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

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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

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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

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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) .............. 16 Figure 16. Attach transducer arm slider and thraded rib strip to bib assembly (rear) ................. 16 Figure 17. Position bib to front of ribs ......................................................................................... 16 Figure 18. Attach front rib end stiffener plate, ribs and bib, to front rib threaded strip .............. 17 Figure 19. Measurement of internal chest depth .......................................................................... 18 Figure 20. Assembling the neck to the upper torso assembly...................................................... 19 Figure 21. Photograph of shoulder assembly components (one left shoulder shown here) ........ 21 Figure 22. Drawing of right shoulder assembly ........................................................................... 22 Figure 23. Front view of the assembled right shoulder on the spine box .................................... 22 Figure 24. Side view of the assembled left shoulder on the spine box ........................................ 23 Figure 25. Positioning and fitting of the left shoulder support into spine box ............................ 23 Figure 26. Fastening the right shoulder support to the spine box behind the neck...................... 24 Figure 27. Fitting the shoulder bumper into the right shoulder support ...................................... 24 Figure 28. Attaching the shoulder and steel stops to the shoulder yoke ...................................... 25 Figure 29. Fitting the shoulder yoke bushing to the shoulder yoke ............................................. 25 Figure 30. Fastening the shoulder yoke assembly to the right clavicle link ................................ 26 Figure 31. Attaching the shoulder stop to the yoke at the right clavicle link interface ............... 26 Figure 32. Connection of clavicle link assembly to right shoulder support ................................ 27 Figure 33. Photograph of chest potentiometer assembly components ......................................... 29 Figure 34. Drawing of chest potentiometer assembly ................................................................. 29 Figure 35. Attach the transducer arm to the arm connector ......................................................... 30 Figure 36. Connecting ball to transducer arm .............................................................................. 31 Figure 37. Attach the transducer assembly to the mounting plate adaptor assembly .................. 31 Figure 38. Photograph of lower torso assembly components ...................................................... 34 Figure 39. Drawing of lower torso assembly ............................................................................... 35 Figure 40. Attaching lumbar attachment to lumbar assembly ..................................................... 36 Figure 41. Attach lumbar adjustment bracket to lumbar load cell simulator............................... 36 Figure 42. Attach load cell simulator to molded pelvis assembly ............................................... 37 Figure 43. Attach femur assemblies to molded pelvis assembly ................................................. 37 Figure 44. Attach ASIS load cell simulators to molded pelvis assembly .................................... 38 Figure 45. Positioning lumbar attachment on lumbar adjustment bracket .................................. 38

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Figure 46. Fasten lumbar attachment to lumbar adjustment bracket ........................................... 39 Figure 47. Attaching the chest potentiometer and lower torso assemblies together .................... 40 Figure 48. Fastening the upper and lower torso assemblies together .......................................... 41 Figure 49. Proper positioning of abdominal insert ...................................................................... 41 Figure 50. Fitting jacket over torso assembly .............................................................................. 41 Figure 51. Drawing of arm assembly ........................................................................................... 43 Figure 52. Photograph of arm assembly components .................................................................. 44 Figure 53. Attach the upper arm lower weldment to the upper arm molded assembly ............... 44 Figure 54. Locate the grooves on the bushing and washer with the lower arm stops ................. 45 Figure 55. Attach the upper arm lower ........................................................................................ 45 Figure 56. Attach the hand to the lower arm via the wrist ........................................................... 45 Figure 57. Align the grooves on teh bushing and washer with the shoulder yoke dowel pins .... 46 Figure 58. Attach the upper arm to the shoulder yoke assembly ................................................. 46 Figure 59. Photograph of leg assembly components ................................................................... 49 Figure 60. Drawing of leg assembly ............................................................................................ 50 Figure 61. Attach the femur load cell or simulator to upper leg .................................................. 50 Figure 62. Attach the knee assembly to the femur load cell or simulator ................................... 51 Figure 63. Insert the lower leg rotation stop assembly ................................................................ 51 Figure 64. Assemble the lower leg bone ...................................................................................... 51 Figure 65. Fit the ankle friction pad into the ankle shell ............................................................. 52 Figure 66. Insert the dowel pin into the ankle shaft ..................................................................... 52 Figure 67. Insert the stop pin retainer and fasten the lower ankle shell....................................... 53 Figure 68. Attach the lower shell and ankle bumper assembly ................................................... 53 Figure 69. Attach the ankle assembly to the lower leg weldment ............................................... 53 Figure 70. Attach the ankle assembly to the foot ......................................................................... 54 Figure 71. Attaching the leg to the lower torso ........................................................................... 54 Figure 72. Head accelerometers shown in correct orientation ..................................................... 56 Figure 73. Accelerometers mounted in the head ......................................................................... 57 Figure 74. Accelerometers mounted on the sternum ................................................................... 58 Figure 75. Spine accelerometers mounted at ribs 6 and 1 ........................................................... 58 Figure 76. Chest accelerometers mounted in the spine box weldment (front view) .................... 59 Figure 77. Accelerometers mounted in the pelvis ....................................................................... 60 Figure 79. IR-Tracc Assembly Drawing ...................................................................................... 62 Figure 80. IR-Tracc Assembly ..................................................................................................... 62 Figure 81. Cable routing schematic ............................................................................................. 63 Figure 82. Head accelerometer and upper neck load cell cables ................................................. 64 Figure 83. Cable slack to allow for head motion. ........................................................................ 64 Figure 84. Rear view of cable routing ......................................................................................... 65 Figure 85. Grounding cable ......................................................................................................... 66 Figure 86. Sternum caccelerometer cables .................................................................................. 66 Figure 87. Lower neck load cell cables ....................................................................................... 67 Figure 88. Shoulder load cell cables with (left) rear and (right) bottom cable exit ..................... 67 Figure 89. ASIS and lumbar load cell cables ............................................................................... 68 Figure 90. Pelvic accelerometer cables ........................................................................................ 68 Figure 91. Umbilical exiting through jacket ................................................................................ 68 Figure 92. Schematic showing external dimension measurement designations .......................... 70

