e2.ai es-2 side impact dummy euroncap test …es-2 side impact euroncap dummy instrumentation for...

© 2005 First Technology Safety Systems, Inc. Rev. B, April, 2005

Section 1-1

ES-2

E2.

AI

E2.AI

ES-2 Side Impact DummyEuroNCAP Test Protocol Version 4.0

The ES-2 side impact dummy from First Technologyis the next generation of the EuroSID1 dummy,incorporating many enhancements recommendedby users and regulators around the world. The ES-2 was developed by the SID2000 Program, aconsortium of European researchers, automotivemanufacturers and dummy manufacturers, andcoordinated by TNO of the Netherlands.

The Alliance of Automobile Manufacturers haspetitioned for an improved EuroSID1 to be analternative dummy for the US side impactregulations, and ES-2 is evaluated for that purpose.

Head and NeckThe head is based on the Hybrid III 50th Male headand can now be equipped with a six-axis upper neckload cell to evaluate neck injury and head contactloads. The neck is based on the EuroSID1 dummyand matches the human response to lateral flexionand can be calibrated with replaceable neck bufferelements. A lower neck six-axis load cell is alsoavailable.

Thorax/AbdomenThe Thorax consists of three rib modules with a sprunglinear slide and hydraulic damper mounted inside asteel spring outer band. Linear potentiometers measurerib deflection and the viscous criteria. The arm isattached to a rotating shoulder/clavicle mechanism.

The rib module linear guides are modified to haveminimal friction under non-lateral loadings. Theclavicles have been made more flexible are theshoulder plates are teflon coated to reduce friction.The back plate width is reduced to minimize seatinteraction and a back plate load cell measuresunintended seat contact.

The abdomen is a weighted deformable element withinternal load cells to measure load transfer throughthe abdomen. The abdomen calibration corridors havebeen updated to improve biofidelity and reliability anda T12 load cell measures load transfer between theupper and lower torso. A neoprene jacket zips overthe entire upper torso assembly.

PelvisThe pelvis contains two deformable urethane iliac wingsattached to the sacrum block with load cells at thelower lumbar spine and pubic symphysis. The pelvisflesh is simulated by a vinyl skin over urethane foammolding with foam inserts at the trochanters.

LegsThe ES-2 thighs use a high density foam for a morehumanlike mass distribution, and six axis femur loadcells can be fitted to the dummy.

Tilt SensorsOptional tilt sensors are available to measure the setup angle for the thorax and pelvis.


Section 1-1

InstrumentationLocation Description ChannelsHead Triax Accelerometer Pack Ax,Ay,AzNeck Six Axis Upper Load Cell Fx,Fy,Fz,Mx,My,Mz

Six Axis Lower Load Cell Fx,Fy,Fz,Mx,My,MzShoulder Three Axis Load Cell Fx,Fy,Fz

Triax accelerometer pack, T1 location Ax,Ay,AzThorax 3 Rib Displacements Dy

3 Rib Accelerations AyFour Axis Torso Back Plate Load Cell Fx,Fy,My,MzTriax Accelerometer Pack, T12 location Ax,Ay,Az

Abdomen Four Axis T12 Load Cell Fx,Fy,Mx,My3 Abdomen Load Cells Fy

Pelvis Three Axis Lower Lumbar Spine Load Cell Fy,Fz,MxPubic Symphysis Load Cell FyTriax Accelerometer Pack Ax,Ay,Az

Legs Six Axis Femur Load Cell Fx,Fy,Fz,Mx,My,Mz

Test EquipmentThe following FTSS fixtures are required to calibrate the ES-2 EuroNCAP dummy:

Head TE-100 Head Drop TableH.AB2 ES-2 Head Drop Support

Neck TE-207 Neck PendulumF.AB HeadformH.AD ES-2 Interface Plate for Neck and

Lumbar SpineThorax G.AA Thorax Certification Drop Rig

H.AE ES-2 Rib Support for Drop RigH.C Teflon Sheets

Abdomen H.AA Impactor Face for Abdomen Test

External Dimensions Assembly Weights

Dimension Spec (mm) Tol (+/-) Segment Mass (kg.) Tol (+/-)

Sitting Height 909 9 Head 4.00 0.20Seat to Shoulder Joint 565 7 Neck 1.00 0.05Seat to Lower Face of Thoracic Spine Box 351 5 Thorax 22.4 1.00Seat to Hip Joint (center of bolt) 100 3 Arm 1.30 0.10Sole to Seat, Sitting 442 9 Abdomen 5.00 0.25Head Width 155 3 Pelvis 12.0 0.60Shoulder/Arm Width 470 9 Leg 12.7 0.60Thorax Width 327 5 Total 72.0 1.20Abdomen Width 280 7Pelvis Lap Width 366 7Head Depth 201 5Thorax Depth 267 5Abdomen Depth 199 5Pelvis Depth 240 5Back of Buttocks to Hip Joint (center of bolt) 155 5Back of Buttocks to Front Knee 606 9


Section 1-1

ES-2 Side Impact EuroNCAP DummyDescription

Part Number Description

E2.AI Complete ES-2 Side Impact EuroNCAP Dummyprepared for accelerometer mountingIncludes accelerometer mounting kit for head, thorax, lumbar spine and pelvis, linear potententiometers (E2.LB) anda modified clavicle for shoulder load cell (E2.CK)

