procedures for assembly, disassembly, and inspection (padi ... 572... · procedures for assembly,...

Procedures for Assembly, Disassembly, and Inspection

(PADI) of the Hybrid III

5th Percentile Adult Female Crash Test Dummy

(HIII-5F), Alpha Version

revised JUNE 2002

National Highway Traffic Safety Administration

revised JUNE 2002 i

TABLE OF CONTENTS Page Introduction................................................................................................................................1 Construction...............................................................................................................................3 Clothing......................................................................................................................................3 Instrumentation ..........................................................................................................................4

Head and Neck Instrumentation.........................................................................................18 Thoracic Instrumentation ...................................................................................................31 Chest Deflection and Spine-mounted Instrumentation ......................................................38 Lower Torso Instrumentation.............................................................................................57 Pelvis Instrumentation .......................................................................................................63 Femur Instrumentation.......................................................................................................69 Lower Leg Instrumentation................................................................................................76

Procedures for Assembly, Disassembly, and Inspection............................................................5 Head and Neck Removal......................................................................................................6 Head ...................................................................................................................................12 Neck ...................................................................................................................................15 Thorax ................................................................................................................................21 Chest Deflection and Transducer Assembly......................................................................32 Shoulder Assembly ............................................................................................................41 Arm Assemblies.................................................................................................................46 Lower Torso.......................................................................................................................51 Pelvis..................................................................................................................................59 Leg Assemblies ..................................................................................................................65 Knee Assemblies................................................................................................................70 Lower Legs.........................................................................................................................74 Ankle/Foot Assemblies......................................................................................................77

External Dimensions................................................................................................................82 Mass Measurements.................................................................................................................86 Instrumentation Cable Routing ................................................................................................92 Appendix A. Flesh Repair.................................................................................................... A-1 Appendix B. Joint Torque Adjustments ...............................................................................B-1 Appendix C. Procedure for Checking Recorded Sensor Polarity .........................................C-1 Appendix D. Procedure for Determining Moment of Inertia of Impact Probes .................. D-1 Appendix E. Procedures for Determining the Free Air Resonant Frequency of Probes Used for

Dummy Calibration ......................................................................................E-1

revised JUNE 2002 ii

LIST OF FIGURES Page

Figure 1. Hybrid III 5th Percentile Adult Female Dummy....................................................1 Figure 2. Extending shoe tongue for ease of fit....................................................................4 Figure 3. Complete Hybrid III Small Adult Female Test Dummy.......................................5 Figure 4. Head and neck assembly .......................................................................................6 Figure 5. Chest jacket removed............................................................................................7 Figure 6. Detaching the head and neck from the torso.........................................................7 Figure 7. Neck components..................................................................................................8 Figure 8. Releasing neck pivot pin set screw .......................................................................9 Figure 9. Nodding block compression tool ........................................................................10 Figure 10. Nodding block compression tool in use..............................................................10 Figure 11. Skull cap removal ...............................................................................................10 Figure 12. Brass washers inside neck structural replacement ..............................................11 Figure 13. Removing head accelerometer mount.................................................................13 Figure 14. Removing neck structural replacement...............................................................13 Figure 15. Guiding neck structural replacement out of the skull .........................................14 Figure 16. Removing head skin............................................................................................14 Figure 17. Neck assembly ....................................................................................................15 Figure 18. Neck disassembly................................................................................................16 Figure 19. Neck cable removal.............................................................................................16 Figure 20. Neck components................................................................................................17 Figure 21. Nodding block orientation ..................................................................................17 Figure 22. Upper neck load cell ...........................................................................................18 Figure 23. Upper neck load cell cables ................................................................................19 Figure 24. Head accelerometer orientation with respect to the upper neck load cell...........19 Figure 25. Upper torso assembly..........................................................................................22 Figure 26. Removing shoulder bolt ......................................................................................23 Figure 27. Detaching the shoulder assembly........................................................................23 Figure 28. Shoulder pivot components.................................................................................24 Figure 29. Removing the lower neck bracket.......................................................................24 Figure 30. Removing rib stiffener strips ..............................................................................25 Figure 31. Rib stiffener strip identification ..........................................................................25 Figure 32. Rib removal.........................................................................................................26 Figure 33. Removing upper rib stops ...................................................................................26 Figure 34. Chest deflection slider removal ..........................................................................27 Figure 35. Chest depth gage .................................................................................................27 Figure 36. Checking rib assembly for permanent deformation ............................................28 Figure 37. Location of the four sternum stops .....................................................................28 Figure 38. Orientation of rib support with respect to the rib and spine box ........................30 Figure 39. Using a C-clamp to compress the clavicle bumper.............................................30 Figure 40. Orientation of sternum-mounted accelerometers ................................................31 Figure 41. Chest deflection assembly...................................................................................33 Figure 42. Separating the upper and lower torso..................................................................33

revised JUNE 2002 iii

Figure 43. Removing the spine box from the spine tower ...................................................34 LIST OF FIGURES

Page Figure 44. Removing the chest accelerometer mount ..........................................................34 Figure 45. Chest accelerometer mounting bracket removal .................................................35 Figure 46. Detaching the adapter assembly..........................................................................35 Figure 47. Removing the chest deflection transducer assembly ..........................................36 Figure 48. Detaching the transducer arm assembly..............................................................36 Figure 49. Removing the chest potentiometer from the bracket ..........................................37 Figure 50. Orientation of chest triaxial accelerometer array ................................................38 Figure 51. Spine-mounted accelerometers ...........................................................................39 Figure 52. Close-up of spine-mounted accelerometers to demonstrate orientation .............39 Figure 53. Thoracic spine load cell ......................................................................................40 Figure 54. Clavicle assembly ...............................................................................................42 Figure 55. Clavicle assembly section view ..........................................................................42 Figure 56. Separating the clavicle link from the clavicle.....................................................43 Figure 57. Clavicle link spacers, spring stop, and shoulder screw.......................................43 Figure 58. Removing the shoulder yoke...............................................................................44 Figure 59. Components of the clavicle.................................................................................44 Figure 60. Removing the steel stop from the shoulder yoke assembly ................................44 Figure 61. Arm assembly .....................................................................................................47 Figure 62. Removing the elbow pivot bolt...........................................................................48 Figure 63. Components of the elbow joint ...........................................................................48 Figure 64. Removing wrist from lower arm.........................................................................49 Figure 65. Removing wrist rotation assembly......................................................................49 Figure 66. Removing the upper arm lower part ...................................................................50 Figure 67. Pelvis assembly...................................................................................................52 Figure 68. Lumbar spine assembly, lumbar-thorax adapter, and lumbar-pelvic adapter .....53 Figure 69. Removing the lumbar-pelvic adapter..................................................................54 Figure 70. Removing the lumbar-pelvic adapter..................................................................54 Figure 71. Detaching the lumbar spine from the pelvic adapter ..........................................55 Figure 72. Detaching the thoracic adapter from the lumbar spine .......................................55 Figure 73. Components of the lumbar spine and lumbar-thoracic adapter ..........................56 Figure 74. Lumbar pad removed from lumbar-pelvis adapter..............................................57 Figure 75. Lumbar spine load cell ........................................................................................58 Figure 76. Loosening the femur set screw............................................................................59 Figure 77. Removing the femur flange from pelvis .............................................................59 Figure 78. Removal of the femur bolt ..................................................................................60 Figure 79. Typical femur removal tool.................................................................................60 Figure 80. Removing the ASIS load cell simulator bolts.....................................................61 Figure 81. Removal of ASIS load cell simulator from pelvis assembly ..............................61 Figure 82. Location of H-point.............................................................................................62 Figure 83. H-point tool.........................................................................................................62 Figure 84. ASIS load cell .....................................................................................................63

revised JUNE 2002 iv

Figure 85. Orientation of pelvic accelerometer in mounting bracket...................................64 Figure 86. Pelvic accelerometers installed into pelvis assembly..........................................64

LIST OF FIGURES Page

Figure 87. Leg assembly.......................................................................................................66 Figure 88. Separating leg into upper and lower segments....................................................67 Figure 89. Detaching the upper leg from femur load cell replacement ................................67 Figure 90. Detaching knee from femur load cell replacement .............................................68 Figure 91. Components of the upper leg and knee...............................................................68 Figure 92. Femur load cell ...................................................................................................69 Figure 93. Knee assembly ....................................................................................................71 Figure 94. Knee slider assembly ..........................................................................................72 Figure 95. Components of the knee assembly......................................................................72 Figure 96. Lower leg structural replacement........................................................................74 Figure 97. Detaching the ankle/foot assembly .....................................................................74 Figure 98. Removing the flesh from the lower leg structural replacement ..........................75 Figure 99. Detaching the knee clevis ...................................................................................75 Figure 100. Instrumented lower leg........................................................................................76 Figure 101. Ankle assembly...................................................................................................78 Figure 102. Detaching the ankle assembly from the foot.......................................................79 Figure 103. Loosening the ankle friction set screw................................................................79 Figure 104. Removing the ankle bumper ...............................................................................80 Figure 105. Components of the ankle assembly.....................................................................80 Figure 106. Foot heel pad.......................................................................................................81 Figure 107. External dimensions............................................................................................85 Figure 108. Load cells and cable routing ...............................................................................92 Figure 109. Head accelerometer and upper neck load cell cable routing...............................93 Figure 110. Cable slack to allow for head motion .................................................................93 Figure 111. Routing the head instrumentation cables through the rib cage ...........................94 Figure 112. Cable bundle exiting the thoracic cavity below rib #6........................................94 Figure 113. Grounding cable..................................................................................................95 Figure 114. Routing of sternum accelerometer cables ...........................................................96 Figure 115. Routing the cables from the interior of the spine box.........................................96 Figure 116. Routing of cables in the abdominal area.............................................................97 Figure 117. Pelvis accelerometer cable routing .....................................................................98 Figure 118. Femur load cell cable routing..............................................................................98 Figure 119. Femur load cell cable shown taped to the side of the pelvis...............................99 Figure 120. Cable routing under chest jacket (rear view) ....................................................100 Figure 121. Cable routing under chest jacket (side view) ....................................................100 Figure B1. 1G setting of shoulder yoke clevis bolt.............................................................B-3 Figure B2. 1G setting of shoulder rotation hex nut.............................................................B-3 Figure B3. 1G setting of elbow rotation bolt ......................................................................B-4 Figure B4. 1G setting of elbow pivot bolt ..........................................................................B-4 Figure B5. 1G setting of wrist pivot bolt ............................................................................B-5

revised JUNE 2002 v

Figure B6. 1G setting of wrist rotation bolt ........................................................................B-5 Figure B7. 1G setting of femur ball set screw ....................................................................B-6 Figure B8. 1G setting of knee pivot bolt.............................................................................B-7 Figure B9. 1G setting of ankle ball set screw .....................................................................B-7 Figure C1. Polarity of x-axis accelerometer data channel ..................................................C-3 Figure C2. Polarity of y-axis accelerometer data channel...................................................C-3 Figure C3. Polarity of z-axis accelerometer data channel...................................................C-4 Figure C4. Accelerometer perpendicular to the force of gravity in two orientation

180 degrees apart ..............................................................................................C-4 Figure D1. Determination of moment of inertia of probes used for dummy calibration ... D-1 Figure E1. Probe impacted with hammer to excite resonance............................................E-1 Figure E2. Probe accelerometer response versus time........................................................E-2 Figure E3. Probe accelerometer response between 38 - 41 milliseconds ...........................E-3

revised JUNE 2002 vi

LIST OF TABLES Page

Table 1. Threaded Fastener Abbreviations ............................................................................2 Table 2. Fastener Torque Specification .................................................................................3 Table 3. Instrumentation ........................................................................................................4 Table 4. Hybrid III Small Adult Female External Dimensions............................................83 Table 5. Hybrid III Small Adult Female External Dimension Details .................................84 Table 6. Hybrid III Small Adult Female Total and Segment Masses ..................................86 Table 7. Head Segment ........................................................................................................86 Table 8. Neck Segment ........................................................................................................87 Table 9. Upper Torso Segment ............................................................................................87 Table 10. Lower Torso Segment ............................................................................................88 Table 11. Left Upper Leg Segment ........................................................................................88 Table 12. Right Upper Leg Segment......................................................................................89 Table 13. Left hand Segment .................................................................................................89 Table 14. Right Hand Segment ..............................................................................................89 Table 15. Left Lower Leg Segment........................................................................................90 Table 16. Right Lower Leg Segment .....................................................................................90 Table 17. Left Foot Segment..................................................................................................90 Table 18. Right Foot Segment ...............................................................................................90 Table 19. Upper Arm Segment (left and right) ......................................................................91 Table 20. Lower Arm Segment (left and right)......................................................................91 Table C1. Instrumentation for Small Female Dummy..........................................................C-7 Table C2. Dummy Manipulations for Checking Recorded Instrumentation Polarity

Relative to SAE J211 Sign Convention for Positive Polarity..............................C-8

Revised JUNE 2002 1

INTRODUCTION The National Highway Traffic Safety Administration has prepared this document under the title AProcedures for Assembly, Disassembly, and Inspection of the Hybrid-III 5th Percentile Adult Female Crash Test Dummy,@ otherwise known as PADI for the H-III5F. The document is based on drawings and test procedures described in the Final Rule that incorporated the H-III5F crash test dummy into Part 572 as subpart O (alpha version). The H-III5F is designed for use in the seated position. Its anthropometry, weight distribution, motion ranges, and general body segments= configuration reflect those of a small adult female. A photograph of the Hybrid III small adult female, H-III5F, is shown in Figure 1.

Revised JUNE 2002 2

Purpose This document contains the procedures for disassembly, assembly, and adjustment of the dummy for the purpose of inspecting and preparing it for testing. Calibration tests are specified in Part 572 Subpart O Final Rule to ensure that the dummy is capable of repeatable and reproducible performance while its responses remain within the specified biofidelity corridors. This document serves as a guide for the user to properly inspect, assemble, and adjust the dummy=s various parts as needed. Each section is written to be independent so that, depending on the user=s objectives, the various sections can be referred to directly. Part Numbers All part numbers in this document refer to the drawing package in 49 CFR, Part 572 Subpart O. Copies of the drawing package for this dummy can be obtained from Reprographic Technologies, 9000 Virginia Manor Road, Beltsville, MD 20705; Telephone: (301) 210-5600. Abbreviations The abbreviations used throughout the document are listed in Table 1. Table 1. Threaded Fastener Abbreviations Abbreviation

Description

SHCS

Socket Head Cap Screw

FHCS

Flat Head Cap Screw

BHCS

Button Head Cap Screw

SHSS

Socket Head Shoulder Screw

SSCP

Socket Screw, Cup Point

RHMS

Round Head Machine Screw

Torque Specifications Unless specified otherwise, the torque requirements for the fasteners used throughout the dummy are shown in Table 2.