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Figure 93. Check shoulders (left) and prlvis (right) for belt fit & interaction ............................. 70 Figure B1. Shoulder torque to 1 g ...............................................................................................B-2 Figure B2. Elbow torque to 1 g ...................................................................................................B-2 Figure B3. Femur torque to 1 g ...................................................................................................B-2 Figure B4. Knee torque to 1 g .....................................................................................................B-3 Figure B5. Ankle torque to 1 g ...................................................................................................B-3 Figure C1. Polarity of X axis accelerometer data channel ..........................................................C-4 Figure C2. Polarity of Y axis accelerometer data channel ..........................................................C-4 Figure C3. Polarity of Z axis accelerometer data channel ..........................................................C-5 Figure C4. Acceleration perpendicular to gravity in two orientation 180 deg apart ..................C-5 Figure D1. Determination of moment of inertia of probes used for dummy certification .............................................................................................................. D-1 Figure E1. Probe impacted with hammer to excite resonance .................................................... E-2 Figure E2. Probe acceleration response (longitudinal axis) versus time .................................... E-2 Figure E3. Probe acceleration response (longitudinal axis) between 38 and 41 ms ................... E-3

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LIST OF TABLES Table 1. Threaded Fastener Abbreviations .................................................................................... 2 Table 2. Torque Specifications ...................................................................................................... 2 Table 3. Dummy Instrumentation Capability ................................................................................ 4 Table 4. Dummy Assembly Groups............................................................................................... 5 Table 5. Head Assembly Components ........................................................................................... 6 Table 6. Neck Assembly Components ........................................................................................... 9 Table 7. Upper Torso Assembly Components ............................................................................. 12 Table 8. Shoulder Assembly Components ................................................................................... 20 Table 9. Chest Potentiometer Assembly Components ................................................................. 28 Table 10. Lower Torso Assembly Components .......................................................................... 33 Table 11. Upper/Lower Arm and Hand Assemblies with Attachment Hardware ....................... 42 Table 12. Upper/Lower leg and Foot Assemblies with Attachment Hardware ........................... 48 Table 13. Head Instrumentation Parts .......................................................................................... 56 Table 14. Sternum Accelerometer Parts ...................................................................................... 57 Table 15. Spine Box Accelerometer Parts ................................................................................... 58 Table 16. Chest Accelerometer Parts ........................................................................................... 59 Table 17. Pelvis Accelerometer Parts .......................................................................................... 60 Table 18. Tilt Sensor Parts ........................................................................................................... 61 Table 19. IR-Tracc Parts .............................................................................................................. 61 Table 20. External Dimension Definitions .................................................................................. 71 Table 21. External Dimensions of HIII-10C Dummy ................................................................. 72 Table 22. Segment Weights of HIII-10C Dummy ....................................................................... 73 Table 23. Head Assembly Segment Weight Components ........................................................... 73 Table 24. Neck Assembly Segment Weight Components ........................................................... 74 Table 25. Upper Torso Assembly Segment Weight Components ............................................... 74 Table 26. Lower Torso Assembly Segment Weight Components ............................................... 74 Table 27. Upper Arm Assembly Segment Weight Components (Left and Right) ...................... 75 Table 28. Lower Arm Assembly Segment Weight Components (Left and Right) ...................... 75 Table 30. Upper Leg Assembly Segment Weight Components (Left and Right) ....................... 76 Table 31. Lower Leg Assembly Segment Weight Components (Left and Right) ....................... 76 Table 32. Foot Assembly Segment Weight Components (Left and Right) ................................. 76