ES-2 Side Impact EuroNCAP DummyInstrumentation

Part Number Description Qty. Req'dPer Dummy

IE-116 Endevco 7264C-2000 Uniaxial Accelerometers 15 - Three (3) in the Head - Three (3) at T1 - Three (3) in the Ribs (one on each rib) - Three (3) at T12 - Three (3) in the Pelvis

E2.LB Displacement Transducer (included in dummy) 3

IF-317 3-Axis Shoulder Load Cell, 350 ohm, EuroSID-1. ES-2 1orIF-306 3-Axis Shoulder Load Cell, 120 ohm, EuroSID-1. ES-2 1

IF-420 4-Axis Lumbar Load Cell (T12), 350 ohm, ES-2 1orIF-421 4-Axis Lumbar Load Cell (T12), 120 ohm, ES-2 1

IF-556 Uniaxial Pubic Load Cell, 350 ohm, EuroSID-1, ES2 1orIF-558 Uniaxial Pubic Load Cell, 120 ohm, EuroSID-1, ES2 1

IF-600 Uniaxial Abdominal Load Cell, 350 ohm, EuroSID-1, ES2 3orIF-619 Uniaxial Abdominal Load Cell, 120 ohm, EuroSID-1, ES2 3

IF-631 6-Axis Femur Load Cell w/Aluminum Caps, 350 ohm, ES-2 1orIF-632 6-Axis Femur Load Cell w/Aluminum Caps, 120 ohm, ES-2 1


Section 1-1

ES-2 Side Impact EuroNCAP Dummy Instrumentationfor ECE-95 or 96/27-EC


IE-116 Endevco 7264C-2000 Uniaxial Accelerometers 3 - Three (3) in the Head

E2.LB Displacement Transducer (included in dummy) 3

IF-317 3-Axis Shoulder Load Cell, 350 ohm, EuroSID-1. ES-2 1orIF-306 3-Axis Shoulder Load Cell, 120 ohm, EuroSID-1. ES-2 1

IF-556 Uniaxial Pubic Load Cell, 350 ohm, EuroSID-1, ES2 1orIF-558 Uniaxial Pubic Load Cell, 120 ohm, EuroSID-1, ES2 1

IF-600 Uniaxial Abdominal Load Cell, 350 ohm, EuroSID-1, ES2 3orIF-619 Uniaxial Abdominal Load Cell, 120 ohm, EuroSID-1, ES2 3


Section 1-1

ES-2 Side Impact EuroNCAP DummyOptional Instrumentation


IE-116 Endevco 7264C-2000 Uniaxial Accelerometers 6 - Six (6) in the Ribs (2 per rib)

TE-2000-58-ES2 Tilt Sensor Package 1

6001901 Compaq IPAQ Model 2210 1 6001805 Tilt Sensor 2-Axis, Metric Screw 2 6001902 Adapter 6 Channel AA Batteries for IPAQ 1 6001903 Flash Card Memory Card 1 6001905 Cable 2 175-0011 Tilt Sensor Mount, Thorax 1 5000151 Screw, SHCS M4 x 0.7 x 10 2 175-0012 Tilt Sensor Mount, Pelvis 1 5000507 Screw, FHCS M4 x 0.7 x 6 1 5000388 Screw, SHCS M3 x 0.5 x 8 2 5000024 Screw, SHCS M4 x 0.7 x 8.0 1

IF-158 Head Assembly modified for 9 Accel Array, 7264-2000

IF-240 6-Axis Upper Neck Load Cell, 350 ohm, ES-2 1orIF-241 6-Axis Upper Neck Load Cell, 120 ohm, ES-2 1

IF-221 6-Axis Lower Neck Load Cell, 350 ohm, EuroSID-1, ES-2 1orIF-226 6-Axis Lower Neck Load Cell, 120 ohm, EuroSID-1, ES-2 1

IF-413 3-Axis Lumbar Load Cell, High Capacity, 350 ohm, ES-1, ES-2 1orIF-425 3-Axis Lumbar Load Cell, High Capacity, 120 ohm, ES-1, ES-2 1

IF-422 3-Axis Lumbar Load Cell, 350 ohm, EuroSID-1, ES-2 1orIF-423 3-Axis Lumbar Load Cell, 120 ohm, EuroSID-1, ES-2 1

IF-437 4-Axis Back Plate Load Cell, 350 ohm, ES-2 1orIF-438 4-Axis Back Plate Load Cell, 120 ohm, ES-2 1

IF-437-5N 4-Axis Back Plate Load Cell Fx-5KN 350 ohm, ES-2 1orIF-438-5N 4-Axis Back Plate Load Cell Fx-5KN, 120 ohm, ES-2 1


Section 1-1

ES-2 Side Impact EuroNCAP DummyTest Equipment

Part Number Description Qty. Req'd

HEAD DROP TEST EQUIPMENT - FTSS Plymouth

TE-100 Head Drop Test Fixture - 110 volt 1orTE-100-E Head Drop Test Fixture - 220 volt 1

- Includes: Nickel plated steel base plate with support stand, hardware suspension structure, electromagnetic release mechanism and the Hybrid III 50th head suspension cables and head positioning gage. - Four Channels are required to record the certification data. - Fixture Dimensions: 25 in. L x 29 in. W x 70 in. H