Revised JUNE 2002 3

Table 2. Torque Specifications

Screw Type

Size

Torque (in-lb)

Torque (N-m)

SHCS/BHCS

6-32

30

3.4

8-32

56

6.3

10-24

80

9.0

10-32

90

10.2

1/4-20

190

21.5

1/4-28

215

24.3

SHSS

1/4

80

9.0

5/16

190

21.5

CONSTRUCTION Following are some of the design highlights of the small female dummy: $ Cast aluminum skull and skull cap with removable vinyl head and skull cap skins. The vinyl

skin has been tuned to give humanlike response for forehead impacts. $ A rubber segmented neck which has been tuned to give humanlike angle versus moment

response in dynamic flexion (forward bending) and extension (rearward bending) articulations. $ A neck cable passing through the neck=s longitudinal axis controls the stretching responses and

provides increased durability against extreme axial tension forces. $ A two-piece aluminum clavicle-link assembly contains integrally cast scapulae to provide a

realistic interface with shoulder belts. $ Six spring steel ribs with polymer-based damping material approximate the human chest force-

deflection response properties. A sternum assembly connects to the front end of the ribs and contains a slider mechanism capable of measuring deflection of the rib cage relative to the thoracic spine.

$ Top and bottom rib stops are incorporated to control the vertical movement of the rib cage. $ A straight lumbar spine provides the proper sitting posture for a person of small stature in the

driving position. $ The pelvis contains the capability for incorporating submarining-indicating transducers. The

pelvis has a humanlike shape. $ A knee slider mechanism allows for displacement of the tibia relative to the femur, simulating

ligament response. $ Consistent joint articulation is achieved by use of a constant friction moveable joint assembly. CLOTHING When used in testing, the dummy should wear a snug-fitting, size medium T-shirt and size small pants, both made of 100% knit cotton. The T-shirt=s neckline should be chosen to ensure that a shoulder belt cannot contact the dummy=s skin and the pants should end above the dummy=s knee. The T-shirt and pants should each weigh no more than 0.14 kg ( 0.3 lb). The shoes are women=s low dress black oxfords, size 7 2 W that meet military specification MIL-S-21711E. Talc may also be

Revised JUNE 2002 4

applied to the foot to facilitate placement of the shoe on the foot. If the foot cannot be placed in the shoe after application of talc, it may be necessary to modify the shoe by extending the shoe=s tongue by approximately one inch as shown in Fig. 2. Any additional clothing requirements are prescribed in accordance with the Federal Motor Vehicle Safety Standard testing procedure or specifications. INSTRUMENTATION The dummy is capable of using the instrumentation shown in Table 3 to evaluate various types of occupant restraint systems. Table 3. Instrumentation Instrument

Part Number

No. of Channels

Comments

Head Accelerometers

SA572-S4

3

Upper Neck Load Cell

SA572-S11

6

Lower Neck Load Cell

SA572-S27

6

optional

Chest Accelerometers

SA572-S4

3

Chest Deflection Transducer

SA572-S51

1

Sternum Accelerometers

SA572-S4

3

optional

Spine Accelerometers

SA572-S4

3

optional

Thoracic Spine Load Cell

SA572-S28

6

optional

Lumbar Spine Load Cell

SA572-S15

5

optional

Pelvis Accelerometers

SA572-S4

3

Iliac Spine (A.S.I.S.) Load Cells

SA572-S16

2 each

optional

Single Axis Femur Load Cell

SA572-S14

1 each

Multi-axis Femur Load Cell

SA572-S29

6 each

optional

Revised JUNE 2002 5

DISASSEMBLY/REASSEMBLY The complete H-III5F dummy consists of 6 major assembly groups as shown in Figure 3. The subsequent section of this document will discuss the disassembly and reassembly of each group. Assembly Group

Part Number

Head

880105-100X

Neck

880105-250

Upper Torso

880105-300

Lower Torso

880105-450

Arms, Left Arms, Right

880105-728-1 880105-728-2

Legs, Left Legs, Right

880105-560-1 880105-560-2

revised JUNE 2002 6

HEAD AND NECK REMOVAL

Description

Part Number

Figure

Number

Item

Number SHCS, 3/8-16 x 1

9000021

3

1

Neck Bracket, Upper

880105-207

3

2

SHCS, 10-24 x 5/8

90000224

3

3

Bib Assembly

880105-1060

3

4

Pivot Pin

78051-339

3

5

Nodding Block

78051-351

3

6

Clamping Washer

78051-305

3

7

Fig. 4. Head and neck assembly

revised JUNE 2002 7

Before beginning the disassembly of the head and neck, it may be desirable to completely remove the chest jacket. Unzip the jacket at the torso posterior and remove it by pulling the jacket forward allowing the arms to slide through the arm holes in the jacket (reference Figs. 5).

Fig. 5. Chest jacket removal The head and neck are disassembled from the upper torso by removing the 3/8-16 x 1 SHCS (Item 1, Fig. 3) and the clamping washer (Item 7, Fig. 3) that holds the upper neck bracket to the lower bracket (see Fig. 6.). The clamping washer is curved on one side in order to mate with the radius on the underside of the lower neck bracket; be sure to install this properly during reassembly. After removing the 3/8-16 x 1 SHCS, the neck will remain attached via the bib assembly; allow the head and neck to hang forward until the neck can be released from the bib.

Fig. 6. Detaching head and neck from torso

revised JUNE 2002 8

Release the head and neck assembly from the bib assembly and upper neck bracket by removing the hex jam nut, the lower neck cable bushing, and the four 10-24 x 5/8 SHCS (Item 3, Fig. 3). The lower neck cable bushing, which is made of Delrin and has a Atop hat@ shape, is critical for minimizing electronic noise in the dummy; be certain that it is installed properly during reassembly. Fig. 7 below, provides an exploded view of the items located at the base of the neck.

Fig. 7. Neck components

revised JUNE 2002 9

Before attempting to remove the pivot pin, loosen the two 8-32 x 1/4 SSCP that hold the pivot pin in the neck load cell or neck structural replacement (Fig. 8). It is recommended that the set screws not be completely removed; it is sufficient to loosen the set screws just enough to allow the pivot pin to be removed. This will minimize the risk of losing the set screws. To remove the head from the neck, a nodding block compression tool may be required (Fig. 9). In order to remove the pivot pin (Item 5, Fig. 3) without damaging it, it will be necessary to compress the nodding blocks (Item 6, Fig. 3) located between the head and the neck. Compression of the nodding blocks removes the applied load from the pivot pin. Next, slide the lower plate of the nodding block compression tool in between two of the aluminum disks of the neck. Turn the handle of the tool until the top plate contacts the surface of the head skin (Fig. 10). Carefully continue to apply pressure by turning the handle until the nodding blocks are compressed enough to relieve the load on the pivot pin. The pivot pin should now slide out of the load cell or load cell replacement, but may require a light tap with a rubber mallet. If the pin still resists removal, readjust the pressure applied by the compression tool until the pin moves with less resistance. Note: There are several designs of the nodding block compression tool used in the industry, some of which require the skull cap to be removed first. To remove the skull cap, remove the four 10-24 x 2 SHCS that hold the skull cap in place (Fig. 11).

Fig. 8. Releasing neck pivot pin set screw

revised JUNE 2002 10

Fig. 9. Nodding block compression Fig. 10. Nodding block compression Tool. Tool in use

Fig. 11. Skull cap removal

After the pin has been extracted, remove the nodding block compression tool. The neck is now free to be pulled away from the head assembly. There are two brass washers located inside of the pivot pin joint that will fall out as the head and neck are separated (Fig. 12). These washers are custom sized to provide the proper fit with each specific head and neck assembly; care should be taken so that these washers are not confused with those of other head and neck assemblies.


Fig. 12. Brass washer inside neck structural replacement Note: Newly purchased washers (78051-253) should be trimmed using the following procedure: 1. Trimming can be accomplished in several ways. The easiest is to rub the washers on coarse sandpaper or a file and check the fit of the joint. Repeat the trimming until the nodding joint and the load cell can be assembled snugly with the washers. 2. The fit of the joint and load cell should be snug but easily assembled. Inspection Inspect the neck for tears or breaks. Replace a neck that has any tears, breaks, or cracks. Reassembly $ Reattach the neck to the head. This may require use of the nodding block compression

tool. Insert the neck pivot pin into neck load cell or structural replacement. A light tap with a mallet may be required.

$ Tighten the two 8-32 x 1/4 SSCP that fix the pivot pin to the neck structural replacement. $ Reattach the skull cap to the back of the head. $ Reattach the neck and the upper neck bracket to the sternum bib. Be sure to properly

install the lower neck cable bushing. The hex jam nut shall be torqued to 10 - 14 in-lbs. $ Position the zero degree mark on the upper neck bracket so that it is aligned with the zero

degree mark on the neck bracket. $ Reattach the upper neck bracket to the lower neck bracket using the 3/8-16 x 1 SHCS and

the clamping washer.


HEAD Part number reference; no figure provided. Description

Part Number

Structural Replacement 6-axis Neck Transducer

78051-383X

Head Accelerometer Mount

880105-1211

Skull, 6-Axis Neck

880105-102

Skull Cap

880105-103

Head Skin

880105-109

Skin, Skull Cap

880105-106

Head Accelerometers

SA572-S4

Triaxial Mounting Block

SA572-S80

Upper Neck Load Cell, 6-axis

SA572-S11

SHCS, 10-24 x 3/8

9000487

SHCS, 1/4-28 x 7/8

9000264

With the head now separated from the neck, the remaining head components can be disassembled. If the skull cap has not already been removed as necessitated by the nodding block compression tool, remove it now (Fig. 11). If the neck load cell is installed, disconnect the instrumentation cables. Also remove the head triaxial accelerometer array if it is installed. This is done by removing the four 10-24 x 3/8 SHCS that hold the head accelerometer mount to the top of the neck load cell or structural replacement. The holes located at the top of the head are used to access these fasteners. Slip the appropriate Allen wrench through the access holes to loosen the four SHCS (Fig. 13). With these screws removed, the head accelerometer mount can be removed from the head through the back of the skull.


Fig. 13. Removing head accelerometer mount Remove the four 1/4-28 x 7/8 SHCS and washers that attach the six-channel upper neck load cell or structural replacement to the skull (Fig. 14). The upper neck load cell or structural replacement is removed from inside the head by guiding it out of the back of the head (Fig. 15). Note the orientation of the load cell structural replacement in Fig. 15 as this orientation is critical to removing it. Fig. 14. Removing neck structural replacement


Fig. 15. Guiding neck structural replacement out of the skull The head skin can be removed from the head assembly by lifting the skin away from the skull casting at the back of the skull and Apeeling@ the flesh from the assembly (Fig. 16).

Fig. 16. Removing head skin Inspection $ Check the head skin for tears or cracks. Replace head skins which have damage in the forehead

area; do not attempt to repair them as this will have an affect on test results. If necessary, repair the head skin as described in Appendix A.

$ Check the skull casting for cracks, dents, and other damage. Replace the skull if damaged. Reassembly $ Place the head skin back on to the skull casting. Be sure that the head skin fits snuggly,

particularly in the forehead area. $ Insert load cell structural replacement into head; reattach using the four 1/4-28 x 7/8 SHCS. $ Reattach the skull cap using the four 10-24 x 2 SHCS.


NECK

Description Part Number

Figure Number

Item Number

Nodding Joint Assembly 880105-201 17 1

Neck Cable 880105-206 17 2

Nodding Blocks 78051-351 17 3

Neck Cable Bushing, Upper 180-2004 17 4

Neck Cable Bushing, Lower 108-2005 17 5

Molded Rubber Neck 880105-255 17 6

½-20 Hex Jam Nut 9000018 17 8

FHCS, 10-24 x 5/8 9000566 17 9

Washer, 1.06 OD x 0.53 ID x 0.06 90001260 17 10

SHCS, 10-24 x 5/8 9000224 17 11

Fig. 17. Neck assembly


The neck can be disassembled by removing the four 10-24 x 5/8 FHCS (Item 9, Fig. 17) from the top of the nodding joint assembly (Fig. 18). With the nodding joint removed, the neck cable (Item 2, Fig. 17) can be pulled out of the neck. Remove the Delrin neck cable bushing (Items 4, Fig. 17) from the ball-end of the cable. Figure 20 depicts the various components of the neck assembly.

Fig. 18. Neck disassembly

Fig. 19. Neck cable removal


Figure 20. Neck components Inspection • During reassembly, check the neck for deformation, tears, or breaks in the rubber. Replace

the neck if any damage is observed. • Check the neck cable by observing the strands. If they are not tightly wound, frayed, or the

cable appears larger in diameter on one end, replace the cable. If the cable cannot be properly torqued, replace the cable.

• Proper orientation of the nodding blocks is critical. They must be installed so that the 90 degree angle is toward the base of the head and the 60 degree angle is toward the nodding joint (Fig. 21). If not oriented properly, the blocks will likely cause the neck responses in flexion and extension to be incorrect.

• Inspect the nodding blocks for deformation. Deformed blocks will cause inadequate loading of the nodding joint and should be replaced. Check the hardness of the nodding blocks often with a Shore “A” type Durometer. The specification is 80-90.

Reassembly • The upper end of the neck is machined to accept the ball-end of the neck cable. During the

reassembly, make sure that this area is free of any extraneous rubber material before installing the cable. Install the upper neck cable bushing into the cup at the upper end of the neck. Insert the cable into the neck such that the ball-end of the cable is seated in the cup at the upper end of the neck.

• Reattach the nodding joint assembly to the upper end of the neck using the four 10-24 x 5/8 FHCS.

• Install the nodding blocks in their proper orientation (Fig. 21).

Fig. 21. Nodding block orientation


Head and Neck Instrumentation The head and neck contain several provisions for instrumentation, including: • head CG triaxial accelerometer array • upper neck load cell (SA572-S11) • lower neck load cell (SA572-S27; optional) This section will describe the installation of these items. Upper Neck Load Cell (SA572-S11) Begin the process with the head removed from the neck. Next, remove the neck load cell structural replacement as described in the head disassembly section. Orient the upper neck load cell such that it will fit inside the skull casting through the back of the head. Once it is inside the skull, rotate the neck load cell such that the two cable ports are located at the posterior of the skull and insert the load cell through the hole at the bottom of the skull casting until the mounting surface is flush with the base of the skull casting (Fig. 22). Attach the four 1/4-28 x 7/8 SHCS and washers through the bottom of the skull and into the load cell. Do not attach the load cell cables until after the head accelerometer array has been installed. Fig. 23 shows the cables attached to the load cell. Head CG Triaxial Accelerometer Array First attach the individual accelerometers (SA572-S4) to the S4 Triaxial Accelerometer Mounting Block (SA572-S80). The accelerometers are mounted to the block such that an imaginary axis passing through their seismic masses and along the direction of primary sensitivity would intersect at a single point. Next, attach the mounting block to the head accelerometer mount (880105-1211). Again, the orientation of the accelerometers is critical; mount the block as shown in Fig. 24. Next, insert the head accelerometer mount into the back of the head; Figure 24 demonstrates the orientation of the head accelerometer mount relative to the upper neck load cell; note that the accelerometer mount cannot be attached to the upper neck load cell before it is installed into the skull as the two items will not fit through the opening in the back of the skull simultaneously. Finish by installing the four 10-24 x 3/8 SHCS which attach the head accelerometer mount to the upper neck load cell.