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1. INTRODUCTION The National Highway Traffic Safety Administration has prepared this document under the title “Procedures for Assembly, Disassembly, and Inspection of the Hybrid III 10 Year Old Child Test Dummy,” otherwise known as PADI for the HIII-10C. The document is based on drawings and test procedures described in the Final Rule that incorporated the HIII-10C crash test dummy into Part 572 as subpart T. This dummy is designed to evaluate child restraints and the potential for injury when a child is seated close to a deploying airbag, and therefore possesses a seated pelvis shape. Its anthropometry, weight distribution, ranges of motion, and general body segment configuration reflect those of a typical pre-adolescent child in the 8 - 10 year old age range. Photographs of the Hybrid III 10 Year Old child test dummy, HIII-10C, are shown in Figures 1 and 2.

1.1. Purpose This document contains the procedures for assembly, disassembly, and adjustment of the dummy for the purpose of inspection and preparation for testing. Certification tests are specified in the 49 CFR Part 572 Subpart T Final Rule to validate dummy responses that could affect dummy measurements used to assess occupant injury potential. Certification tests are performed by the dummy manufacturer to assure that a new component or assembly meets the specified response requirements. The crash dummy user will periodically perform the certification tests to assure the dummy is maintained at the specified performance levels.

Figure 1. HIII-10C dummy without clothing

Figure 2. HIII-10C dummy with clothing

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1.2. Part Numbers All part numbers in this document are detailed for each component assembly and refer to the drawing package specified in the 49 CFR, Part 572 Subpart T. Electronic files of the drawings for this dummy may be downloaded from the docket at http://www.regulations.gov. The files are searchable by part number, provided Adobe Acrobat is configured correctly1. 1.3. Abbreviations The abbreviations for threaded fasteners used throughout the PADI are listed in Table 1.

Table 1. Threaded Fastener Abbreviations

Abbreviation Description SHCS Socket Head Cap Screw BHCS Button Head Cap Screw FHCS Flat Head Cap Screw SHSS Socket Head Shoulder Screw SSCP Socket Screw, Cup Point

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

Table 2. Torque Specifications

Screw Type Size Torque (in-lb) Torque (N-m) SHCS/BHCS 0-80 1 0.113

2-56 2.5 0.283 4-40 12 1.36 6-32 23 2.60 8-32 41 4.63 10-24 60 6.78 10-32 68 7.68 1/4-20 144 16.3 1/4-28 168 19.0 3/8-16 540 61.0 3/8-24 600 67.8

SHSS 1/4-20 144 16.3 5/16-24 300 33.9

FHCS 10-24 60 6.78 10-32 68 7.68

SSCP 8-32 41 4.63 4-40 12 1.36 5/16-24 300 33.9

1 Make sure “Include Bookmarks” is selected in the “Find” drop-down menu before typing in the drawing number.

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2. CONSTRUCTION Following are some of the design highlights of the Hybrid III 10 Year Old child test dummy: • One-piece cast aluminum skull with removable vinyl head and cap skins. The vinyl skin has

been tuned to give human-like response for forehead and chin impacts. • A rubber segmented neck with aluminum intervertebral disks that is tuned to give humanlike

rotation versus moment responses in dynamic flexion (forward bending) and extension (rearward bending) articulations.

• A neck that can be adjusted to four different angle settings: 0, 8, 16, and 23 degrees from the

vertical reference frame. Tilt sensors can be incorporated for initial dummy setup. • A neck cable passing through the neck’s longitudinal axis controls the stretching responses

and provides increased durability against extreme axial tension forces. • Six spring steel ribs with polymer-based damping material to 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. • Two methods are available for chest deflection measurement: a traditional ball-slider rotary

potentiometer arrangement or optical IR-TRACC transducer. • Sternum stops prevent the ribs from contacting the spine box during extreme sternal

compression. • Top and bottom rib stops are incorporated to control the vertical movement of the rib cage. • A human-like shoulder contour and shoulder load cells. • Cylindrical rubber lumbar spine. • The pelvis and abdominal assembly has a seated design with vinyl skin and foam flesh

molded over an aluminum pelvis casting. Features have been incorporated to allow the dummy to be seated in a human-like slouched posture when appropriate.