TE-2000-64 Junction Box, 4 Signal Lines 1

IE-116-33 Three (3) Uniaxial 7264C-2000 Accelerometer , Full Bridge, 33' Cable 34-Conductor Cable required, but not included

TE-100-200 Head Drop Test Kit 1

TE-100-330 Bracket for ES2 Head Drop 1

HEAD DROP TEST RIG - FTSS Europe

H.P Head Drop Test Rig (FTSS-Europe)

H.AB2 Support for Head Drop Test 1

NECK PENDULUM TEST EQUIPMENT

TE-207 Neck Pendulum Test Fixture - 110 volt 1orTE-207-E Neck Pendulum Test Fixture - 220 volt 1

Includes: Support for pendulum, hoist for lifting pendulum, impact plate for mounting honeycomb blocks and the head/neck rotation measurement unit for the Hybrid III 50th & 95th - Six Channels are required to record the certification data. - Fixture dimensions: 96 in. L x 28 in. W x 150 in. H

TE-2000-65 Junction Box, 9 Signal Lines 1

IE-101-33L One (1) 7231C-750 Uniaxial Accelerometers, Full Bridge, 33' 14-Conductor Cable required for all pendulums, but not included

F.AA Headform Assembly for the Eurosid-1 and ES-2 Neck Test 1Excludes Potentiometers

orF.AB Headform Assembly for the Eurosid-1 and ES-2 Neck Test 1

Includes three F.IA Potentiometers

H.AD Interface Plate for the Neck and Lumbar Spine for the ES-2 1


Section 1-1

ES-2 Side Impact EuroNCAP DummyTest Equipment

Part Number Description Qty. Req'd

THORAX IMPACT TEST EQUIPMENT

G.AA Thorax Certification Droprig - Instrumentation Included

H.AE Rib Support for ES-2 1

H.C Teflon Sheets for Rib Support for Eurosid-1 and ES-2 1 Set of 2 for full body impact tests;

900 x 1200 x 2 mm and 400 x 1200 x 2 mm

H.AA Impactor Face for Abdomen Test for Eurosid-1 and ES-2 1

SOFTWARE

TE-7100 Data Acquisition and Analysis Controlling Software - V2.0

TE-7119 Data Acquisition and Analysis Windows Software for the ES2 - V2.0 1


Section 1-1

ES-2 Side Impact EuroNCAP DummyMount Kit Matrix

Accelerometer Complete DummyType E2.AI Head Upper Spine T12 Pelvis

Entran EGAS-FS-500 1032366 1032369 1032367 1032368 1032367

Endevco 7264A 1032366 1032369 1032367 1032368 1032367

Endevco 7264B 1032366 1032369 1032367 1032368 1032367

Kyowa ASM-200BA 1032365 1032372 1032371 1032370 1032371

Endevco 7264-2000 1032365 1032372 1032371 1032370 1032371

Endevco 7264C-2000 1032365 1032372 1032371 1032370 1032371

Components


Section 1-1

ES-2 Side Impact EuroNCAP to ES-2reTested/Certified Upgrade Kit (175-4900)

(5) 5000108Screw, FHCS M6 x 18

(8) 5000399BHCS M3 x 0.5 x 6

175-4080Back Plate, LoadCell ReplacementRib Extension

175-4090Cover, Rib Extension

175-4060Rib Rear Backet,Rib Extension

175-4081Guide, Rib Extension

(6) 5000282Screw, SHCS M6 x 22

175-4001Spine Box,Rib Extensioin

175-4003Rib Assembly,Rib Extension

(12) 5000005Screw, BHCS M4 x 0.7 x 12.0(4 per rib)

(6) 5000075Screw, SHCSM8 x 1.25 x 20

(6) 9002664Bearing, Needle Roller, 1/4

175-4082Shaft, RibExtension

(12) 175-4085Spacer, Rib Extension

(2) 175-3004Shoulder Cam ClavicleAssembly, L/R


Section 1-1

ES-2 Side Impact EuroNCAP to ES-2reTested/Certified Upgrade Kit (175-4900)

ES-2re Description Qty. Req'dPart Number Per Dummy

175-4900 Rib Extension Kit, Thorax Tested/Certified 1 5000075 Screw, SHCS M8 x 1.25 x 20 6 5000108 Screw, FHCS M6 X 18 5 5000282 Screw, SHCS M6 X 22 6 5000399 Screw, BHCS, M3 X 0.5 X 6 8 9002664 Bearing, Needle Roller, 1/4, MCM 5905K21 6 175-4001 Spine Box, Rib Extension 1 175-4080 Backplate, Load cell Replacement, Rib Extension 1 175-4085 Spacer, Rib Extension 12 175-4081 Guide, Rib Extension 1 175-4090 Cover, Rib Extension 1 175-4082 Shaft, Rib Extension 1 175-4002 Complete Rib Module with Rib Extensions 3

5000005 Screw, BHCS M4 X 0.7 X 12.0 4 5000010 Screw, BHCS M4 X 0.7 X 10.0 5 174-4005 Damper Spring Locator ES-1/ES-2 1 175-4050 Damper Spring Assembly ES-2 1 175-4060 Rib, Rear Bracket, Rib Extension 1 175-4003 Rib Assembly, Rib Extension 1175-4006 Rib Rail Assembly 1