Fig. 22. Upper neck load cell


Fig. 23. Upper neck load cell

Fig. 23. Upper neck load cell cables

Fig. 24. Head accelerometer orientation with respect to the upper neck load cell.


Lower Neck Load Cell (SA572-S27; optional) This description assumes that the head and neck have already been removed from the upper torso. Refer back to the section on removal of the head and neck if necessary. Detach the lower neck bracket from the upper torso by removing the four 1/4-20 x 3/4 SHCS that hold it in place. Reattach the neck and the lower neck load cell to the sternum bib. Be sure to properly install the lower neck cable bushing. The hex jam nut shall be torqued to 10 - 14 in-lbs. Attach the lower neck load cell to the upper torso with the four 1/4-20 x 3/4 SHCS.

Revised JUNE 2002 21

THORAX Description

Part Number

Figure

Number

Item

Number Lower Neck Bracket

880105-208

25

1

Spine Weldment

880105-1000

25

2

Rear Rib Support

880105-320

25

3

Upper Rib Stop Assembly

880105-1015

25

4

Sternum Slider

880105-1050

25

5

Behind Rib Strips

880105-323

25

6

Stiffener Strip

880105-324

25

7

Bib Assembly

880105-1060

25

8

Clavicle Link Pivot Nut

880105-340

25

9

Shoulder Bumper

880105-341

25

10

Clavicle Link Washer (Delrin)

880105-342

25

11

Clavicle Link Washer (Urethane)

880105-359

25

14

BHCS, 10-32 x 5/8

9000025

25

15

SHCS, 1/4-20 x 5/8

9000144

25

16

Shoulder Assembly

880105-380 left -381 right

25

17

Rib Set

880105-361

25

18

Lower Rib Stop Assembly

880105-1030

25

20

Adaptor Assembly

880105-1085

25

21

Sternum Stop

78051-9

25

22

Chest Transducer Assembly

880105-1080

25

23

SHSS, 3/8 x 1

9000074

25

24

BHCS, 10-32 x 3/4

9001193

25

25

Washer, .281 ID x .5 OD x .06

9000244

25

27

SHCS, 1/4-20 x 3/4

9000454

25

28

SHCS, 5/16-18 x 1/2

9000489

25

29

BHCS, 10-32 x 3/8

9000538

25

30

Lower Neck Load Cell

SA572-S27

n/a

n/a

Sternum Accelerometers

SA572-S4

n/a

n/a


Fig. 25. Upper torso assembly


Begin disassembling the torso by removing the arm assemblies. Remove the 3/8 x 1 SHSS which attaches each arm to the shoulder (Fig. 26). Pay close attention to placement of the washers and bushings in the shoulder. Proper assembly of these items are necessary in achieving the one G joint adjustments (ref. Appendix B). If the chest flesh was not removed during disassembly of the head and neck, remove it now. Also, lean the upper torso back and remove the abdomen insert.

Fig. 26. Removing shoulder bolt Detach the shoulder assembly by removing the 3/8 x 1 SHSS (Item 24, Fig. 25) from the front of the spine box and pulling the assembly up and away from the torso (Fig. 27). When the shoulder is removed, the two clavicle link pivot washers (Item 11, Fig 25), the urethane pivot nut washer (Item 14, Fig. 25), and the pivot nut (Item 9, Fig. 25) will fall from the assembly (Fig. 28).

Fig. 27. Detaching the shoulder assembly


Fig. 28. Shoulder pivot components The shoulder bumper (Item 10, Figure 25), a AU@ shaped black rubber part, can now be removed. These bumpers provide tension for the clavicle link and also aid in noise damping. Next, remove the lower neck bracket from the spine box. To remove the bracket, remove the four 1/4-20 x 3/4 SHCS (Item 28, Figure 25) and washers (see Fig. 29).

Fig. 29. Removing lower neck bracket


Now the ribs can be disassembled. Before disassembling, note the orientation of the rib stiffener strips and the behind rib strips; in particular, recognize that there is a distinct top and bottom to each strip. This orientation is important for proper reassembly of the thorax (Fig. 31). First, detach the rib stiffeners from the bib assembly by removing the twelve 10-32 x 5/8 BHCS (Item 15, Fig. 25) (see Fig. 30). The behind rib strips will fall inside the thorax when these screws are removed. The sternum bib can be removed by pulling upward and allowing the transducer arm ball to fall from the groove in the rear side of the transducer arm slider.

Fig. 30 Removing rib stiffener strips

Fig. 31. Rib stiffener strip identification


Next, remove the twelve 10-32 x 3/8 BHCS (Item 30, Fig. 25) at the rear of the spine box (see Fig. 32). After these screws are removed, the six rib stiffeners and the ribs themselves can be removed. If the individual ribs are not already identified, it is recommended that they be numbered 1 through 6, starting at the top and working down. This will be useful later when reassembling the thorax. When removing the ribs from the thorax, it may be necessary to slightly spread the ribs open to fit them around the spine box. Removing the ribs should be done carefully to insure that they are not opened so wide so as to permanently deform their shape.

Fig. 32. Rib removal The upper rib stops (Item 4, Fig. 25) can now be removed by removing the two 10-32 x 2 SHCS on the left and right sides (see Fig. 33). The lower rib stops (Item 20, Fig. 25) are not recommended to be removed unless the Delrin stops have been damaged.

Fig. 33. Removing upper rib stop


The chest deflection transducer slider can be removed from the bib assembly by removing the twelve 10-32 x 3/4 BHCS (item 25, Fig. 25) (see Fig. 34)

Fig. 34. Chest deflection slider removal Inspection $ Inspect the ribs for any damage. In particular, look for damage to the damping material and

any debonding of the damping material from the steel ribs. Replace any ribs that have suffered significant damage.

$ Using the chest depth gage, check the rib assembly for any permanent deformation (reference Fig. 35 and 36). With the rib cage fully assembled, insert the appropriate side of the gage between ribs #1 and #2. Hold surface A on the handle against the spine box surface to which rib #1 is attached on the spine box. If the end of the depth gage makes contact with the behind rib strip, then the chest depth at rib #1 is not acceptable. Surface B of the depth gage is used similarly to check the depth between ribs #5 and #6. Hold surface B on the handle against the spine box surface to which rib #5 is attached on the spine. If the end of the depth gage makes contact with the behind rib strip, then the chest depth at rib #6 is not acceptable. Ribs of unacceptable depth must be replaced.

$ Check for the presence of all four sternum stops (see Fig. 37). If a sternum stop is loose, damaged, or lost, it can be replaced. The stops can be glued in place using epoxy cement. When replacing stops, be sure that they are in the proper position and do not interfere with the motion of the chest deflection transducer assembly.

Fig. 35. Chest depth gage


Fig. 36. Checking rib assembly for permanent deformation Fig. 37. Location of the four sternum stops


Reassembly $ Reattach the upper rib stops if they have been removed. $ Reattach the ribs and ribs stiffeners to the back of the spine box. There are several important

aspects to this procedure: $ Make sure that the proper rib is attached at the proper location; rib #1 is the upper most

rib and rib #2 is second from the top and so on. $ The rib stiffeners must be installed such that the beveled ends of the stiffeners face the

ribs (see Fig. 38). Failure to install the rib stiffeners in the proper orientation will result in improper thoracic response to impacts.

$ Use the correct size fastener to mount the ribs and rib stiffeners to the spine box. The correct fasteners are the 10-32 x 3/8 BHCS.

$ Reattach the chest deflection transducer slider to the bib assembly using the twelve 10-32 x 3/4 BHCS. Insert the ball of the chest transducer assembly into the groove in the rear side of the transducer arm slider. Then reattach the bib assembly to the ribs. During installation of the stiffener strips and the behind rib strips, make sure that the proper orientation of these units is maintained (refer back to Fig. 31).

$ Reattach the lower neck bracket using the 1/4-20 x 3/4 SHCS. $ Install the shoulder bumpers, the Delrin clavicle link washers, urethane pivot nut washer, and

the pivot nut. The Delrin clavicle link washers have a machined flat on the outside radius. This flat must mate with the flat on the other clavicle link washer for the opposite shoulder assembly in order to assemble the shoulders properly.

$ Install the shoulder assembly to the spine box. A small C-clamp will be needed to compress the shoulder bumper enough to allow for insertion of the shoulder screw (see Fig. 39). Be careful not to apply too much pressure to the shoulder as this could cause the aluminum casting to crack.

$ Place the chest jacket on the upper torso. $ Reattach the arm assemblies to the upper torso. Be certain to assemble the washers and

bushings in the shoulder in the proper orientation (refer to the Arm Assembly section if needed).


Fig. 38. Orientation of rib support with respect to the rib and spine box.

Fig. 39. Using a C-clamp to compress the clavicle bumper


Thoracic Instrumentation The thorax contains provisions for the following instrumentation: $ chest CG triaxial array $ sternum-mounted uniaxial accelerometers $ spine-mounted uniaxial accelerometers $ chest deflection transducer $ thoracic spine load cell This section will discuss only the details of the sternum-mounted uniaxial accelerometers. The chest CG triaxial array, spine-mounted uniaxial accelerometers, chest deflection transducer, and thoracic spine load cell will be covered in the Chest Deflection and Transducer Assembly section. Sternum-mounted Uniaxial Accelerometers The front of the chest deflection transducer slider contains provisions for mounting three uniaxial accelerometers (SA572-S4). Each accelerometer is mounted to the slider using two 0-80 x 1/8 SHCS. The chest deflection transducer slider contains integral cable routing channels. These channels provide an indication of the orientation of the accelerometers. Fig. 40 has also been included to document the orientation of the accelerometers.

Fig. 40. Orientation of sternum-mount accelerometer


CHEST DEFLECTION AND TRANSDUCER ASSEMBLY Description

Part Number

Figure

Number

Item

Number Spine Mounting Assembly

880105-1040

41

1

Load Cell Mount

880105-326

41

2

Thoracic Spine Load Cell Structural Replacement

880105-328

41

3

Chest Accelerometer Mounting Bracket

880105-329

41

4

Transducer Arm Assembly

880105-1071

41

5

Molded Stop Assembly

78051-85

41

6

Chest Accelerometer Mount

H350-1006

41

7

Chest Deflection Transducer Slider

880105-1050

41

10

SSCP, 4-40 x 3/16

78051-334

41

11

Potentiometer

SA572-S51

41

12

Potentiometer Bracket

78051-354

41

13

Arm Connector

78051-355

41

14

SHCS, 10-24 x 5/16

9000031

41

15

SHCS, 5/16-18 x 2

9000489

41

18

BHCS, 1/4-20 x 2

9000407

41

19

Chest Accelerometers

SA572-S4

n/a

n/a


SA572-S80

n/a

n/a

Spine Accelerometers

SA572-S4

n/a

n/a

Thoracic Spine Load Cell

SA572-S28

n/a

n/a


Fig. 41. Chest deflection assembly To disassemble the chest deflection transducer assembly, the upper torso must first be separated from the lower torso. This is accomplished by removing the four 1/4-20 x 5/8 SHCS (item 16, Fig. 25) at the top of the lumbar spine mounting assembly (Fig. 42).

Fig. 42. Separating the upper and lower torso With these four bolts removed, the upper torso can be lifted off of the lower torso. If the spine mounted accelerometers are installed, remove them now. This is done by removing the two 4-40 x 1/4 SHCS that hold each of the three accelerometer mounting plates to the spine box (refer to the Instrumentation instructions at the end of this section for more details).


Next, remove the six 5/16-18 x 2 SHCS (item 29, Fig. 25) that appear on the sides of the spine box (Fig. 43).

Fig. 43. Removing the spine box from the spine tower. With these six bolts removed, the adapter assembly (sometimes referred to as the spine tower) can now be removed from the spine box. The adapter assembly includes the spine mounting assembly, the thoracic load cell or load cell simulator, and the chest accelerometer mount bracket. The chest accelerometer triaxial array, if installed, can be disassembled by removing the four 10-24 x 2 SHCS that hold the chest accelerometer mount to the accelerometer bracket (Fig. 44).

Fig. 44. Removing the chest accelerometer mount


Remove the four 10-24 x 5/16 SHCS (Item 15, Fig. 41) that hold the chest accelerometer mounting bracket to the load cell or structural replacement (Fig. 45).

Fig. 45. Chest accelerometer mounting bracket removal

The adapter assembly can be disassembled by first removing the four 5/16-18 x 2 SHCS (Item 18, Fig. 41) that attach the load cell or structural replacement to the spine mounting assembly. These fasteners are located at the bottom of the adapter assembly (Fig. 46)

Fig. 46. Detaching the adaptor assembly


Next, remove the chest deflection transducer assembly. This is accomplished by removing the 1/4-20 x 2 BHCS (item 19, Fig. 41) that secures the potentiometer bracket to the spine mounting assembly (Fig. 47).

Fig. 47. Removing the chest deflection transducer assembly

The transducer arm assembly can be removed by loosening the 4-40 SSCP (item 11, Fig. 41) in the potentiometer connector (Fig. 48).

Fig. 48. Detaching the transducer arm assembly


Remove the potentiometer from the potentiometer bracket by loosening the jam nut (item 8, Fig. 41) (Fig. 49).

Fig. 49 Removing the potentiometer from the bracket. Inspection $ Inspect for the presence of and the condition of the sternum stops. If they are missing or

damaged, replace them. The sternum stops can be reattached using an epoxy cement. $ Inspect the chest deflection potentiometer by rotating the pot arm through its range of motion.

The motion should feel smooth and free of restrictions; if it does not feel smooth, have it inspected by an electronics technician.

Reassembly $ Slide the potentiometer body into the bracket, making sure that the roll pin in the bracket is

properly aligned on the potentiometer body. This insures that the potentiometer body will not turn. Tighten the jam nut.

$ Reattach the transducer arm to the arm connector. $ Reattach the potentiometer bracket to the adapter assembly. $ Reattach the chest accelerometer mounting bracket to the load cell simulator. $ Install the chest accelerometer mounting block to the mounting bracket. If installing

accelerometers, make sure that the accelerometers are properly oriented (reference Fig. 50). $ Reattach the load cell simulator to the spine mounting assembly. If the thoracic spine load cell

is being installed, position the transducer so that the cables are toward the rear of the spine box (Fig. 53). This will help to prevent damage to the cables when inserting the adapter assembly into the spine box (next step).