• The thighs contain ball-jointed femurs and retaining rings for the hip pivot joint. A knee

insert under a vinyl knee impact surface controls impact response. • Zippered torso jacket and lower leg skins for easy removal.

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3. CLOTHING When required for testing, the dummy should wear a shirt and pants (children’s size 10-12) that are thermal knit, waffle weave, and cotton underwear or equivalent. The neckline must be small enough to prevent contact between a shoulder belt and the dummy’s skin. The pants should end above the dummy’s knee. The shirt and pants should weigh no more than 0.20 kg (0.45 lb) together. The shoes, when required, should be youth size 3 wide athletic shoes. Each shoe should weigh less than 0.59 kg (1.30 lb). Any additional clothing requirements are prescribed in accordance with the specific Federal motor vehicle safety standard testing procedure or specifications. 4. AVAILABLE INSTRUMENTATION The dummy has provisions for mounting the following sensors listed in Table 3.

Table 3. Dummy Instrumentation Capability

Transducer Type

Location in Dummy Part Number Measurements Total # Channels

Accelerometers Head SA572-S4 Ax, Ay, Az 3 Chest (T-4 spine) SA572-S4 Ax, Ay, Az 3 Upper Sternum SA572-S4 Ax 1 Lower Sternum SA572-S4 Ax 1 Upper Spine Box SA572-S4 Ax 1 Lower Spine Box SA572-S4 Ax 1 Pelvis SA572-S4 Ax, Ay, Az 3 Chest Deflection Thorax SA572-S50

(Pot), SA572-S43 (IR-TRACC)

Dx (Chest Pot) or DU, DL (IR-TRACC)

1 or 2

Load Cells Anterior Superior Iliac Spine (ASIS)

SA572-S13-L SA572-S13-R

Fx upper, Fx lower 4

Upper Neck SA572-S11 Fx, Fy, Fz, Mx, My, Mz 6 Lower Neck SA572-S40 Fx, Fy, Fz, Mx, My, Mz 6 Lumbar SA572-S9 Fx, Fy, Fz, Mx, My, Mz 6 Shoulder SA572-S41-L

SA572-S41-R Fx, Fz 4

Femur SA572-S10 Fx, Fy, Fz, Mx, My, Mz 12 Tibia SA572-S10 Fx, Fy, Fz, Mx, My, Mz 12 Tilt Sensors Head, Chest, Pelvis SA572-S42 Θx, Θy 6

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5. PROCEDURES FOR ASSEMBLY, DISASSEMBLY AND INSPECTION The complete HIII-10C dummy (shown in Figure 3) consists of six major assembly groups. Table 4 shows the breakdown of the assembly groups as they are described in the Procedures for Assembly, Disassembly and Inspection.

Figure 3. Major assembly groups of the HIII-10C dummy

Table 4. Dummy Assembly Groups

Assembly Group Part Number Head 420-1000 Neck 420-2000 Upper Torso 420-3000 Lower Torso 420-4000 Leg L Ri h

420-5000 420 5000 2 Arm

420-7000 420 7000 2

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5.1. Head The components in Table 5 list the parts that are included in the head assembly (420-1000). Figure 4 shows a drawing of a section through the center of the head with parts labeled as shown in Table 5. Figure 5 shows a photograph of the head assembly components with parts labeled as shown in Table 5.

Table 5. Head Assembly Components

Part Description Quantity Part Number Figure # Item # Neck Transducer Structural Replacement 1 (420-383X) 4, 5 1 Head Accelerometer Mount 1 (420-1006) 4 2 Skull, 6-Axis 1 (420-1001) 4, 5 3 Skull Cap 1 (420-1002) 4, 5 4 Skin, Head 1 (420-1003) 4, 5 5 Skin, Skull Cap 1 (420-1004) 4, 5 6 SHCS, 1/4-28 x 7/8 4 (9000264) 4, 5 7 SHCS, #10-24 x 1/2 4 (9000624) 4, 5 8 Washer, 1/4 ID x 3/8 OD x 1/16 TH 4 (9000677) 4, 5 9 SHCS, #10-24 x 3/8 (Ref) 4 (9000487) 4 10 SSCP, #8-32 x 1/4 2 (9000452) 4 11 Neck Transducer Pivot Pin 1 (420-1005) 4, 5 12