5000283 Screw, SHCS M2.5 X 16 15000285 Screw, SHCS M6 X 18 35000287 Screw, SHCS M4 X 20 65000295 Set Screw, FPSS M4 X 8 45000289 Screw, FHCS M4 X 30 65000290 Nut M4 Selt Locking 65000291 Screw, SHCS M5 X 10 15000294 Screw, Pan Head Phillips M3 X 8 45000343 Screw, SHCS M1.6 X 6 CLASS 12.9 ALLOY STEEL 25000355 Screw, FHCS M3 X 25 (07400.030.025) 26000081 Rod End 4-40 P/N A7A Plastic and P/N 78A04 Ball 1175-4031 Cover Thorax ES-2 1175-4007 Cylinder ES-2 1175-4020 Piston Thorax ES-2 1175-4010 Rail Guide Assembly ES-2 2175-4008 Guidance Bracket Thorax ES-2 1175-4021 Tuning Spring Support Thorax ES-2 1175-4032 Rib Accelerometer Mount ES-2 1175-4041 Spring 13.8 N/MM (COLOR CODE WHITE) 1175-4040 Spring 16.4 N/MM (COLOR CODE BLACK) 1175-4042 Spring 19.0 N/MM (COLOR CODE BLUE) 1175-4022 Transducer Mount Thorax ES-2 1175-4033 Transducer Bushing Thorax ES-2 1175-4950 Linear Position Transducer 1

175-3004 Shoulder Cam Clavicle Assembly (L/R) 2


Section 1-1

ES-2 Side Impact EuroNCAP to ES-2rePre-Tested and Certified Upgrade Kit (175-4910)

ES-2re Description Qty. Req'dPart Number Per Dummy

175-4910 Rib Extension Kit, Pre-tested and - certified 1 5000005 Screw, BHCS M4 X 0.7 X 12.0 12 5000075 Screw, SHCS M8 x 1.25 x 20 6 5000108 Screw, FHCS M6 X 18 5 5000282 Screw, SHCS M6 X 22 6 5000399 Screw, BHCS, M3 X 0.5 X 6 8 9002664 Bearing, Needle Roller, 1/4 6 175-4001 Spine Box, Rib Extension 1 175-4080 Backplate, Load Cell Replacement, Rib Extension 1 175-4085 Spacer, Rib Extension 12 175-4081 Guide, Rib Extension 1 175-4060 Rib, Rear Bracket, Rib Extension 3 175-4090 Cover, Rib Extension 1 175-4082 Shaft, Rib Extension 1 175-4003 Rib Assembly, Rib Extension 3 175-3004 Shoulder Cam Clavicle Assembly (L/R) 2


Section 1-1

ES-2 Side Impact EuroNCAP DummyOptional Products


E2.IC ES-2 Users manual 1

E2.CK ES2 Cam clavicle Modified 1

E2.IA ES-2 rubber suit 1

Shoes, Men's Oxford 11XW MIL-S-13192P (Pair) 1

E.IE T-shirt 1

E.IF Underpant mid-calf length 1

E2.DP Set of tuning springs (9 total) 1 E2.DPB Spring 13.8 kN/m - White 3 E2.DPC Spring 16.4 kN/m - Black 3 E2.DPD Spring 19.0 kN/m - Blue 3

E2.DF Screws and Fixings Thorax 1

E2.GX Screws and Fixings Pelvis 1

E.HB Upper arm swivel joint assy. (set) 1 E.HCL Pivot stop plate left 1 E.HCR Pivot stop plate right 1 E2.HD Arm screw and bearing 1 5000105 Washer, Flat M10 X 2 4 5000104 Bearing Thrust 10.5 ID 2 5000040 Screw, BHCS M10 X 1.5 X 30.4 2


Section 1-1

ES-2 Side Impact EuroNCAP DummyHead Assembly

78051-228-E2Head Skin, Tested/Certified

E2.JCUpper Neck Load CellStructural Replacement

78051-229Skin, Cap Skull

78051-220Skull CapMachined

E2.JBSkull Machined

(4) 5000081Screw, SHCS M6 x 1.0 x 16 (2) 5000291

Screw, SHCS M5 x 10

5000020Screw, SHCS M5 x 0.8 x 16.0

*Accelerometer MountRefer to AccelerometerMatrix

(4) 5000282Screw, SHCS M6 x 22

(4) 5000281Screw, SHCS M6 x 12


E2.J Head Assembly, Tested/Certified 1 E2.JB Skull Machined 1 78051-229 Skin, Cap Skull 1 78051-220 Skull Cap, Machined 1 5000081 Screw, SHCS M6 x 1.0 x 16 4 E2.JC Upper neck load cell structural replacement 1 5000282 Screw, SHCS M6 x 22 4 5000291 Screw, SHCS M5 x 10 2 5000020 Screw, SHCS M5 x 0.8 x 16.0 1 78051-228-E2 Head Skin, Tested/Certified 1 5000281 Screw, SHCS M6 x 12 4


Section 1-1

ES-2 Side Impact EuroNCAP DummyNeck Assembly

E2.BCHalf Spherical Screw

E2.BDInterface Plate, Neck Head &Torso

E2.BANeck Molded

E2.BBA, E2.BBB or E2.BBCNeck Buffer Assembly60 Shore (Red),70 Shore (Yellow) and80 Shore (Blue)