$ Place the adapter assembly inside the spine box. Align the holes in the thoracic load cell or load cell simulator with the holes in the spine box and insert the six 5/16-18 x 2 SHCS. Tighten the bolts only after all six have been aligned and started.

$ Install the three spine mounted accelerometers if needed. $ Place the thorax on the upper torso and reattach it to the lumbar spine mount assembly using

the four 1/4-20 x 5/8 SHCS.


Instrumentation The chest deflection assembly contains provisions for the following instrumentation: $ chest CG triaxial accelerometer array $ spine-mounted uniaxial accelerometers $ chest deflection transducer $ thoracic spine load cell Chest CG Triaxial Accelerometer Array First attach the individual accelerometers (SA572-S4) to the S4 Triaxial Accelerometer Mounting Block (SA572-S80) using two 0-80 x 1/8 SHCS. The accelerometers are mounted to the block such that an imaginary axis passing through their seismic masses and along the direction of primary sensitivity would intersect at a single point. Next, attach the mounting block to the chest accelerometer mount (H350-1006). Next, attach the chest accelerometer mount to the chest accelerometer bracket. Figure 50 shows the chest CG triaxial accelerometer array mounted to the chest accelerometer bracket in the proper orientation. Fig. 50. Orientation of the chest triaxial accelerometer array. Spine-mounted Uniaxial Accelerometers The front of the spine box contains provisions for mounting three uniaxial accelerometers (SA572-S4). Each accelerometer is mounted to the appropriate accelerometer mounting plate using two 0-80 x 1/8 SHCS. Next, the mounting plates are attached to the spine box using two 4-40 x 1/4 SHCS in the orientation shown in Figures 51 and 52. It is recommended that particular attention be given to the location and orientation of each of the three spine accelerometer mounting plates so that they are reassembled properly. Although they appear to be similar, each one is unique. All three accelerometers are mounted such that their direction of positive polarity are towards the posterior of the dummy.


Fig. 51. Spine-mounted accelerometer Fig. 52 Close-up of spine-mounted accelerometers to demonstrate orientation


Chest Deflection Transducer In general, the chest deflection transducer remains installed in the dummy and is typically only removed for calibration and/or inspection purposes. Refer back to the appropriate section for details on removing and installing the chest deflection transducer. Thoracic Spine Load Cell Attach the thoracic spine load cell to the load cell mount using the four 5/16-18 x 2 SHCS. Be sure that the instrumentation cables are oriented such that they are facing the rear side of the dummy (Fig. 53). Fig. 53. Thoracic spine load cell.


SHOULDER ASSEMBLY Description

Part Number

Figure Number

Item Number

Clavicle Link

880105-334 (left), -335 (right)

54

1

Clavicle (machined)

880105-336 (left), -337 (right)

54

2

Clavicle Stop Spring

880105-338

54

3

Clavicle Spacers

880105-339

54

4

SHCS, 10-24 x 3/8

900487

54

5

Shoulder Stop Assembly

880105-344

54

6

Clavicle Stop Spring

880105-338

55

5

Clavicle Spacers

880105-339

55

6

Shoulder Yoke

880105-343

55

7

Steel Stop

880105-346

55

9

Shoulder Stop Assembly

880105-347

55

10

Shoulder Yoke Pivot Bushing

880105-348

55

11

Shoulder Yoke Pivot Washer

880105-349

55

12

Retaining Washer

880105-350

55

13

Shoulder Joint Spring Washer

880105-351

55

14

Steel Washer

880105-352

55

15

Clavicle Link Washer

880105-367

55

16

SHSS, 3/8 x 1

9000074

55

17

SHCS, 6-32 x 2

900119

55

18

SHCS, 10-24 x 3/8

9000487

55

19

Lock Nut, 5/16-18

9000656

55

20

Clavicular Link Bearing

880105-357

55

21


Fig. 54. Clavicle Assembly

Fig. 55. Clavicle assembly section view


Instructions for removing the clavicle from the upper torso are contained in the Thorax section; refer to that section if necessary. Remove the 3/8 x 1 SHSS (item 17, Fig. 55) to separate the clavicle link from the clavicle (Fig. 56). After removing the shoulder screw and pulling the two pieces apart, the two clavicle spacers (Item 4, Fig.54) and the urethane spring stop (Item 3, Fig. 54) can be removed from the assembly. Figure 57 below shows the spacers and spring stop.

Fig. 56. Separating the clavicle link from the clavicle

Fig. 57. Clavicle link spacers, spring stop, and shoulder screw Next, remove the shoulder yoke by loosening the 5/16-18 lock nut (item 20, Fig. 55) located inside the machine clavicle (Fig. 58). The shoulder yoke can then pulled away from the machined clavicle. After the shoulder yoke is removed the steel shoulder yoke washer (item 15, Fig. 55), retaining washer (item 13, Fig. 55), and urethane spring washer (Item 14, Fig. 55) will be free to be removed from the machined clavicle as well. Fig. 59 below shows the various clavicle components.


Fig. 58. Removing the shoulder yoke

Fig. 59. Components of the clavicle The steel stop (Item 9, Fig. 55) on the shoulder yoke can be disassembled by removing the two 6-32 x 2 Nylok SHCS (Fig. 60). The steel stop works in conjunction with the stop assembly mounted to the machined clavicle to control the range of motion of the arm.

Fig. 60. Removing the steel stop from the shoulder yoke.


Inspection $ Inspect the plastic and Delrin pieces - the shoulder yoke pivot washer and bearing, and the

clavicle spacers - for damage. Also inspect the urethane pieces - the clavicle stop spring and the shoulder yoke spring washer. Replace any pieces which are damaged.

$ Inspect the clavicle link and machined clavicle castings for structural damage and cracking. Replace any casting that is damaged.

Reassembly $ Reattach the steel stop to the shoulder yoke if it was removed. $ Install the shoulder yoke bushing and washer on to the two dowel pins which are pressed into the

machined clavicle. $ Replace the shoulder yoke retaining washer, urethane spring washer, and steel shoulder yoke

washer into the machined clavicle. Insert the shoulder yoke and align the holes in the retaining washer with the press pins in the shoulder yoke. Reattach the 5/16-18 lock nut to the shoulder yoke.

$ If removed, replace the urethane spring stop into the clavicle link. Place the two Delrin clavicle spacers onto the machined clavicle and attach the machined clavicle to the clavicle link with the 3/8 x 1 SHSS.


ARM ASSEMBLIES Description

Part Number

Figure Number

Item Number

Upper Arm Molded Assembly

880105-700

61

1

Elbow Washer

880105-708

61

2

Elbow Bushing

880105-709

61

3

Elbow Pivot Nut

880105-710

61

4

Elbow Pivot Washer

880105-711

61

5

Lower Arm Molded Assembly

880105-712

61

6

Wrist Rotation Assembly

880105-718

61

7

Hand Assembly

880105-722 (left), -723 (right)

61

8

Upper Arm, Lower Part

880105-705

61

9

SHCS, 3/8-16 x 1

9000079

61

10

SHSS, 3/8 x 1

9000074

61

12

SHSS, 5/16 x 3/4

9000578

61

13

Washer

880105-351

61

14


Fig. 61. Arm assembly


If the arms have not already been detached from the upper torso, remove them now (refer back to the Thorax section if needed). Begin by separating the arm into its upper and lower portions. This is done by removing the 3/8 x 1 SHSS (item 12, Fig. 61) at the elbow joint (see Fig. 62). Pay attention to the configuration of the components in the elbow joint so that they can be reassembled properly later (Fig. 61 and 63).

Fig. 62. Removing the elbow pivot bolt

Fig. 63. Components of the elbow joint


Detaching the hand from the lower arm is achieved by removing the 3/8-16 x 1 SHCS (Item 10, Fig. 61) at the base of the hand (see Fig. 64).

Fig. 64. Removing wrist from lower arm Next, the wrist rotation assembly (Item 7, Fig. 61) can be detached from the lower arm, as well, by removing the 5/16 x 3/4 SHSS (Item 13, Fig. 61) located at the wrist end of the lower arm (see Fig. 65).

Fig. 65. Removing wrist rotation assembly


In the upper arm near the elbow exists a feature which allows the lower arm to rotate relative to the upper arm. This feature, referred to as the upper arm lower part (Item 9, Fig. 61), can be detached by removing the 5/16 x 1-1/4 SHSS from the upper arm (Fig. 66). The upper arm lower part can then be pulled away from the upper arm through the arm flesh.

Fig. 66. Removing upper arm lower part Inspection $ Inspect the arm flesh for damage. If the damage is minor, repair the flesh referring to

Appendix A. For more significant damage, the arm may be returned to the manufacturer for remolding.

$ Inspect the washers and bushing of the elbow joint, replacing any part that has sustained serious damage.

Reassembly $ Reattach the wrist rotation assembly to the wrist end of the lower arm. $ Reattach the hand to the wrist rotation assembly. $ Reattach the upper arm lower part to the elbow end of the upper arm. $ Finally, reattach the lower arm to the upper arm. Pay close attention to reassemble all of the

washers and bushings in the proper order (refer to Figs. 61 and 63). Proper assembly of this joint is critical to its performance.


LOWER TORSO Description

Part Number

Figure

Number

Item

Number Molded Pelvic Assembly

880105-440

67

1

Molded Lumbar Spine

880105-1095

67

2

Spine Cable

880105-404

67

3

Lumbar-Thorax Adapter

880105-405

67

4

Lumbar-Pelvic Adapter

880105-1094

67

5

Abdominal Insert

880105-434

67

6

SHCS, 5/16-18 x 5/8

9000142

67

7

SHCS, 1/4-20 x 5/8

9000144

67

8

SHCS, 5/16-18 x 7/8

9000476

67

9

Jam Nut, 2 - 20

9000018

67

10

Accelerometer Mount

1200056

67

11

SHCS, 10-24 x 2

9000624

67

12

Pelvic Plunger Set Screw

1200050

67

13

Femur with Bumper

880105-420 left, -421 right

67

14

Modified Screw

880105-1101

67

15

Anterior Superior Iliac Spine Load Cell Simulator

880105-432-1 left, -2 right

67

16

SHCS, 3/8-24 x 3/4

9000750

67

17

Lumbar Cable Insert, Upper

180-2005

67

18

Lumbar Cable Insert, Lower

180-2004

67

19

Femur Bumper

880105-426 left, -427 right

67

20

Pelvis Accelerometer

SA572-S4

n/a

n/a


SA572-S80

n/a

n/a

Iliac Spine (A.S.I.S.) Load Cells

SA572-S16

n/a

n/a


Fig. 67. Pelvis Assembly


Description

Part Number

Figure Number

Item Number

Upper Lumbar Cable Insert

180-2005

68

1

Lower Lumbar Cable Insert

180-2004

68

2

Lumbar Pad

880105-1091

68

3

SHCP, 1/4-20 x 3/4

9000454

68

4

Lumbar Spine Load Cell

SA572-S15

n/a

n/a

Fig. 68. Lumbar spine assembly, lumbar-thorax adaptor, and lumbar-pelvic adaptor


Lumbar Spine The first step in disassembling the lower torso is to remove the lumbar spine assembly, lumbar-thorax adapter, and lumbar-pelvic adapter. Remove the two 5/16-18 x 5/8 SHCS (Item 7, Fig.67) located at the base of the spine, inside the abdominal insert area (see Fig. 69)

Fig. 69. Removing lumbar-pelvic adaptor. Next, remove the two 5/16-18 x 7/8 SHCS (Item 9, Fig. 67) which are located inside the pelvic instrumentation cavity at the rear of the pelvis (see Fig. 70). The lumbar spine assembly, lumbar-thorax adapter, and lumbar-pelvic adapter can now be removed from the pelvis.

Fig. 70. Removing lumbar-pelvic adaptor


Detach the lumbar spine assembly (item 2, Fig. 67) from the lumbar-pelvis adapter (item 5, Fig. 67) by removing the four 1/4-20 x 3/4 SHCS (item 4, Fig. 68) (see Fig. 71).

Fig. 71. Detaching the lumbar spine from the Pelvic adapter

Next, separate the lumbar spine assembly from the lumbar-thoracic adapter (item 4, Fig. 67). First remove the two 1/4-20 x 5/8 SHCS (item 8, Fig. 67) (see Fig.72). Then remove the 2-20 jam nut (item 10, Fig. 67). The lumbar thoracic-adapter and the upper lumbar cable insert (item 1, Fig. 68) will be free from the assembly

Fig. 72. Detaching the thoracic adapter plate from the lumbar spine

The cable (item 3, Fig. 67) can now be removed from the lumbar spine. Finally, remove the lower lumbar cable spine insert (item 2, Fig. 68) from the lumbar spine.


Fig. 73 below shows the various components of the lumbar spine assembly.

Fig. 73. Components of the lumbar spine assembly and lumbar-thoracic adaptor


Inspection $ Inspect the lumbar spine for cracking in the molded rubber; replace it if damaged. $ Inspect the upper and lower cable spine inserts for any damage; replace them if damaged. $ Inspect the lumbar spine cable for broken or frayed wires; replace it if damaged. $ Inspect the lumbar-pelvis adapter for presence of the lumbar pad (item 3, Fig. 68). The lumbar

spine pad is important for preventing electronic noise caused by the spine cable contacting the lumbar-pelvis adapter.

Fig. 74. Lumbar pad removed from lumbar-pelvis adapter Reassembly $ Install the lower lumbar cable insert in the lumbar spine. $ Insert the spine cable into the lumbar spine. $ Place the lumbar-thoracic adapter over the threaded end of the spine cable. Place the upper

lumbar cable insert onto the threaded end of the spine cable and insert it through the lumbar thoracic adapter and into the lumbar spine. Install the two 1/4-20 x 5/8 SHCS that hold the lumbar thoracic adapter to the lumbar spine.

$ Fasten the 2-20 jam nut to the threaded end of the spine cable. The jam nut should be torqued to 11 +/- 1 in-lbs during assembly and should be checked before using the dummy for testing. Note: The spine cable nut should not be left torqued when the dummy is in storage. This may cause permanent deformation to the spine.

$ Make certain that the lumbar spine pad is installed in the lumbar-pelvic adapter. Reattach the lumbar-pelvic adapter to the lumbar spine using the four 1/4-20 x 3/4 SHCS.

Instrumentation The lower torso contains provisions for the following instrumentation: $ lumbar spine load cell $ anterior superior iliac spine (ASIS) load cells $ pelvis triaxial accelerometer array The details for installing the lumbar spine load cell will be discussed here; the ASIS load cells and pelvis triaxial array will be handled in the pelvis section.


