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  • Procedures for Assembly, Disassembly, and Inspection

    (PADI) of the Hybrid III

    10 Year Old Child Test Dummy (HIII-10C)

    Vehicle Research & Test Center National Highway Traffic Safety Administration

    March 2015

  • ii

    TABLE OF CONTENTS

    LIST OF FIGURES ............................................................................................................... iv LIST OF TABLES ................................................................................................................ vii 1. INTRODUCTION................................................................................................................1 1.1. Purpose .......................................................................................................................1 1.2. Part Numbers .............................................................................................................2 1.3. Abbreviations .............................................................................................................2 1.4. Torque Specifications ................................................................................................2 2. CONSTRUCTION ...............................................................................................................3 3. CLOTHING..........................................................................................................................4 4. AVAILABLE INSTRUMENTATION...............................................................................4 5. PROCEDURES FOR ASSEMBLY, DISASSEMBLY AND INSPECTION .................5 5.1. Head ...........................................................................................................................6 5.1.1. Assembling the Head ..........................................................................................7 5.1.2. Disassembling the Head ......................................................................................8 5.1.3. Inspecting the Head.............................................................................................8 5.2. Neck ...........................................................................................................................8 5.2.1. Assembling the Neck ........................................................................................10 5.2.2. Disassembling the Neck ....................................................................................11 5.2.3. Inspecting the Neck Assembly..........................................................................12 5.3. Upper Torso .............................................................................................................12 5.3.1. Assembling the Upper Torso ............................................................................14 5.3.2. Disassembling the Upper Torso ........................................................................17 5.3.3. Inspecting the Upper Torso ...............................................................................18 5.3.4. Assembling the Neck to the Upper Torso Assembly ........................................19 5.3.5. Shoulder ............................................................................................................19 5.3.5.1. Assembling the Shoulder .....................................................................19 5.3.5.2. Disassembling the Shoulder .................................................................27 5.3.5.3. Inspecting the Shoulder........................................................................27 5.3.6. Chest Potentiometer ..........................................................................................28 5.3.6.1. Assembling the Chest Potentiometer ...................................................30 5.3.6.2. Disassembling the Chest Potentiometer ..............................................32 5.3.6.3. Inspecting the Chest Potentiometer .....................................................32 5.4. Lower Torso .............................................................................................................33 5.4.1. Assembling the Lower Torso ............................................................................35 5.4.2. Disassembling the Lower Torso .......................................................................39 5.4.3. Inspecting the Lower Torso ..............................................................................40 5.4.4. Assembling the Upper and Lower Torso Assemblies.......................................40

  • iii

    5.5. Arms .........................................................................................................................42 5.5.1. Assembling One Arm .......................................................................................43 5.5.2. Assembling the Upper Arm to the Torso ..........................................................46 5.5.3. Disassembling the Arm .....................................................................................47 5.5.4. Inspecting the Arm ............................................................................................47 5.6. Legs ..........................................................................................................................47 5.6.1. Assembling One Leg .........................................................................................47 5.6.2. Assembling the Ankle and Foot ........................................................................52 5.6.3. Assembling the Leg to the Lower Torso...........................................................54 5.6.4. Disassembling the Leg ......................................................................................54 5.6.5. Inspecting the Leg .............................................................................................55 6. INSTRUMENTATION INSTALLATION ......................................................................56 6.1. Head Accelerometers ..............................................................................................56 6.2. Sternum Accelerometers .........................................................................................57 6.3. Spine Box Accelerometers ......................................................................................58 6.4. Chest Accelerometers .............................................................................................59 6.5. Pelvis Accelerometers .............................................................................................60 6.6. Tilt Sensor ...............................................................................................................61 6.7. IR-Tracc ..................................................................................................................61 6.8. Load Cells ...............................................................................................................62 7. INSTRUMENTATION CABLE ROUTING ..................................................................63 8. EXTERNAL DIMENSIONS.............................................................................................69 9. SEGMENT WEIGHTS .....................................................................................................73 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. Procedure for Determining the Free Air Resonant Frequency of Probes Used for Dummy Certification ..................................................E-1

  • iv

    LIST OF FIGURES Figure 1. HIII-10C dummy without clothing ................................................................................. 1 Figure 2. HIII-10C dummy with clothing ...................................................................................... 1 Figure 4. Drawing of head assembly ............................................................................................. 6 Figure 5. Photograph of head assembly components .................................................................... 7 Figure 6. Remove head instrumentation ......................................................................................... 8 Figure 7. Remove neck load cell simulator ................................................................................... 8 Figure 8. Drawing of neck assembly section A-A ......................................................................... 9 Figure 9. Photograph of neck assembly component .................................................................... 10 Figure 10. Connecting the head to the neck using the pivot pin and washers ............................. 11 Figure 11. Photograph of upper torso assembly components ...................................................... 13 Figure 12. Drawing of upper torso assembly with chest potentiometer and shoulder assembly . 14 Figure 13. Attachment of the lower sternum stops to the spine box............................................ 15 Figure 14. Attaching rib assemblies and rear rib supports to spine box weldment ..................... 15 Figure 15. Attach transducer arm slider and threaded rib strip to bib assembly (front) ...

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