E2.BDInterface Plate - Neck, Head & Torso

E2.BCHalf Spherical Screw

(4) 5000285Screw, SHCS M6 x 18


E2.B Neck Assembly, Tested/Certified 1 E2.BC Half Spherical Screws 2 E2.BD Neck Head & Torso Interface Plate 2 E2.BBA Neck Buffers 60 Shore A Red (set of 8) 1 E2.BBB Neck Buffers 70 Shore A Yellow (set of 8) 1 E2.BBC Neck Buffers 80 Shore A Blue (set of 8) 1 E2.BA Neck, molded 1 5000285 Screw, SHCS M6 x 18 4

E.BG Neck Bracket including lifting eye-bolt 1 E.BH Eye bolt 1

E2.BHEye bolt

E2.BGNeck Bracket

E2.BBA, E2.BBB or E2.BBCNeck Buffer Assembly60 Shore (Red),70 Shore (Yellow) and80 Shore (Blue)


Section 1-1

ES-2 Side Impact EuroNCAP DummyUpper Torso Assembly

E2.CJShoulder Foam Pad

(4) 5000008Screw, SHCS M6 x 1.0 x 30.0(3) 5000009

Screw, FHCS M6 x 1.0 x 50.0E2.CAShoulder Top Plate5000003

Screw, BHCS M5 x 0.8 x 10.0(4) 5000007Screw, BHCS M4 x 0.7 x20.0 (2 on each side)

(2) E.CGCam Stop Block

(2) E.CEShoulder Cover Plate

(2) E2.CFShoulder Cam ClavicleAssembly (L or R)

(4) 5000005Screw, BHCS M4 x 0.7 x 12.0

E.CBShoulder Spacer Block

E2.CCShoulder Bottom Plate

E2.CMElastic Cord Holder

(4) 5000004Screw, BHCS M4 x 0.7 x25.0

(2) E2.CHElastic Cord and EndBushing


E2.C Shoulder Assembly 1 E2.CJ Shoulder Foam Pad 1 5000008 Screw, SHCS M6 x 1.0 x 30.0 4 5000009 Screw, FHCS M6 x 1.0 x 50.0 3 E2.CA Shoulder Top Plate 1 5000003 Screw, BHCS M5 x 0.8 x 10.0 1 E.CD Shoulder U-Spring 1 5000007 Screw, BHCS M4 x 0.7 x 20.0 4 E.CG Cam Stop Blocks 2 E.CE Shoulder Cover Plate 2 E2.CF Shoulder Cam Clavicle Assembly (L or R) 2 5000005 Screw, BHCS M4 x 0.7 x 12.0 4 E.CB Shoulder Spacer Block 1 E2.CM Elastic Cord Holder 1 5000004 Screw, BHCS M4 x 0.7 x 25.0 4 E2.CC Shoulder Bottom Plate 1 E2.CH Elastic Cord & End Bush ES-2 2

E.CDShoulder U-Spring


Section 1-1



E2.D Thorax Assembly 1 5000139 Screw, FHCS M6 x 12 2 5000281 Screw, SHCS M6 x 12 2 E2.DDA T12 Structural Replacement 1 E2.DA Spine Box 1 5000075 Screw, SHCS M8 x 1.25 x 20.0 6 E2.DCA Torso Back Plate Load Cell Replacement 1 5000001 Screw, SHCS M6 x 1.0 x 20.0 6 E2.DCC Back Plate Curved Narrow 1 5000036 Screw, FHCS M6 x 1.0 x 20.0 12

(12) 5000036Screw, FHCS M6 x 1.0 x 20.0

E2.DCCBack Plate CurvedNarrow

E2.DCATorso Back Plate LoadCell Replacement

(6) 5000075Screw, SHCS M8 x 1.25 x 20.0

E2.DASpine Box

E2.DDAT12 Structural Replacement

(2) 5000139Screw, FHCS M6 x 12

(2) 5000281Screw, SHCS M6 x 12

(6) 5000001Screw, SHCS M6 x 1.0 x 20.0


Section 1-1


E2.DGRib Covered with Foam

A40212-ADamper Assembly

E.DJStiff Damper Spring


E2.DW Complete Rib Module 3 E2.DG Rib Covered with Foam 3 E.DK Damper Spring Locator 3 E.DH Damper incl. bracket 3 E.DO Damper Clamp 3 A40212-A Damper Assembly 3 5000014 Screw, SHCS M6 x 1.0 x 35.0 6 E.DJ Stiff Damper Spring 3 E2.DL Damper Spring Cup 3 E.DI Damper Return Spring 3 5000010 Screw, BHCS M4 x 0.7 x 10.0 27