Lumbar Spine Load Cell These instructions assume that the lumbar-pelvic adapter has already been removed from the lower torso. If it has not already been removed, remove it now referring back the appropriate section. Attach the lumbar spine load cell to the molded lumbar spine assembly using the four 1/4-20 x 3/4 SHCS. Next, attach the load cell to the pelvic assembly using the two 5/16-18 x 5/8 SHCS in the front and the two 5/16-18 x 7/8 SHCS in the rear. Fig. 75 demonstrates the proper orientation of the lumbar load cell with respect to the pelvis assembly.

Fig. 75. Lumbar spine load cell


PELVIS The femurs can be removed from the lower torso; however, due to the difficult nature of the task, it is recommended that they only be removed when damage to the femur is suspected. The first step in removing the femurs from the lower torso is to loosen the femur plunger set screws (item 13, Fig. 67). These screws are located in the abdominal insert area (Fig. 76) and are used to adjust the femur joint to the ‘one G’ specification for testing (see Appendix B). The femur flange is disassembled from the pelvis bone by removing the three 10-24 x ½ SHCS (Item 12, Fig. 67). These screws are located in the access holes on the sides of the pelvis (see Fig. 77).

Fig. 76. Loosening femur plunger set screw

Fig. 77. Removing femur flange from pelvis


With these three screws removed, the femurs can be removed from the pelvis flesh. Removing the femur is a difficult task and requires use of a tool which simulates the upper leg bone (Fig. 79). First detach the leg assemblies by removing the femur bolt (p/n 880105-1101) from each femur (see Fig. 78). Once the femur bolt has been removed, pull the leg assemblies from the femur . Attach the femur removal tool (Fig. 79) to the femur using the femur bolt. Use the tool to pull the femur from the pelvis flesh.

Next, detach the anterior superior iliac spine (ASIS) load cell simulators (Item 16, Fig. 67) from the pelvis. Each ASIS load cell simulator is held in place with two 3/8-24 x 3/4 SHCS (Item 17, Fig. 67). To remove theses fasteners, use the access ports located on the rear side of the pelvis (see Fig. 80).

Fig. 78. Removal of the femur bolt

Fig. 79. Typical femur removal tool


The ASIS load cell simulators can then be removed by guiding them out of the pelvis flesh, through the rectangular cut-out sections provided (see Fig. 81) H-Point Features The “H-Point” is a dummy reference point which is commonly used for positioning the dummy in a test vehicle seat. The “H-Point” represents the location of the centerline for both the right and left

Fig. 80. Removing the ASIS load cell simulator bolts

Fig. 81. Removal of ASIS load cell simulator from pelvis assembly


hip sockets. A square hole is present in the pelvis assembly which can be used for determining the location of the H-point. The H-point is located 68 mm (2.69 in) forward and 59 mm (2.33 in) below the center of the square hole (see Fig. 82). In practice, it is common to use an H-point tool (TE-2504) for finding the dummy’s H-point (see Fig. 83). The tool is also useful for determining the pelvic angle.

Fig. 82 Location of H-point Inspection • Inspect the pelvis flesh for cracks and/or tears; repair damaged flesh (reference Appendix A). • Inspect the pelvis plunger set screws for the presence and condition of the nylon which push

down on the femur to achieve the 1G torque setting. If the nylon is damaged, replace the pelvic plunger set screws.

Fig. 83. H-point tool


Reassembly • If the femurs have been removed, reattach them first. Insert the femurs through the pelvis flesh.

Fasten the femur flange to the pelvis bone using the three 10-24 x ½ SHCS. • Reassemble the ASIS structural replacements. Insert the structural replacements into the pelvis

through the rectangular cut-out section in the abdominal area of the pelvis. Install the 3/8-24 x 3/4 SHCS (two for each ASIS structural replacement).

• Reassemble the femur plunger set screws if they have been removed from the pelvis. Instrumentation The pelvis contains provisions for the following instrumentation: • Anterior Superior Iliac Spine (ASIS) Load Cells • Pelvic Triaxial Accelerometer Array Anterior Superior Iliac Spine (ASIS) Load Cells Begin by removing the ASIS structural replacements (refer back to the appropriate section if needed). Insert the ASIS load cell through the rectangular cut-out section in the abdominal area of the pelvis such that the cables are facing toward the interior of the dummy’s abdomen (Fig. 84). Install the 3/8-24 x 3/4 SHCS (two for each ASIS load cell).

Fig. 84. ASIS Load Cell


Pelvic Triaxial Accelerometer Array First attach the individual accelerometers (SA572-S4) to the S4 Triaxial Accelerometer Mounting Block (SA572-S80) using two 0-80 x 1/8 SHCS. The accelerometers are mounted to the block such that an imaginary axis passing through their seismic masses and along the direction of primary sensitivity would intersect at a single point. Next, attach the mounting block to the pelvic accelerometer mount (part number 1200056) (Fig. 85) . Insert the pelvic accelerometer mount into the pelvic cavity and attach the mount using the 3/8-16 x 3/4 SHCS (Fig. 86). Cover the pelvic cavity with the cover plate, routing the cable wires out through the access hole provided and using the 10-24 x ½ SHCS to attach the cover. Fig. 85. Orientation of pelvic accelerometer in mounting Bracket

Fig. 86. Pelvic accelerometers installed into pelvis cavity


LEG ASSEMBLY Description

Part Number

Figure Number

Item Number

Upper Leg Weldment

880105-502 (left), -503 (right)

87

1

Upper Leg Flesh

880105-530L (left), -530R (right)

87

2

SHCS, 3/8-16 x 1-1/2

9000479

87

3

Sliding Knee Assembly

880105-528L (left), -528R (right)

87

4

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

9000449

87

5

Femur Load Cell Simulator

78051-319

87

6

FHCS, 10-32 x 3/8

9000249

87

7

Lower Leg Structural Replacement

880105-603

87

8

Lower Leg Flesh

880105-601

87

9

Bolt, Ankle to Leg

A-1887

87

10

Ankle Assembly

880105-660

87

11

Ankle Bumper Assembly

880105-631

87

12

SHSS, 1/4 x 5/8

9000619

87

13

Foot Assembly

880105-650 (left), -651 (right)

87

14

Single Axis Femur Load Cell

SA572-S14

n/a

n/a

Multi-axis Femur Load Cell

SA572-S29

n/a

n/a


Fig. 87. Leg assembly


The leg assemblies should already be removed from the lower torso assembly; if not, remove them by removing the femur bolt (p/n 880105-1101) from each leg (reference Fig. 78). Begin by separating the leg into its upper and lower segments. This is done by removing the eight 10-32 x 3/8 FHCS (Item 7, Fig. 87) (four on each side of the knee) found at the knee joint (see Fig. 88).

Fig. 88. Separating leg into upper and lower segments Next, separate the upper leg weldment from the femur load cell structural replacement by removing the 3/8-16 x 1-2 SHCS (Item 3, Fig. 87) that connects the two items (see Fig. 89).

Fig. 89. Detaching upper leg from femur load cell replacement


Now the knee can be separated from the femur load cell structural replacement. This is done by removing the 3/8-16 x 1-3/4 SHCS (Item 5, Fig. 87) located nearest the knee (see Fig. 90). Figure 91 demonstrates the various components of the upper leg.

Fig. 90. Detaching knee from load cell replacement

Fig. 91. Components of the upper leg and knee Inspection $ Inspect the upper leg flesh for damage. The flesh can be removed from the upper leg by pushing

the upper leg weldment out at the end that attaches to the pelvis. If the flesh has sustained minor damage, repair it by referring to Appendix A. If the damage is beyond repair, replace it with a new unit.

Reassembly $ Reattach the femur load cell structural replacement to the knee using the 3/8-16 x 1-3/4 SHCS.

Pay attention to use the correct bolt. $ If the upper leg flesh was removed, replace it on the upper leg weldment. $ Reattach the upper leg to the femur load cell structural replacement using the 3/8-16 x 1-1/2

SHCS. $ Reattach the upper and lower leg segments using the eight 10-32 x 3/8 FHCS.


Instrumentation The leg contains provisions for mounting a femur load cell. There are two type of femur load cells: the single axis femur load cell (SA572-S14) and the multiple axis femur load cell (SA572-S29). Both load cells are installed in the same manner. Femur Load Cell Remove the femur load cell structural replacement. Insert the femur load cell into the knee in the orientation shown in Fig. 92. Reinstall the 3/8-16 x 1-3/4 SHCS. Insert the opposite of the load cell into the upper leg weldment and reinstall the 3/8-16 x 1-1/2 SHCS.

Fig. 92. Femur load cell


KNEE ASSEMBLY Description

Part Number

Figure Number

Item Number

Knee Flesh

880105-508

93

1

Knee Insert

880105-511

93

2

Machined Knee Cap

880105-510

93

3

Knee Slider Assembly, Right

880105-67

93

4

Linear Pot Shaft Support, Right

880105-515-02

93

6

Rotation Stop Arm

880105-526

93

8

Rotation Stop Cover

79051-34

93

9

Shoulder Bolt

880105-527

93

10

Washer

79051-32

93

11

Compression Washer

79051-33

93

12

BHCS, 8-32 x 2

9000076

93

13

SHCS, 8-32 x 2

9000516

93

14

Potentiometer Shaft Pin

79051-19

93

15

Potentiometer

SA572-S52

93

16

RDMS, 1-72 x 5/8

9000340

93

17


Fig. 93. Knee Assembly


Detach the knee slider assembly (Item 4, Fig. 93) from the knee by removing the modified shoulder bolt (Item 10, Fig. 93) (see Fig. 94).

Fig. 94. Knee slider removal This modified shoulder bolt controls the 1G joint torque setting for the knee joint (refer to Appendix B). Once removed, the inboard and outboard halves of the knee slider will be free of the knee cap. The outboard slider contains a steel washer (item 11, Fig. 93) and two compressible spring washers (item 12, Fig. 93). Be careful not to lose these parts as they are critical to achieving the 1G joint torque setting. The various components of the knee assembly are shown in Fig. 95 below.

Fig. 95. Components of the knee assembly


Located between the knee flesh and the machined knee cap is the knee insert (Item 2, Fig. 93). The knee insert is critical to the system performance in the knee impact calibration test. It can be accessed by removing the knee flesh from the knee cap. Inspection $ Inspect the knee insert for any damage. If it is damaged, replace it. $ Inspect the knee flesh for any damage. Repair all minor damage (reference Appendix A). If the

damage is significant, have the knee flesh replaced with a new one. Reassembly $ If the knee insert was removed, reinstall it now. Make sure that the knee insert is properly

installed and fully seated inside the knee flesh. $ Reattach the knee slider assembly using the knee joint shoulder screw. Make sure that the

compression washers and steel washer are present and in the right positions. The compression washers go into the outboard slider first; the steel washer fits directly under the head of the knee joint shoulder screw.


LOWER LEG Description

Part Number

Figure Number

Item Number

Lower Leg Weldment

880105-628

96

1

Dowel Pin, 1/8 x 3/8

9000046

96

2

Knee Clevis Assembly

880105-622

96

3

SHCS, 1/4-28 x 2

9000115

96

4

Fig. 96. Lower leg structural replacement Detach the ankle/foot assembly from the lower leg by removing the modified shoulder bolt located at the ankle (Item 10, Fig. 87) (see Fig. 97).

Fig. 97. Detaching the ankle/foot assembly


With the modified shoulder bolt removed, the ankle/foot assembly will slide off the lower portion of the lower leg. Remove the flesh from the lower leg structural replacement. This is best accomplished by pulling on the knee clevis while holding the flesh. Fig. 98 below shows the flesh being removed from the structural replacement.

Fig. 98. Removing flesh from the lower leg structural replacement The knee clevis can be detached from the lower leg by removing the four 1/4-28 x 2 SHCS (Item 4, Fig. 96) (see Fig. 99).

Fig. 99. Detaching the knee clevis


Inspection Inspect the lower leg flesh for any damage. Repair all minor damage (reference Appendix A). If the damage is significant, have the lower leg flesh replaced with a new one. Reassembly $ Attach the knee clevis to the lower leg using the four 1/4-28 x 2 SHCS. $ Reassemble the lower leg structural replacement into the lower leg flesh. Insert the ankle end of

the structural replacement into knee of the flesh. Continue to push the structural replacement until it is completely inside the flesh. If necessary, a small amount of talcom powder may be used to assist in the procedure.

$ Reattach the ankle/foot assembly to the lower leg using the modified shoulder bolt. Instrumentation Instrumented lower legs are commercially available for optional use in the lower leg assembly. The instrumented lower leg replaces the lower leg structural replacement in the assembly. Simply insert the instrumented lower leg into the flesh and attach the ankle/foot assembly. A picture of the instrumented lower leg appears in Fig. 100.

Fig. 100. Instrumented lower leg


ANKLE/FOOT ASSEMBLY Description

Part Number

Figure Number

Item Number

Ankle, Upper Shell

880105-609

101

1

Ankle, Lower Shell

880105-633

101

2

Ankle Shaft

880105-615

101

3

Stop Pin Retainer

880105-626

101

4

Dowel Pin, 3/16 x 3/8

9000044

101

5

Ankle Friction Pad

A-1888

101

6

SSCP, 5/16-18 x 3/8

9000073

101

7

SSCP, 8-32 x 1/4

9000452

101

8

BHCS, 6-32 x 2

9000247

101

9

Ankle to Leg Attachment Bolt

A-1887

101

10

FHCS, 6-32 x 2

9001279

101

11

SSCP, 5/16-18 x 3/8

9000073

101

12


Detach the foot from the ankle by removing the 1/4 x 5/8 SHSS (item 13, Fig. 87).

Fig. 102. Detaching the ankle assembly from the foot Next disassemble the ankle. Begin by loosening the 5/16-18 x 3/8 SSCP (item 12, Fig. 101). This set screw, in conjunction with the ankle friction pad, provides the joint torque for the ankle joint. It is used for setting the 1G joint torque requirement (see Appendix B).

Fig. 103. Loosening the ankle friction set screw


Next, remove the four 6-32 x 2 BHCS (item 9, Fig. 101) that hold the ankle bumper (item 12, Fig. 87) to the lower ankle shell (see Fig. 104). With these four fasteners removed, the ankle bumper can now be removed.

Fig. 104. Removing the ankle bumper

Releasing the pressure on the two 8-32 x 1/4 SSCP set screws (item 8, Fig. 101) will allow the brass stop pin retainer (item 4, Fig. 101) to be removed from the upper ankle shell. The 3/16 x 3/8 dowel pin (item 5, Fig. 101) can also be extracted now. Remove the three 6-32 x 2 FHCS (item 11, Fig. 101) and the lower ankle shell can now be separated from the upper ankle shell. The ankle shaft (item 3, Fig. 101) is now free to be removed. The various components of the ankle assembly are displayed in Fig. 105 below.

