be released from the rig within 10 ms to ensure free flight condition 6 3 1 2 Temperature The test facility used for the certification must have a stabilized temperature of 20 2 C during the certification and the temperature is to be recorded 6 3 1 3 Impactor Pitch Roll and Yaw angle corridor The pitch angle of the impactor rotation around y axis at the time of first contact shall be within a tolerance of 0 2 in relation to the lateral vertical plane The roll angle of the impactor rotation around x axis at the time of first contact shall be within a tolerance of 2 in relation to the longitudinal vertical plane The yaw angle of the impactor rotation around z axis at the time of first contact shall be within a tolerance of 0
55. ptional instrumentation 3 9 9 Tibia Disassembly Disassembly is the reverse of assembly starting at knee end however care must be observed when removing bone spaces and shims not to damage bone wires and gages down the center of the bone The double sided tape can be reused if still sticky and is not folded over It will also be important to check for any damaged parts that would need replacement 3 3 4 Leg Assembly When the leg is not being used or shipped the tight fitting flesh system should be removed to prevent stretching and long term indentation from the leg components Carefully prize away the two blue front plastic covers if assembled on the knee assembly Use a screw driver inside one of the covers lightening holes and gently lever off the double sided tape attaching it to the knee Insert the Femur into the knee block femur 133 5320 Fit two M8x35 BHCS into the counter bored holes and loosely tighten Fit two M8x30 set screws to the rear of the leg and screw in to their stops Carry out the same fitting for the tibia tighten all these screws The M8 set screws on the non impact side must be tightened to 8 Nm as do the 8 set screws in the aluminum leg segments see figure below Note when tightening the segment screws start with the screw nearest to the knee Remove the four side knee covers if fitted and make wire connections For off board and on board configurations wires will require careful routing and securing see section
56. re 18 for wiring on right hand side All the sensors use miniature round connectors with locking latch either a 7 pin or 16 pin is used The 16 pin connectors are for the 3 femur strain gages and for 3 of the 4 tibia strain gages 16 pin connectors are also used for optional triaxial accelerometers All the sensor wires are identified to ensure correct connection Figure 18 Off Board DAS wiring right hand side of impact face 3 04 leg wires must balanced to ensure good free flight after launch with 6 channels each side the right side are 2 single channel string pots 1 single channel accelerometer and 1 three channel wire for the three femur bone gages On the left side there are 2 single channel string pots 1 single channel tibia bone gage and 1 three channel wire for the other tibia bone gages It is important to route the off board cables out of the knee to ensure good free flight to the target See Figure 14 for an example Users can establish there own wire routing but the important issues to note are that both sides are balanced and there is no restriction at release from the pusher plate when fired 2 6 Messring M BUS On Board Data Acquisition 2 6 1 M BUS description An overview of the M BUS system is shown in Figure 19 The M BUS is a 6 channel logger fitted inside a magnesium housing connection is made to the logger via a plug in PCB board For the standard 12 channels there are two M BUS units one
57. ridor see Tables 13 and 14 Temperature for this test must be between 20 2 C Note that the loading path from the machine must have no rubber damping otherwise the load curve will be inaccurate To calculate moment loading centres for femur it is 330mm and for tibia 410mm For femur moment MF F N 2 0 165 and for tibia MT F N 2 0 205 Loading rate is 10 to 100 mm min G 3 04 Figure 58 Bone Assembly Fixture tibia shown Moment vs Deflection Moment Nm 50 0 lt 2 4 6 8 10 12 14 16 18 20 22 Deflection mm Table 13 Draft Femur assembly calibration corridor showing a typical result G 3 04 Moment vs Deflection gt 10 15 20 25 30 35 Deflection Table 14 Draft Tibia assembly calibration corridor showing a typical result 3 04 5 3 Knee Calibration This operation requires the use of a materials testing machine with high definition load cell and some parts from calibration fixture 133 8120 Temperature for this test must be between 20 2 Locate the femur insert into the femur knee block and tibia insert into the tibia block fit M8 x 35 BHCS and tighten then fit the M8 x 30 set screws on the opposite side and torque to 8 Nm Assemble the fixture as shown ensuring the impact side is on the top and the two blue plastic covers have been removed Place assembly over
58. the center of the roller carriages on the base plate The testing machine must be fitted with 2100 D shaped profile part 133 8105 see Figure below The center of the profile must be aligned with the corner of the meniscus a line is marked on the profile for this alignment Plug string pots into recording equipment A piece on Neoprene 90 x 150 x 5mm thick is placed over the loading point to prevent damage The knee is then loaded to 4 kN at 10 to 100 mm min moment knee Mk F 2 x 0 2 LCL ACL PCL and MCL string pot deflections are recorded The LCL deflection is not specifically needed for this test as it would be in compression The results must be inside the corridors below in Tables 15 and 16 I k dE 6 1 Figure 59 Knee Calibration Fixture ACL and PCL elongation mm A N O Upper MCL eee e 3 Lower corridor MCL es ave MCL 2 O 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 MCL elongation mm Table 15 Figure MCL sensor elongation corridor 1000 2000 3000 4000 5000 Force N Table 16 Figure ACL and PCL corridors G I R9 3 04 3 04 5 4Pendulum Dynamic Calibration The dynamic pendulum calibration test is carried on the Dynamic Certification Test Rig as shown in Figure 60 All standard 12 channels are tested 7 must meet the Draft GTR 9 regulation see Table 17 The corridors will be finalized when more t
59. the interfacing parts wear Having some play is acceptable as long as the leg passes either pendulum or inverse test certification If the user is concerned with a high amount of play the bone can be re shimmed to remove it GTR Pendulum Dynamic Calibration Peak Moment Tibia Gage 1 Peak Moment Tibia Gage 2 Peak Moment Tibia Peak Moment Tibia Peak ACL Elongation Peak MCL Elongation Peak PCL Elongation Table 17 Draft GTR 9 Regulation Pendulum test corridors values are up to 250 ms after impact G I 3 04 yoo g uonebDuo 3 191 D ju8uJo A D 1 synsee 419 Draft non injurious Pendulum test corridors values are up to 250 ms after impact Table 18 G 3 04 Section 6 Leg Preparation for Dynamic Inverse Test 6 1 Introduction After 30 car tests or before homologation testing a dynamic inverse test must be carried out The preparation for the leg is described below All standard 12 channels must be tested 7 of these channels must meet the test corridor as per the GTR 9 specification 6 2 Leg Preparation for Dynam
60. try standard wire wound and non wire wound precision potentiometers G 3 04 5 2Femur and Tibia Bone Assembly Certification 5 2 1 Introduction Prior to the femur and tibia assembly calibration the bone cores are tested to established corridors Each pair of gages impact side and none impact side compression and tension are tested individually to check correct function and establish gage sensitivity It is highly recommended that this operation is carried out by the FTSS Bone gage sensitivities must be taken form the bone gage calibration sheet provided in the calibration report and not the bone assembly The assembly components are certified to ensure biofidelity at component level and to help assure acceptance at dynamic certification 5 2 2 Femur and Tibia assembly Certification This operation requires the use of a materials testing machine with high definition load cell and calibration fixture 133 8120 Fit the bone assembly to fixture as shown see Figure 58 and place assembly over the roller carriages on the fixture base Do not tighten the two cap head screws at the end segments of the assembly to allow free rotation The femur bone is loaded on the third plastic segment from the knee and on the tibia the forth plastic segment The loading spigot is connected to a high definition load cell Connect to recording equipment Each bone assembly is loaded to 400 Nm 4848 N for femur and 3902 N for tibia Check output is inside cor
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