(4) 5000010Screw, BHCS M4 x0.7 x 10.0

E.DKDamper Spring Locator

E2.DLDamper Spring Cup

(4) 5000010Screw, BHCS M4 x 0.7 x 10.0

(1) 5000010Screw, BHCS M4 x 0.7 x 10.0

(2) 5000014Screw, SHCS M6 x 1.0 x 35.0

E.DMM (shown as reference)Rib Rail Assembly

E2.DIDamper Return Spring

E.DODamper Clamp


Section 1-1



E2.DMM Rib rail assembly ES2 3 E2.DME Guidance Bracket Thorax 3 5000289 Screw, FHCS M4 x 30 18 5000290 Nut M4 Self Locking 18 E2.DMD Rail guide assembly ES2 6 E2.DMA Cylinder 3 5000285 Screw, SHCS M6 x 18 9 E2.DMH Tuning Spring Support, Thorax 3 5000283 Screw, SHCS M2.5 x 16 3 E2.DMB Piston, Thorax 3 E2.DX Transducer Mount, Thorax 3 E2.DB Cover, Thorax 3 5000295 Set Screw FPSS M4 X 8 12 5000355 Screw FHCS M3 X 25 6 E2.LB Thorax Displacement transducer 3 E2.DZ Displacement Bushing, Thorax 3 E2.DML Rib Accelerometer Mount 3 E2.DY Rod end for transducer 3 5000287 Screw, SHCS M4 x 20 18 5000291 Screw, SHCS M5 x 10 3 E2.DMC Piston buffer 3 E2.DPB Spring 13.8 kN/m - White 3 E2.DPC Spring 16.4 kN/m - Black 3 E2.DPD Spring 19.0 kN/m - Blue 3

E2.DMEGuidance Bracket Thorax

(3) 5000285Screw, SHCS M6x 18

E2.DMACylinder

E2.DPB, E2.DPC or E2.DPDSpring - White, Black or Blue

(2) 5000355Screw, FHCS M3 x 25

(4) 5000295Screw, FPSS M4 x 8

E2.DBCover, Thorax

E2.DXTransducer Mount, Thorax

(6) 5000287Screw, SHCS M4 x 20

E2.LBThoraxDisplacementTransducer

E2.DMLRib Accelerometer Mount

(6) 5000290Nut M4 Self Locking

5000283Screw, SHCS M2.5 x 16

E2.DMHTuning Spring Support

5000291Screw, SHCSM5 X 10

(6) 5000289Screw, FHCS M4 x 30

E2.DMBPiston, Thorax

(2) E2.DMDRail Guide Assembly (1 on each side)

E2.DZDisplacement Bushing


Section 1-1

ES-2 Side Impact EuroNCAP DummyArm Assembly, Left

E.HAUpper ArmLeft or Right

E.HCLPivot Stop Plate, Left

5000040Screw, BHCS M10 x1.5 x 30.4

(2) 5000105Washer Flat M10 x 2

5000104Bearing Thrust 10.5 ID


E2.HL Arm Assembly Left, ES2 1 E.HA Upper arm (left or right) 1 E.HCL Pivot stop plate left 1 5000105 Washer Flat M10 x 2 2 5000104 Bearing Thrust 10.5 ID 1 5000040 Screw, BHCS M10 x 1.5 x 30.4 1


Section 1-1

ES-2 Side Impact EuroNCAP DummyArm Assembly, Right

5000040Screw, BHCSM10 x 1.5 x 30.4

(2) 5000105Washer Flat M10 x 2

5000104Bearing Thrust

E.HCRPivot Stop Plate, Right

E.HAUpper Arm Left or Right


E2.HR Arm Assembly Right, ES2 1 E.HA Upper arm (left or right) 1 E.HCR Pivot stop plate right 1 5000105 Washer Flat M10 x 2 2 5000104 Bearing Thrust 10.5 ID 1 5000040 Screw, BHCS M10 x 1.5 x 30.4 1


Section 1-1

ES-2 Side Impact EuroNCAP DummyLower Torso

E2.EBLumbar Spine Molded

E2.EALumbar Cable Assembly


E2.E Lumbar Spine Assembly Tested/Certified 1 E2.EA Lumbar Cable Assembly 1 E2.EB Lumbar Spine Molding 1


Section 1-1


(4) 5000023Screw, FHCS M4 x0.7 x 10.0E.FC

Cover Plate

(4) 5000591Screw, FHCS 1/4-20 x 1 E2.DDB

T12 Base Adaptor

E2.FBAbdominal Drum

(2) 5000089Screw, SHSS M8 x 60

(3) E.FENon-MeasuringDummy Unit(Abdomen Load CellStructural Replace-ment)

(12) 5000025Screw, SHCS M4 x0.7 x 16.0

E2.FAFoam Covering Including Slabs(Abdomen, Tested/Certified)

E.FDLatching Plate

(2) 5000024Screw, SHCS M4 x 0.7 x 8


E2.F Abdomen, Complete Tested/Certified 1 5000023 Screw FHCS M4 X 0.7 X 10.0 4 E.FC Cover plate 1 5000591 Screw FHCS 1/4-20 X 1 4 E2.FB Abdominal drum 1 5000089 Screw SHSS M8 X 60 2 E.FD Latching plate 1 E.FE Non measuring dummy unit 3 5000025 Screw SHCS M4 X 0.7 X 16.0 12 E2.FA Foam covering incl. slabs tested/certified 1 E2.DDB T12 Base Adaptor 1 5000024 Screw, SHCS M4 x 0.7 x 8 2


Section 1-1


(3) 5000030Screw, SHCS M8 x 1.25 x 25.0

E.GPLumbar Mounting Plate

(4) 5000005Screw, BHCS M4 x 0.7 x 12.0

E.GNSacrum Cover Plate

(3) 9000144Screw, SHCS 1/4-20 x 5/8

E2.GDSacrum Block

E2.GHRH-Point FoamBlock, Right

(2) 5000296Screw, LHCS M6 x 16(1 on each side)

E2.GHLH-Point FoamBlock, Left

(2) E2.GKTransducer Bushing(1 on each side)

(4) 5000032Screw, SHCS M10 x 1.5 x 40.0(2 on each side)