Fig. 105. Component of the ankle assembly


The foot is comprised of two basic components: the molded foot assembly and the Ensolite heel pad. The heel pad can be removed for inspection by simply sliding it out the side of the foot (Fig 106).

Fig. 106. Foot heel pad Inspection $ Inspect the ball-end of the ankle shaft and the hemispherical portions of the upper and lower

ankle shells for any damage or galling. Any damage in these areas can cause problems with proper ankle joint torque. Replace any damaged parts.

$ Inspect the ankle friction pad (item 5, Fig.101) for presence and condition. This item also plays an important role in determining the proper joint torque.

$ Inspect the ankle bumper for any damage; replace it if damaged. $ Inspect the foot for the presence and condition of the heel pad. If the heel pad is damaged,

replace it with a new one. Reassembly $ Insert the ankle shaft into the upper ankle shell. $ Insert the 3/16 x 3/8 dowel pin into the upper ankle shell and align it into the slot in the ankle

shaft. $ Place the lower ankle shell over the ankle shaft and assemble the lower shell to the upper shell

using the three 6-32 x 2 FHCS. $ Insert the stop pin retainer into the upper ankle shell and fasten it in place using the two 8-32 x

1/4 SSCP. $ Install the ankle bumper using the four 6-32 x 2 BHCS. $ Make certain that the ankle friction pad is inserted into the upper ankle shell and tighten the 5/16-

18 x 3/8 SSCP until the proper joint torque is achieved (reference Appendix B).


EXTERNAL DIMENSIONS 1. Remove the dummy=s chest jacket and the abdominal insert. 2. Seat the dummy on a flat, rigid, smooth, clean, dry, horizontal surface as shown in Fig. 107.

The seating surface must be at least 406 mm (16 in) wide and 406 mm (16 in) deep, with a vertical section at least 406 mm (16 in) wide and 914 mm (36 in) high attached to the rear of the seating fixture. The dummy=s midsaggital plane is vertical and centered on the test surface.

3. Remove the four 1/4-20 x 5/8 SHCS that attach the lumbar spine to the thoracic spine. Lift the upper torso off of the lower torso. Check the torque on the 2 - 20 jam nut that attaches to the end of the lumbar spine cable. The torque should be 1.13 - 1.35 Nm (10-12 in-lbs).

4. Reassemble the upper torso to the lower torso. 5. Secure the dummy to the test fixture so that the button head screws (that attach the top rib to

the spine box) and the adapter plate (that connects the upper torso to the lower torso) are against the vertical surface of the fixture. The rear surface of the buttocks now contacts the fixture.

6. Position the dummy=s H-point so it is 83.8 +/- 2.5 mm (3.3 +/- 0.1 in) above the horizontal seating surface and 147.3 +/- 2.5 mm (5.8 +/- 0.1 in) forward of the rear vertical surface of the fixture. (Note: the H-point is located 68.6 mm (2.7 in) forward and 58.4 (2.3 in) downward from the center of the square hole in the pelvis.)

7. Extend the dummy=s neck so that the base of the skull is level both fore-and-aft and side-to-side, within 0.5 degrees. The rear surface of the skull cap should be 45.7 +/- 2.5 mm (1.8 +/- 0.1 in) from the vertical surface of the test fixture. A strap or bungee cord may be placed around the forehead of the dummy to stabilize the head in this position.

8. Position the upper and lower legs parallel to the midsagittal plane so the centerline between the knee pivot and the screw attaching the ankle to the lower tibia is vertical.

9. Position the feet parallel to the dummy=s midsagittal plane with the bottoms horizontal and parallel to the seating surface.

10. Position the upper arms downward vertically so the centerline between the shoulders and elbow pivots is parallel to the rear vertical surface of the fixture.

11. Position the lower arms horizontally so the centerline between the elbow and wrist pivots is parallel to the seat surface.

12. Record the dimensions listed in Table 4, except for dimension Y and Z (reference Fig. 107). 13. Install the abdominal insert and chest jacket. Reposition the dummy on the test fixture. The

head need not be level as previously specified. 14. Mark the locations and record the dimensions Y, Z, AA, and BB as specified in Table 4 and

Fig. 107.


Table 4. Hybrid III Small Adult Female External Dimensions

English (in)

Metric (mm)

Dim.

Description Spec.

Tolerance

+/-

Spec.

Tolerance

+/-

A Total Sitting Height 31.00 0.50 787.4 12.7

B Shoulder Pivot Height 17.50 0.50 444.5 12.7

C H-Point Height 3.30 0.10 83.8 2.5

D H-Point Forward 5.80 0.10 147.3 2.5

E Shoulder Pivot from Back Line 3.00 0.30 76.2 7.6

F Thigh Clearance 5.00 0.30 127.0 7.6

G Back of Elbow to Wrist Point 9.90 0.30 251.5 7.6

H Head Back from Backline 1.80 0.10 45.7 2.5

I Shoulder to Elbow Length 11.30 0.40 287.0 10.2

J Elbow Rest Height 7.60 0.40 193.0 10.2

K Buttock to Knee Length 21.00 0.50 533.4 12.7

L Popliteal Height 14.40 0.40 365.8 10.2

M Knee Pivot Height 16.00 0.50 406.4 12.7

N Buttock Popliteal Length 16.80 0.50 426.7 12.7

O Chest Depth without Jacket 7.20 0.30 182.9 7.6

P Foot Length 8.90 0.30 226.1 7.6

R Buttock to Knee Pivot Length 18.50 0.50 469.9 12.7

S Head Breadth 5.60 0.20 142.2 5.1

T Head Depth 7.20 0.20 182.9 5.1

U Hip Breadth 12.10 0.30 307.3 7.6

V Shoulder Breadth 14.10 0.30 358.1 7.6

W Foot Breadth 3.40 0.30 86.4 7.6

X Head Circumference 21.20 0.40 538.5 10.2

Y Chest Circumference with Jacket 34.10 0.60 866.1 15.2

Z Waist Circumference 30.50 0.60 774.7 15.2

AA Reference Location for dim. AY@ 13.6 0.50 345.4 12.7

BB Reference Location for dim. AZ@ 6.50 0.20 165.1 5.1


Table 5. External Dimension Details

Dim.

Description

Details

A

Total Sitting Height

seat surface to highest point on top of head

B

Shoulder Pivot Height

centerline of shoulder pivot bolt to seat surface

C

H-Point Height

REFERENCE

D

H-Point Forward

REFERENCE

E

Shoulder Pivot from Back Line

center of shoulder clevis to rear vertical surface

F

Thigh Clearance

seat surface to highest point on the upper femur segment

G

Back of Elbow to Wrist Point

back of elbow flesh to wrist pivot bolt

H

Head Back from Backline

REFERENCE - back of skull cap to vertical surface

I

Shoulder to Elbow Length highest point on top of the shoulder clevis to the lowest part of the

flesh on the elbow, in line with the elbow pivot bolt

J

Elbow Rest Height

the flesh below the elbow pivot bolt to the seat surface

K

Buttock to Knee Length

most forward surface of the knee flesh to the rear surface of the buttocks, in line with the knee pivot and hip pivot

L

Popliteal Height

seat surface to the horizontal plane of the bottom of the feet

M

Knee Pivot Height

knee pivot bolt to horizontal plane of the bottom of the feet

N

Buttock Popliteal Length

the rearmost surface of the lower leg to the same point on the rear

surface of the buttocks used for dim. AK@

O

Chest Depth without Jacket

measured 304.8 +/- 5.1 mm (12 +/- 0.2 in) above seat surface

P

Foot Length

tip of toe to rear of heel

R

Buttock to Knee Pivot Length

the rear surface of the buttocks to the knee pivot bolt

S

Head Breadth

the widest part of the head

T

Head Depth

back of the head to the forehead

U

Hip Breadth

the widest part of the hip

V

Shoulder Breadth

outside edges of right and left shoulder clevises

W

Foot Breadth

the widest part of the foot

X

Head Circumference

measured at the point as in dim. AT@

Y

Chest Circumference with Jacket

measured 304.8 +/- 5.1 mm (12 +/- 0.2 in) above seat surface

Z

Waist Circumference

measured 165.1 +/- 5.1 mm (6.5 +/- 0.2 in) above seat surface

AA

Reference Location for dim. AY@

REFERENCE

BB

Reference Location for dim. AZ@

REFERENCE


Fig. 107. External dimensions


MASS MEASUREMENTS Check the masses of the various dummy segment assemblies. They should conform to the specifications in Table 6. Consult Tables 7 - 20 which define the contents of each segment. Table 6. Hybrid III Small Adult Female Total and Segment Masses

English (lbs)

Metric (kg)

Segment

Spec.

Tolerance +/-

Spec.

Tolerance

+/- Head Assembly

8.23

0.10

3.73

0.05

Neck Assembly

2.00

0.20

0.91

0.09

Upper Torso Assembly with Torso Jacket

26.50

0.30

12.02

0.14

Lower Torso Assembly

29.20

0.30

13.25

0.14

Upper Arm, Left or Right

2.60

0.10

1.18

0.05

Lower Arm, Left or Right

1.98

0.10

0.90

0.05

Hand, Left or Right

0.62

0.10

0.28

0.05

Upper Leg, Left or Right

6.90

0.20

3.13

0.09

Lower Leg, Left or Right

7.20

0.20

3.27

0.09

Foot, Left or Right

1.75

0.10

0.79

0.05

Total Dummy Mass

108.03

2.50

49.05

0.91

Table 7. Head Segment Description

Part Number

Qty

Head Assembly

880105-100X

1


SA572-S80

1

Uniaxial Peizoresistive Accelerometer (or mass equivalent)

SA572-S4

3

SHCS, 0-80 x 1/8

9000152

6

SHCS, 2-56 x 5/8

9000531

2


Table 8. Neck Segment Description

Part Number

Qty

Neck Assembly

880105-250

1

Washer, Clamping

78051-305

1

SHCS, 3/8-16 x 1

9000021

1

Bib Simulator

880105-210

1

Table 9. Upper Torso Segment Description

Part Number

Qty

Upper Torso Assembly

880105-300

1

SHCS, 1/4-20 x 5/8 (connect lumbar-thoracic adapter to upper torso assembly)

9000144

4

Upper Arm Washer (right and left)

880105-708

2

Upper Arm Bushing (right and left)

880105-709

2

Upper Arm Pivot Nut (right and left)

880105-710

2

Upper Arm Pivot Washer (right and left)

880105-711

2

SHSS, 3/8 x 1 (right and left)

9000074

2

Washer

880105-351

2

Chest Accelerometer Mount

H350-1006

1

SHCS, 1/4-24 x 2 (for chest accel. mount, H350-1006)

9000624

4


SA572-S80

1


SA572-S4

3

SHCS, 0-80 x 1/8

9000152

6

SHCS, 2-56 x 5/8

9000531

2


Table 10. Lower Torso Segment Description

Part Number

Qty

Lower Torso Assembly

880105-450

1

Pelvic Accelerometer Mount

1200056

1

SHCS, 3/8-16 x 3/4 (for pelvic accel mount, 1200056)

9000490

1


SA572-S80

1


SA572-S4

3

SHCS, 0-80 x 1/8

9000152

6

SHCS, 2-56 x 5/8

9000531

2

Table 11. Left Upper Leg Segment Description

Part Number

Qty

Upper Leg Weldment

880105-502

1

Upper Leg Flesh

880105-530L

1

SHCS, 3/8-16 x 1- 2

9000479

1


780551-319

1

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

9000449

1

Knee Insert

880105-511

1

Rotation Stop Cover

79051-34

1

Knee Skin

880105-508

1

Machined Knee Cap

880105-510

1


Table 12. Right Upper Leg Segment Description

Part Number

Qty

Upper Leg Weldment

880105-503

1

Upper Leg Flesh

880105-530R

1

SHCS, 3/8-16 x 1- 2

9000479

1


780551-319

1

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

9000449

1

Knee Insert

880105-511

1

Rotation Stop Cover

79051-34

1

Knee Skin

880105-508

1

Machined Knee Cap

880105-510

1

Table 13. Left Hand Segment Description

Part Number

Qty

Hand Assembly, Left

880105-722

1

Table 14. Right Hand Segment Description

Part Number

Qty

Hand Assembly, Right

880105-723

1


Table 15. Left Lower Leg Segment Description

Part Number

Qty

Lower Leg Flesh

880105-601

1


880105-603

1

Ankle Assembly

880105-660

1

Ankle Bumper

880105-631

1

Ankle Bolt

A-1887

1

Knee Slider Assembly, Left

880105-66

1

Table 16. Right Lower Leg Segment Description

Part Number

Qty

Lower Leg Flesh

880105-601

1


880105-603

1

Ankle Assembly

880105-660

1

Ankle Bumper

880105-631

1

Ankle Bolt

A-1887

1

Knee Slider Assembly, Left

880105-67

1

Table 17. Left Foot Segment Description

Part Number

Qty

Foot Assembly, Left

880105-650

1

SHSS, 1/4 x 5/8

9000619

1

Table 18. Right Foot Segment Description

Part Number

Qty

Foot Assembly, Right

880105-651

1

SHSS, 1/4 x 5/8

9000619

1


Table 19. Upper Arm Segment (Left and Right) Description

Part Number

Qty

Upper Arm Assembly, Molded

880105-700

1

Upper Arm, Lower Part

880105-705

1

SHSS, 5/16 x 1-1/4

9000248

1

Note: Quantity is for each upper arm segment.

Table 20. Lower Arm Segment (Left and Right) Description

Part Number

Qty

Washer, Elbow

880105-708

1

Bushing, Elbow

880105-709

1

Elbow Pivot Nut

880105-710

1

Washer, Elbow Pivot

880105-711

1

Lower Arm Molded Assembly

880105-712

1

Wrist Rotation Assembly

880105-718

1

SHCS, 3/8-16 x 1

9000079

1

SHSS, 3/8 x 1

9000074

1

SHSS, 5/16 x 3/4

9000578

1

Washer

880105-351

1

Note: Quantity is for each lower arm segment.


INSTRUMENTATION CABLE ROUTING The dummy contains provisions for numerous electronic instruments to evaluate various types of occupant restraint systems. Typically, the instruments are connected to the data acquisition system through the use of long cables. The instrumentation cables must be routed in and around the dummy in a manner which insures that the dummy=s motion is not affected by the cables while also being careful not to place the cables in a position where they are susceptible to damage from the test event. There are many acceptable methods of routing the cables and the following section is intended to be used as a reference. Below is a schematic of the small female dummy which indicates some of the instrumentation and sample cable routing (Fig. 108).

Fig. 108. Load Cell and Cable Routing.


Head accelerometer and upper neck load cell cables (Fig. 109) exit the head between the skull and skull cap. It is important to leave enough extra cable to allow the head and neck to rotate forward without introducing tension in the instrumentation cables (Fig. 110).

Fig. 109. Head accelerometer and upper neck Load cell cable routing.

Fig. 110. Cable slack to allow for head motion.


Cables are typically routed inside the thoracic cavity to protect them from damage during the test event. The head accelerometer/upper neck load cell cables are routed inside the rib cage along the side of the spine box (Fig. 111). The cables exit the rib cage just below rib number 6 and next to the lumbar spine (Fig. 112), bundled along with other instrumentation cables routed through the rib cage. The bundle of cables exiting the dummy is often referred to as the umbilical.

Fig. 111. Routing the head instrumentation cables through the rib cage.

Fig. 112. Cable bundle exiting the thoracic cavity below rib #6.


To reduce the possibility of static electricity discharge and subsequent noise in the data acquisition system, a small length of cable, referred to as a grounding cable, is placed between the bottom of the skull and the lower neck bracket (Fig. 113). Attach one end of the cable under one of the rear 1/4-28 x 7/8 SHCS which holds the neck load cell or structural replacement to the skull. Attach the opposite end under one of the 1/4-20 x 3/4 SHCS which holds the lower neck bracket to the top of the spine box. Next, attach one end of a second longer length of cable at this same location (at the lower neck bracket) and route the cable through the rib cage along with the rest of the instrumentation cables. The opposite end of this cable is then attached to a common ground.

Fig. 113. Grounding cable If the sternum mounted accelerometers are installed, route them along the sternum bib and into the thoracic cavity along the number 1 rib. Typically, duct tape is used to secure the cables to the bib to protect them until the cables reach the interior of the rib cage (Fig. 114). From there, route the cables to the rear of the thoracic cavity and then down along the spine box.


Fig. 114. Routing of sternum accelerometer cables Cables for the chest triaxial accelerometer array, the optional thoracic spine load cell, and the optional spine mounted accelerometers will all be routed through the interior of and out the top of the spine box. The cable bundle is then turned downward along the side of the spine box and inside the thoracic cavity (Fig. 115). This cable bundle will then exit the thoracic cavity along with the other cables under the number 6 rib and next to the lumbar spine. Fig. 115. Routing the cables from the interior of the spine box.


In this example, the chest instrumentation cables have been mounted along the right side of the spine box while the head/neck instrumentation cables have been routed along the left side of the spine box (refer back to Figs. 111 and 115). In order to provide a secure exit from the dummy for all the cable, the cables mounted along the right side of the spine are then passed to the left side of the spine by routing them in front of the lumbar spine, inside the abdominal cavity (Fig. 116).

Fig. 116. Routing the cables in the abdominal area. Also visible in Fig. 116 above are the cables for the A.S.I.S. load cells, the lumbar spine load cell, and the chest deflection transducer. These instruments are in close proximity to the umbilical and thus the cables can be routed directly to the rear of the spine where they are combined with the other cables into the bundle. The cables for the pelvis triaxial accelerometer array, which exit the pelvic cavity located in the posterior of the pelvis, should be routed up into the bottom of the thoracic cavity before being combined into the cable bundle (Fig. 117).


Fig. 117. Pelvis accelerometer cable routing The cables for the femur load cells will exit the thigh flesh through a small access hole provided. The cables are then routed across the top of the thigh and are typically held in place there with a small length of tape (Fig. 118).

Fig. 118. Femur load cell cable routing


The cables are then routed along the side of the pelvis where another piece of tape is used to hold the cable in place (Fig. 119). Finally, the cable is routed up into the bottom of the thoracic cavity before being combined into the cable bundle.

Fig. 119 Femur load cell cables shown taped to the side of the pelvis Place the chest jacket on the dummy, being careful not to pinch any of the cables in the jacket zipper. The cable bundle should exit the dummy just beneath the chest jacket (see Fig. 120 and 121). Protection of the instrumentation cable bundle from the dummy to the data collection point is important. A protective sleeve manufactured for fire hose can be used. The sleeve includes a zipper and/or velcro enclosure system and is made of rubberized cloth.


Fig. 120. Cable routing under chest Fig. 121. Cable routing under chest jacket jacket (rear view) (side view)

revised JUNE 2002 A-1

APPENDIX A. FLESH REPAIR Common flesh damage comes from punctures, tears, and scrapes. Typically, an iron, similar to a standard electronic soldering iron, is used to make flesh repairs. A flat paddle (duck bill) tip is often used and the iron is usually set at 60 to 90 watts. For best results, use a variable power supply to control the amount of heat provided by the iron. When repairing flesh, use a well ventilated area, clean the flesh with 99% isopropyl alcohol and remove all loose material from the damaged areas. Since the alcohol is a flammable liquid, wait until the alcohol-wetted area is dry and remove the alcohol container from the area before attempting to repair the flesh. Clean the iron tip frequently by quickly tapping it on a buffing wheel or rubbing it with a wire brush. Scrapes can be repaired by rubbing the iron over the affected area. If black flakes of burnt flesh start to appear on the iron tip, the iron is either too hot or has been in the same spot too long. Larger areas of damage may require a patch. The patch should be 10 mm (0.4 in) wider than the damaged area on all sides. One method of patching is to position the iron between the patch and the piece that is damaged. When the patch and flesh take on the appearance of a gel, move the iron to a new point while holding the patch in place until they both cool. For larger areas, it may be desirable to tack it in several places around the patch, then fill in the untacked areas. Moving the iron in a circular motion will eliminate rough, uneven areas.

revised JUNE 2002 B-1

APPENDIX B. JOINT TORQUE ADJUSTMENTS Throughout this document, reference has been made to the A1G@ torque setting for adjusting joint stiffness. The 1G torque setting is defined as the joint torque required to support the weight of the specified segment, yet that which also allows the segment to move when a small force is applied to the unsupported end of the segment. For example, when the dummy=s arm is fully extended laterally perpendicular to the dummy=s body, the shoulder yoke clevis bolt should be tight enough to support the weight of the arm, yet loose enough so that the entire arm will fall slowly when tapped at the wrist. The 1G torque setting can be difficult to achieve and requires some patience and practice. The following guidelines may be helpful. Hands and Arms 1. Remove the chest jacket in order to have access to the shoulder yoke rotation hex nut (necessary

for step 3 below). 2. Extend the arm laterally outward to a horizontal position. Orient the lower arm so the elbow

cannot rotate downward. Tighten the shoulder yoke clevis bolt until the shoulder joint torque will support the weight of the arm (see Fig. B1). Tap the lower arm near the wrist with a vertical impact. The arm should slowly fall back down along the dummy=s side. If it does not fall, loosen the shoulder yoke clevis bolt. Repeat the procedure of tapping at the wrist and adjusting the shoulder yoke clevis bolt until the 1G torque requirement is satisfied.

3. Rotate the complete arm assembly so that it is horizontal and pointing forward. Orient the lower arm so the elbow cannot rotate downward. Adjust the shoulder yoke rotation hex nut, which is located internally to the machined clavicle and accessed from the bottom side, until the joint torque will support the weight of the arm (see Fig. B2). Tap the lower arm near the wrist with a vertical impact. The arm should slowly fall back down along the dummy=s side. If it does not fall, loosen the shoulder yoke rotation hex nut. Repeat the procedure of tapping at the wrist and adjusting the shoulder yoke rotation hex nut until the 1G torque requirement is satisfied.

4. Start with the arm extended horizontally and pointing forward (as in step 3). Bend the elbow 90 degrees so that the hand moves toward the chest. Adjust the elbow rotation pivot bolt through the access hole found in the upper arm until the joint torque will support the weight of the lower arm (see Fig. B3). Tap the lower arm near the wrist with a vertical impact. The lower arm should slowly fall down. If it does not fall, loosen the elbow rotation pivot bolt. Repeat the procedure of tapping at the wrist and adjusting the elbow rotation pivot bolt until the 1G torque requirement is satisfied.

5. Start with the arm extended horizontally and pointing forward (as in step 3), only this time, orient the lower arm so that it is able to pivot downward. Adjust the elbow pivot bolt until the elbow joint torque will support the weight of the lower arm (see Fig. B4) Tap the lower arm near the wrist with a vertical impact. The lower arm should slowly fall down. If it does not fall, loosen the elbow pivot bolt. Repeat the procedure of tapping at the wrist and adjusting the elbow pivot bolt until the 1G torque requirement is satisfied.

6. Extend the arm and twist the hand until the palm is facing downward. Adjust the wrist pivot bolt until the wrist joint torque is sufficient to support the weight of the hand (see Fig. B5). Tap the hand at the tip of the fingers with a vertical impact. The hand should slowly fall down. If it does


not fall down, loosen the wrist pivot bolt. Repeat the procedure of tapping at the finger tips and adjusting the wrist pivot bolt until the 1G torque requirement is met.

7. Extend the arm and bend the wrist 90 degrees. Orient the hand so that the fingers are horizontal. Adjust the wrist rotation bolt through the access hole in the lower arm flesh until the joint torque is sufficient to support the weight of the hand (see Fig. B6). Tap the hand at the tip of the fingers with a vertical impact. The hand should slowly fall down. If it does not fall down, loosen the wrist rotation bolt. Repeat the procedure of tapping at the finger tips and adjusting the wrist rotation bolt until the 1G torque requirement is met.

8. Repeat steps 2 - 7 for the other arm and hand. Legs and Feet 1. Place the dummy in a seated position.. 2. Remove the abdominal insert 3. Orient the lower leg at 90 degrees relative to the upper leg. Lift the upper leg assembly above

horizontal. Adjust the femur ball set screw, which is located on the pelvis inside the abdominal cavity, until the joint torque is sufficient to support the weight of the leg (see Fig. B7). Tap the leg at the knee with a vertical impact. The leg should slowly fall down. If it does not fall down, loosen the femur ball set screw. Repeat the procedure of tapping at the knee and adjusting the femur ball set screw until the 1G torque requirement is met.

4. Rotate the entire leg assembly to a horizontal position. Adjust the knee pivot bolt until the joint torque is sufficient to support the weight of the lower leg (see Fig. B8). Tap the lower leg near the ankle with a vertical impact. The lower leg should fall down slowly. If it does not fall down, loosen the knee pivot bolt. Repeat the procedure of tapping at the ankle and adjusting the knee pivot bolt until the 1G torque requirement is met.

5. Orient the lower leg at 90 degrees relative to the upper leg. Adjust the ankle ball set screw, which is accessed through the lower leg skin, until the joint torque is sufficient to support the weight of the foot (see Fig. B9). Tap the foot near the toes with a vertical impact. The foot should slowly fall down. If it does not fall, loosen the ankle ball set screw. Repeat the procedure of tapping at the toes and adjusting the ankle ball set until the 1G torque requirement is met.

6. Repeat steps 3 - 5 on the other leg and foot.


Fig. B1. 1G setting of shoulder yoke clevis bolt. Fig. B2. 1G setting of shoulder rotation hex nut.


Fig. B3. 1G setting of elbow rotation bolt. Fig. B4. 1G setting of elbow pivot bolt.


Fig. B5. 1G setting of wrist pivot bolt.

Fig. B6. 1G setting of wrist rotation bolt.


Fig. B7. 1G setting of femur ball set screw.


Fig. B8. 1G setting of knee pivot bolt

Fig. B9. 1G setting of ankle ball set screw

revised JUNE 2002 C-1

APPENDIX C. PROCEDURE FOR CHECKING RECORDED DUMMY SENSOR POLARITY

Purpose: The purpose of this procedure is to provide a practical methodology for checking and documenting the recorded polarity of the data channel for each dummy mounted sensor relative to the NHTSA sign convention. It is intended to be used by the engineer conducting the testing. It is not a fool proof answer to documenting the polarity of channels, but will serve to increase the confidence that polarities have been correctly determined. The polarities in this document are the same as those of the SAE J211 and J1733. This procedure is recommended for each and every test conducted for NHTSA. Background: Standardized coordinate systems and recorded polarities for various transducer outputs defined relative to positive directions of those coordinate systems are defined for crash test dummies, vehicle structures, and laboratory fixtures in the SAE J211 standard. The standardized coordinate system and polarities for data permits comparison of data from different crash test facilities. There are many ways to influence the polarity of a data channel. NHTSA has required the polarity of any given manufacturers instrumentation be compatible with and recordable in a J211 channel. The channel by definition includes all the instrumentation from the transducer to the data acquisition system output. The channels therefore include a variety of load cells, accelerometers, and deflection measuring sensors (see Table C1) mounted in the dummy connected to a data acquisition system using connectors, wiring, data acquisition software and hardware. The polarity of a data channel for any given dummy may therefore be affected by changing the manufacturer of the sensor, positive and negative pins from the sensor to the wiring in a connector, the polarity assigned in software, and for some sensors by changing the way it is mounted in the dummy. Since there are many ways to influence the polarity of a data channel it is appropriate to determine the polarity of the assembled channel as it is ready to be tested. So when a test dummy is delivered for a test and connected to the data acquisition system how is polarity of the internal sensors established? In summary, the procedure requires the user to think of the data channel as a black box. The procedure requires manipulating the dummy to determine the polarity of the black box with respect to the sign convention. If the polarity is wrong, than steps must be taken to correct it prior to submitting data to NHTSA, so that data is in accordance with the sign convention. However it is recommended to correct and document the channel polarity at the test site so no further modifications to the data are required. If difficulty is experienced in determining the polarity when these procedures are being properly followed it may indicate that the instrumentation has not been mounted in accordance with the dummy instrumentation assembly drawings.


Although hands on manipulations are defined for fourteen types of load cells in the SAE J211, they are not provided for all loads cells available or for accelerometers. This procedure expands manipulations to include accelerometers, load cells, and displacement transducers used by NHTSA HIII Fifth Percentile Female Dummy. PROCEDURE Table C1 lists the required and optional transducers (load cells, accelerometers, and deflection devices) used in the CFR Part 572 Anthropomorhic Test Device Subpart O - Hybrid III Fifth Percentile Female Dummy. A separate procedure is defined for each type of transducer (i.e. accelerometer, load cell, displacement transducer). Accelerometer Data Channel The SAE J1733 explains that for any dummy component oriented in its standard standing position blows to the back side, left side, and top will produce positive accelerations relative to its +x, +y, and +z directions, respectively. As an example to document the polarity of the dummy=s head x axis accelerometer data channel in a plot similar to Figure C1 apply a blow to the back of the head with a rubber mallet and record the data channel output and time of event. The polarity of the Figure C1 dummy channel is positive and no changes are needed to conform to the sign convention. Similarly to document the polarity of the dummy=s head y and z axis accelerometer data channels apply a blow to the left side and top of the head, respectively, with a rubber mallet (never apply the blow directly to an accelerometer mount) and record the data channel output and time of event as shown in Figures C2 and C3. An analysis of Figure C2 and C3 for the y and z axes show that the polarities of both the y and z axis accelerometer data channel in the head of this dummy are negative. Therefore these polarities must be changed to be positive to agree with the sign convention. Following this approach it is possible to document the polarity of each dummy data channel. An alternate approach to determine the polarity of the accelerometers mounted in the dummy uses the constant force of gravity as the input. This procedure will yield the same polarity as the previous procedure. Since the sign convention is fixed with respect to the dummy, this procedure can be conducted outside the test vehicle on the laboratory floor or table, but the dummy must be attached to the data acquisition system. The body coordinate system used for reference is attached to the dummy and is x positive pointing forward, y positive pointing to the right, and z positive pointing down.