E2.GILBack Plate, Left

E2.GIRBack Plate,Right

(2) E2.GSSpacer Ring(1 on each side)

(2) 5000033Screw, SHSS M12 x 40(1 on each side)(2) E2.GR

BackplateBuffer(1 on eachside)

(2) E2.GTTube Spacer(1 on eachside)

E2.GEUpper Femur, Left includes bearing

E2.GFUpper Femur,Right includesbearing

(2) E2.GGHip Pivot Pin(1 on eachside)

E2.GQLFemur Buffer Assy, Left

(2) E2.GWTransducerSpacer(1 on each side)

E2.GBIliac Wing, Right

E2.GCIliac Wing, Left

(4) E.GOSacrum Spacers

E2.GAPelvis Molded

E2.GJPubic Force Structural Replacement

(2) 5000030Screw, SHCSM8x1.25x25.0


Section 1-1


E2.G Pelvis Assembly Complete, Tested/certified 1 E2.GHR H-point foam block R 1 5000296 Screw, LHCS M6 x 16 2 5000032 Screw, SHCS M10 x 1.5 x 40.0 4 E2.GK Transducer bush 2 E2.GIR Back Plate RH 1 E2.GG Hip Pivot Pin 2 5000033 Screw, SHSS M12 x 40 2 E2.GR Backplate Buffer 2 E2.GF Upper Femur RH (incl. bearing) 1 E2.GQR Femur Buffer Assy. RH 1 E2.GS Spacer ring 2 5000030 Screw, SHCS M8 x 1.25 x 25.0 5 E.GP Lumbar mounting plate 1 5000005 Screw BHCS M4 X 0.7 X 12.0 4 E.GN Sacrum cover plate 1 9000144 Screw, SHCS 1/4-20 x 5/8 3 E2.GC Iliac wing LH (modified) 1 E.GJ Dummy pubic force transducer 1 E.GO Sacrum spacers 4 E2.GB Iliac wing RH (modified) 1 E2.GA Pelvis flesh moulding 1 E2.GW Transducer spacer 2 E2.GQL Femur Buffer Assy. LH 1 E2.GE Upper Femur LH (incl bearing) 1 E2.GT Tube Stop 2 E2.GIL Back Plate LH 1 E2.GHL H-point foam block L 1 E2.GD Sacrum block 1



Section 1-1

ES-2 Side Impact EuroNCAP DummyLeg Assembly, Left

E2.KDThigh Flesh, Left

9000405Screw, SHCS 3/8-16 x 2

9000449Screw, SHCS 3/8-16 x 1-3/4

ATD-3801-1Knee Flesh, Left

78051-319Load Cell Simulator

ATD-3774-1Knee Joint Assembly, Left

E2.KCUpper Leg BoneWeldment

ATD-3738-1Lower Leg Assembly, Left

ATD-3141-1Foot Molded, Left


E2.KA Leg Assembly, Left 1 E2.KD Thigh Flesh, Left 1 9000449 Screw, SHCS 3/8-16 x 1-3/4 1 9000405 Screw, SHCS 3/8-16 x 2 1 E2.KC Upper Leg Bone Weldment 1 78051-319 Load Cell Simulator 1 ATD-3774-1 Knee Joint Assembly, Left 1 ATD-3801-1 Knee Flesh, Left 1 ATD-3773 Torque Adjusting Screw 1 9000013 Screw. SHCS 5/16-24 x 7/8 1 9000118 Washer 5/16 ID Spring Lock 1 ATD-3738-1 Lower Leg Assembly, Left 1 9000111 Screw, SHCS 1/2-20 x 2 1 ATD-3141-1 Foot, Molded, Left 1

ATD-3773Torque Adjusting Screw

9000113Screw, SHCS 5/16-24 x 7/8

9000118Washer 5/16 ID Spring Lock

9000111Screw, 1/2-20 x 2


Section 1-1

ES-2 Side Impact EuroNCAP DummyLeg Assembly, Right


E2.KB Leg Assembly, Right 1 E2.KE Thigh Flesh, Right 1 9000449 Screw, SHCS 3/8-16 x 1-3/4 1 9000405 Screw, SHCS 3/8-16 x 2 1 E2.KC Upper Leg Bone Weldment 1 78051-319 Load Cell Simulator 1 ATD-3774-2 Knee Joint Assembly, Right 1 ATD-3801-2 Knee Flesh, Right 1 ATD-3773 Torque Adjusting Screw 1 9000013 Screw. SHCS 5/16-24 x 7/8 1 9000118 Washer 5/16 ID Spring Lock 1 ATD-3738-2 Lower Leg Assembly, Right 1 9000111 Screw, SHCS 1/2-20 x 2 1 ATD-3141-2 Foot, Molded, Right 1

ATD-3801-2Knee Flesh,Right

9000449Screw, SHCS 3/8-16 x 1-3/4

9000405Screw, SHCS 3/8-16 x 2

ATD-3774-2Knee JointAssembly, Right

ATD-3738-2Lower LegAssembly, Right

ATD-3141-2Foot Assembly,Right

9000111Screw, SHCS 1/2-20 x 2

E2.KEThigh Flesh, Right

E2.KCUpper Leg Bone Weldment

78051-319Load Cell Simulator

ATD-3773Torque Adjusting Screw

90000113Screw, SHCS 5/16-24 x 7/8

9000118Washer 5/16 ID Spring Lock


Section 1-1

ES-2 Side Impact EuroNCAP DummyTools


E2.IB ES-2 Toolbox 1 E.IBA Toolbox empty 1 E.BF Neck Compression Tool 1 E.GM Puller Tool 1 5000129 Set Allen Key BLX9MN 1 9002397 3/16" Allen Key 1 9002398 5/32" Allen Key 1 9002399 3/4" Open Ended Spanner 1 5000125 Screw SHSS M6 X 8 X 60 2 9000591 Screw FHCS 1/4-20 X 1 4 9002389 Oil Bottle - 100 ml 1 8002561 Anti-seize Compound Tube (100 gram tube) 1 8002509 Adhesive Loctite 222-10 ml 1 E2.CH Elastic Cord & End Bush 2 5000295 Set Screw FPSS M4 X 8 8 5000296 Screw LHCS M6 X 16 2 E2.CL M10 X30 Self Locking Screw 2 5000281 Screw SHCS M6 X 12 4 5000283 Screw SHCS M2.5 X 16 3 E2.CK Shoulder Cam Clavicle 1

E2.IC ES-2 Users manual 1


Section 1-1

ES-2 Side Impact EuroNCAPSmall Parts Kit

ES2-RE Description Qty. Req'dPart Number Per Dummy

E2-SPK Small Parts Kit ES2-re 1 5000001 Screw, SHCS M6 X 1.0 x 20.0 6 5000003 Screw, BHCS M5 x 0.8 x 10.0 1 5000004 Screw, BHCS M4 x 0.7 x 25.0 4 5000005 Screw, BHCS M4 x 0.7 x 12,0 8 5000007 Screw, BHCS M4 x 0.7 x 20.0 4 5000008 Screw, SHCS M6 x 1.0 x 30.0 4 5000009 Screw, FHCS M6 x 1.0 x 50.0 3 5000010 Screw, BHCS M4 x 0.7 x 10.0 24 5000014 Screw, SHCS M6 x 1.0 x 35.0 12 5000023 Screw, FHCS M4 x 0.7 x 10.0 4 5000024 Screw, SHCS M4 x 0.7 x 8.0 12 5000025 Screw, SHCS M4 x 0.7 x 16.0 2 5000030 Screw, SHCS M8 x 1.25 x 25.0 4 5000032 Screw, SHCS M10 x 1.5 x 40.0 4 5000036 Screw, FHCS M6 x 1.0 x 20.0 12 5000075 Screw, SHCS M8 x 1.25 x 20 6 5000081 Screw, SHCS M6 x 1.0 x 16 4 E2.GU Bearing Spherical 17 ID 2 E2. GV Bearing Snap Ring 2 5000125 Screw, SHSS M6 x 8 x 60 4 5000139 Screw, FHCS M6 x 12 6 5000265 Screw, FHCS M6 x 30 4 5000281 Screw, SHCS M6 x 12 10 5000283 Screw, SHCS M2.5 x 16 3 5000285 Screw, SHCS M6 x 18 11 5000295 Set Screw FPSS M4 x 8 12 5000289 Screw, FHCS M4 x 30 18 5000290 Nut M4 Self Locking 18 5000291 Screw, SHCS M5 x 10 3 5000292 Screw, FHCS M4 x 25 6 5000293 Screw, SHCS M1.4 x 5 12 5000294 Screw, SHCS M3 x 8 24 5000296 Screw, LHCS M6 x 16 2 5000297 Screw, LHCS M5 x 18 4 5000298 Screw, Shoulder Bolt M12 x 16 x 40 2 5000343 Screw, SHCS M1.6 x 6 6 5000355 Screw, FHCS M3 x 25 6 6000081 Rod End 4-40 3 9000046 Pin Dowel 1/8 x 3/8 2 9000083 Screw, SHCS 3/8-16 x 1-3/4 Nylok 4 9000454 Screw, SHCS 1/4-20 x 3/4 4 9000477 Screw, FHCS 1/2-20 x 1/2 4 E.CD Shoulder "U" Spring 1 E.CG Cam Stop Block 2 E.DI Damper Return Spring 3


Section 1-1

ES-2 Side Impact EuroNCAPSmall Parts Kit

ES2-RE Description Qty. Req'dPart Number Per Dummy

E2-SPK Small Parts Kit ES2-re 1

E.DJ Stiff Damper Spring 3 E.EA Lumbar Cable Assembly 3 E.HCL Pivot Stop Plate, Left 1 E.HCR Pivot Stop Plate, Right 1 E2.CH Bungee (Elastic) Cord 2 E2.DZ Transducer Bushing Thorax 3 E2.GT Tube Stop 2 E2.HD Arm Screws and Bearings, includes:

Washer Flat M10 x 2 4 Bearing Thrust 10.5 ID 2 Screw, BHCS M10 x 1.5 x 30.4 2 E2.DX Transducer Mount Thorax 2 E.GO Sacrum Spacer 2 E2.GHL H-Point Foam Block Left 1 E2.GHR H-Point Foam Block Right 1 E2.GQR Femur Buffer Assembly, Right 1 E2.GQL Femur Buffer Assembly, Left 1 E2.GR Back Plate Buffer 2

e2.ai es-2 side impact dummy euroncap test …es-2 side impact euroncap dummy instrumentation for...

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