Fig. C 1. Polarity of X Axis Accelerometer Data Channels

Fig. C 2. Polarity of Y Axis Accelerometer Data Channel


Fig. C 3. Polarity of Z Axis Accelerometer Data Channel

Fig. C 4. Accelerometer Perpendicular to

the force of Gravity in Two Orientations 180 Degrees Apart.

The procedure for each axis requires placing the accelerometers to be checked perpendicular to the axis of gravity in two orientation each 180 degrees apart and recording the sign and value of the acceleration channel due to the earths gravity for a short period of time. The accelerometer is defined as perpendicular to the axis of gravity when the plane containing both mounting screw holes is perpendicular to the force of gravity. See Figure C4.


The orientation of the dummy that is most positive when mounted in a plane perpendicular to the force of gravity will have a positive polarity when moved away from the earth center. The polarity must agree with the SAE J211 sign convention. The data collected should be recorded in the Polarity Check Data Sheet respectively for the x, y, and z accelerometers. Samples of these sheets are provided in this Appendix. As an example refer to the Polarity Check Data Sheet for documenting the x axis polarity. To determine the polarity of the head x-accelerometer, lay the dummy face down (FD) and record the x-accelerometer=s channel output in g=s in the appropriate column. Now place the dummy face up (FU) and record the channel output in g=s in the appropriate column. Note that the difference in FD and FU outputs should be about 2 g=s. List the orientation of the most positive value in the next column, either FD or FU, paying attention to the sign from the data acquisition system (-1 is more positive than -2 g=s). Next, compare the orientation of the most positive value with the J211orientation for positive sign convention. If the dummy=s orientation of the most positive value is consistent with that of the J211 sign convention, then the channel output will be in accordance with the sign convention. If, however, the dummy=s orientation of the most positive value is different than that of the J211 sign convention, then the channel=s output will have to be reversed by the data acquisition software in order to be in accordance with the sign convention. Place a check in the column titled AChannels To Be Reversed@ for those channels that will require reversal by the data acquisition software. The channel outputs for the x-axis accelerometers can be recorded simultaneously for each orientation. For example, when the dummy is turned face down, the channel outputs for the head, sternum, spine, chest, and pelvis can all be recorded at the same time. Then the dummy can be oriented face up and the corresponding channel outputs can be recorded again. The procedure for the y-axis accelerometers is very similar to that used for the x-axis and can be accomplished on a floor or bench surface. In this instance, the dummy is placed on its side in two different orientations - one where the right shoulder is down (RSD) and one where the right shoulder is up (RSU). Once again, all of the channels can be recorded at one time. Then flip the dummy onto its other side and record the values again. At this point, the procedure is similar to that used for the x-axis channels. List the orientation of the most positive value and compare that with that J211 orientation for positive sign convention. For the z-axis turning the dummy over and standing it on its head is quite difficult for the larger adult dummies. Thus for the z-axis check it is recommended to secure the dummy in a chair, seat it upright and then rotate the dummy in the chair forward or backward about 60 degrees. The force on the accelerometer varies with the cosine of the angle it makes with respect to tangent to the earth=s surface. With the dummy sitting upright (U) in the chair, record the z-axis accelerometer channel outputs in the appropriate column on the Polarity Check Data Sheet. Next, lean the dummy forward or backward approximately 60 degrees and record the z-axis accelerometer outputs in the column labeled ALean Down.@ (Note that the symbol AD@ for down has been associated with this orientation.) Again, follow the procedure outlined for the x-axis and y-axis accelerometers to complete the z-axis Polarity Check Data Sheet.


Load Cell and Deflection Transducer Data Channels Polarities of accelerations, velocities, displacements, forces and moments are discussed in SAE J211 Instrumentation for Impact Test - Part 1 - Electronic Instrumentation of 1 Mar 1995. SAE J1733 Dec 94 Sign Convention for Vehicle Crash Testing also list recorded output polarities for various transducers. The manipulations identified in J211 and those of additional load cells and the deflection sensors are shown in Table C2. Sit the dummy on a bench and secure it so that it does not slip on the bench when performing the manipulation about the load cell or deflection transducer. Manually manipulate the dummy as described in Table C2 and record the appropriate data channel output from the data acquisition system. If the polarity of the channel output does not agree with that given in Table C2, then change the polarity of the channel to agree with the sign convention. Typically, this can be accomplished by multiplying the channel by -1 in the data acquisition software. After reversing the polarity, repeat the manipulation to insure that the channel output is in agreement with the J211 requirements listed in Table C2. Sample Polarity Check Data Sheets have been included in this appendix for the various load cells and transducers. For example, to document the polarity of the dummy=s upper neck x-axis shear force data channel, push the head rearward while simultaneously pushing the chest forward and then record the data channel output and time of event. Record the sign of the output, either positive (+) or negative (-), in the Channel Output column. Next, compare the sign in the Channel Output column with the sign listed in the J211 Polarity column. If the signs are in agreement, then no action need be taken. If, however, the signs are not in agreement, then the channel output must be changed to agree with the J211 sign convention for positive polarity.


Table C1. Instrumentation for Small Female Dummy

INSTRUMENTATION

DRAWING NUMBER

STANDARD/ OPTIONAL

Load Cells

Upper Neck

SA572-S11

standard

Lower Neck

SA572-S27

optional

Thoracic

SA572-S28

optional

Lumbar

SA572-S15

optional

Femur, Single Axis

SA572-S14

standard

Femur, Multiple Axis

SA572-S29

optional

Anterior Superior Iliac Spine (A.S.I.S.)

SA572-S16

optional

Accelerometers

Head (x,y,z)

SA572-S4

standard

Chest (x,y,z)

SA572-S4

standard

Pelvis (x,y,z)

SA572-S4

standard

Sternum (x)

SA572-S4

optional

Spine (x)

SA572-S4

optional

Deflection Transducer

Chest

SA572-S51

standard


Table C-2. Dummy Manipulations for Checking Recorded Instrumentation Polarity Relative to SAE

J211Sign Convention for Positive Polarity TRANSDUCER

MEASURE

DUMMY MANIPULATION

POLARITY

Fx

head rearward, chest forward

+

Fy

head leftward, chest rightward

+

Fz

head upward, chest downward

+

Mx

left ear toward left shoulder

+

My

chin toward sternum

+

Upper and Lower Neck

Mz

chin toward left shoulder

+

Fx

chest rearward, pelvis forward

+

Fy

chest leftward, pelvis rightward

+

Fz

chest upward, pelvis downward

+

Mx

left shoulder toward left hip

+

My

sternum toward front of legs

+

Thoracic Spine and Lumbar Spine

Mz

right shoulder forward, left shoulder rearward

+

Fx

upper iliac spine rearward, chest forward

-

Anterior Superior Iliac Spine (A.S.I.S)

My

top of iliac rearward, chest forward

+

Fx

knee upward, upper femur downward

+

Fy

knee rightward, upper femur leftward

+

Fz

knee forward, pelvis rearward

+

Mx

knee leftward, hold upper femur in place

+

My

knee upward, hold upper femur in place

+

Femur loads (dummy in seated position, femurs horizontal)

Mz

tibia leftward, hold pelvis in place

+

Chest Deflection

ªx

chest rearward, spine forward

-


Polarity Check Data Sheet For X - Axis Accelerometers

Dummy Type:_____________ Serial No._______________ Date:_____________

Channel Output

( g )

Orientation

Component

Face Down

(FD)

Face Up

(FU)

Orientation of Most Positive Value

(FU or FD)

J-211 Orientation for Positive Polarity

Negative Channels to be Changed In Data Acquisition System

Head

FU

Sternum, top

FU

Sternum, middle

FU

Sternum, lower

FU

Spine, top

FU

Spine, middle

FU

Spine, lower

FU

Chest

FU

Pelvis

FU


Polarity Check Data Sheet For Y - Axis Accelerometers


Channel Output

( g )

Orientation

Component

Right Shoulder

Down (RSD)

Right

Shoulder Up (RSU)

Orientation of Most Positive Value

(RSU or RSD)

J-211 Orientation for Positive Polarity


Head

RSU

Chest

RSU

Pelvis

RSU


Polarity Check Data Sheet For Z - Axis Accelerometers


Channel Output

( g )

Orientation

Component

Upright

(U)

Lean Down

(D)

Orientation of Most Positive

Value (U or D)

J-211 Orientation for

Positive Polarity


Head

D

Chest

D

Pelvis

D


Polarity Check Data Sheet For Load Cells and Deflection Transducers

Dummy Type: Dummy Serial No. Date:

Dummy Part/ Channel

Dummy Manipulation for which J211

Polarity is indicated

Channel Output

J211

Polarity

List

Channels to be

Reversed Upper Neck

Fx head rearward, chest forward

+

Fy


+

Fz


+

Mx


+

My

chin toward sternum

+

Mz


+

Lower Neck

Fx head rearward, chest forward

+

Fy


+

Fz


+

Mx


+

My

chin toward sternum

+

Mz


+

Thoracic Spine

Fx chest rearward, pelvis forward

+

Fy


+

Fz


+

Mx


+

My


+

Mz


+


Polarity Check Data Sheet For Load Cells and Deflection Transducers

Dummy Type: Dummy Serial No. Date:

Dummy Part/ Channel

Dummy Manipulation for which J211

Polarity is indicated

Channel Output

J211

Polarity

List

Channels to be

Reversed Lumbar Spine

Fx chest rearward, pelvis forward

+

Fy


+

Fz


+

Mx


+

My


+

Mz


+

Femur (dummy in seated position, femurs horiznotal)

Fx knee upward, upper femur downward

+

Fy

knee rightward, upper femur leftward

+

Fz

knee forward, pelvis rearward

+

Mx

knee leftward, hold upper femur in place

+

My

knee upward, hold upper femur in place

+

Mz

tibia leftward, hold pelvis in place

+

Anterior Superior Iliac Spine (A.S.I.S.)

Fx upper iliac spine rearward, chest forward

+

My

top of iliac rearward, chest forward

+

revised JUNE 2002 D-1

APPENDIX D. PROCEDURE FOR DETERMINING THE MOMENT OF INERTIA OF PROBES USED FOR DUMMY CALIBRATION TESTS

The impact probes used for calibrating new dummies are less massive than previously used probes for the adult dummies. Experience with these less massive probes provided a lesson learned that a stable trajectory as required by the calibration procedures in the CFR Part 572 can more easily be achieved if the probe meets a minimum moment of inertia requirement in yaw (about z axis) and pitch (about y axis) about the probe=s center of gravity. This appendix to the Procedures for Assembly and Disassembly of the dummy provides a method used by the NHTSA for determining the moment of inertia of the impact probes. Moment of Inertia of an Unsprung Mass I = moment of inertia of a probe about a line through its center of gravity and parallel to the z-axis, lb A in.A sec2. Since the probes are symmetrical, the moment of inertia about the y and z axis are equal. This value can be determined using the classical torsional pendulum method. As shown in the Figure D1, the probe is suspended freely on two splayed flexible wires. The body of the probe is given a torsional motion of small angular displacement around the vertical axis (z axis), and the period of oscillation is obtained by measuring the time of at least 50 complete oscillations.

Fig. D1. Determination of moment of inertia of probes used for dummy calibration

revised JUNE 2002 D-2

The moment of inertia about the vertical axis (z axis), is equal to that about the y axis (going into the page) since the probe is symmetrical. The moment of inertia is calculated from

I z = I y = Wr1 r2T2 4p2L

where W = total weight of body

L = vertical distance between points of suspension and points of attachment to the body

r1 = radial distance of each attachment point from axis of oscillation

r2 = radial distance of each suspension point from axis of oscillation

T = period of oscillation.

In order to reduce errors, its is recommended to limit the applied small angular displacement to approximately 20 degrees.

revised JUNE 2002 E-1

APPENDIX E. PROCEDURE FOR DETERMINING THE FREE AIR RESONANT FREQUENCY OF PROBES USED FOR DUMMY CALIBRATION

Requirement Recent Department of Transportation, National Highway Traffic Safety Administration, 49 CFR Part 572, Final Rules For Anthropometric Test Dummies; Occupant Crash Protection specifies in '572.137 Test conditions and instrumentation, for knee impact test probes and or thoracic impact test probes that: AThe impact probe shall have a free air resonant frequency of not less than 1000 Hz.@

Background This test procedure, developed by the Vehicle Research and Test Center, is used to determine the free air resonant frequency of impact probes employed by the agency in dummy calibration tests. The directionality of the resonant frequency measured by this test procedure is in line with the motion axis of the probe (a longitudinal axis) at the instant of impact with the dummy. While other procedures may be available for this purpose, this procedure is to facilitate those who need to know how the agency conducts this test. Test equipment 1. The impact probe 2. Suspension wires 3. An accelerometer 4. Impact hammer (steel - approx. 4 lbs.) 5. Data acquisition equipment Test instrumentation The impact probe has an accelerometer rigidly mounted at the opposite end of the probe on which the impact surface is located. The accelerometer's sensitive axis is in collinear alignment with the longitudinal axis of the impact probe. Test Set-up and Test procedure Suspend the impact probe by its suspension system along with all equipment that is attached to the probe for a typical calibration impact, including the accelerometer, velocity vane, etc. as shown in Figure E1. Tap the probe with a hammer (a 4 lb. engineers= hammer works fine) on the impact surface sufficiently hard to excite the resonant frequency, but not hard enough to damage the accelerometer.


Data recording Record the data using a sampling rate at 50 kHz and anti-aliasing filter at 20 kHz. Typical response are shown in Figures E2 and E3. Data analysis The resonant frequency can be determined from the data plots by a variety of techniques, such as counting peaks during selected time periods, calculating the average frequency, spectral analysis, etc. A sample calculation based on counting the peaks over a period of time after the transient response has decayed is shown in Figure E3.

Figure E1. Probe impacted with hammer to excite resonance


Figure E2. Probe acceleration response (longitudinal axis) versus time

Figure E3. Probe acceleration response (longitudinal axis) Between 38 and 40 milliseconds

procedures for assembly, disassembly, and inspection (padi ... 572... · procedures for assembly,...

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