Figure 4. Drawing of head assembly

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Figure 5. Photograph of head assembly components

5.1.1. Assembling the Head First, secure the head skin (420-1003) to the skull (420-1001). Some massaging of the skin will be necessary to attain the appropriate position and fit of the skin onto the skull. It is important to get any air pockets out of the skin/skull interface as this can alter its performance. A small hole in the side of the skull upward and forward from the occipital condyle location designates the head cg location (Figure 5). There is a matching hole in the head skin that is to be aligned with the hole in the skull when fitting the head skin over the skull. The head instrumentation can be installed on the upper neck load cell or neck transducer structural replacement (420-383X) as described in the Instrumentation Installation section. Lower the load cell or structural replacement into the large hole in the base of the skull. Position it so that the flat edge of the structural replacement is aligned with the back of the skull. Attach the replacement to the bottom face of the skull base using four 1/4-28 x 7/8" SHCS (9000264) with four 1/4” ID x 3/8" OD x 1/16" thick washers (9000677). Fit the skull cap skin (420-1004) to the skull cap (420-1002), aligning the screw holes and positioning the lip of the skin into the ridge around the inside face of the cap. The skull cap may be attached to the skull with four #10-24 x 1/2" SHCS (9000624), completing the head assembly.

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6

3

7

5 4

8

9

CG hole

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5.1.2. Disassembling the Head 1. Remove four #10-24 x 1/2" SHCS and separate the skull cap from the head. 2. Remove four 1/4-28 x 7/8" SHCS with four 1/4" ID x 3/8" OD x 1/16" thick washers (Figure

6) and take out either the upper neck load cell or upper neck transducer structural replacement as shown in Figure 7.

3. Remove the head instrumentation by removing four #10-24 x 3/8" SHCS (see

Instrumentation Installation, section 6.1). Figure 6. Remove four 1/4-28 x 7/8" SHCS Figure 7. Remove upper neck load cell or

upper neck structural replacement 5.1.3 Inspecting the Head 1. Check the head skin for tears or cracks. Replace damaged head skins. 2. Check the skull for cracks or other damage. Replace the skull if it is damaged. 5.2. Neck Figures 8 and 9 show a drawing and photograph, respectively, of the neck assembly (420-2000) with parts labeled as shown in Table 6.

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Table 6. Neck Assembly Components

Part Description Quantity Part Number Figure # Item # Molded Neck Assembly 1 (420-2550) 8, 9 1 Nodding Joint Assembly 1 (420-2010) 8, 9 2 FHCS, #10-24 x 5/8 4 (9000566) 8, 9 3 Washer, Nodding Joint 2 (420-2022) 8 4 Nodding Block Neck – Hybrid III 2 (420-2023) 8, 9 5 Neck Bushing Upper 1 (420-2080) 8, 9 6 Neck Bushing Lower 1 (420-2090) 8, 9 7 Neck Cable 1 (420-2060) 8, 9 8 Washer, 13/32 ID x 3/4 OD x 3/32 TH 1 (9002950) 8, 9 9 Hex Jam Nut, 3/8-24 2 (9000130) 8, 9 10 Lower Neck Bracket Assembly 1 (420-2070) 8, 9 11 SHCS, 1/4-28 x 1 4 (9000567) 8, 9 12

Front of Dummy

Figure 8. Drawing of neck assembly section A-A

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Figure 9. Photograph of neck assembly components

5.2.1. Assembling the Neck Beginning with the molded neck assembly (420-2550), insert the upper and lower neck bushings (420-2080, 420-2090) into the upper and lower mount plates of the neck, respectively. Then, after assuring that the neck cable (420-2060) is not bent or frayed, insert it through the hole in the top of the molded neck assembly. Insert the 3/4" OD x 13/32" ID x 3/32" thick washer (9002950) over the threaded end of the neck cable at the bottom of the neck before securing the neck cable to the molded neck assembly by using two 3/8-24 jam nuts (9000130). In order to tighten the nuts, it is necessary to hold the bottom of the cable with a flathead screw driver in the slot so that the cable doesn’t twist around preventing proper torque to be applied.

12

11 7

10

8 1

5

3 6

2

9

11

The first jam nut must be torqued to 6 – 10 in-lbs (0.68 – 1.13 N-m). Once the first jam nut has been installed at the appropriate torque, a second jam nut is screwed onto the end of the neck cable to ensure that the first jam nut is secure. Attach the nodding joint assembly (420-2010) to the upper mount plate of the neck with four #10-24 x 5/8" FHCS (9000566). Attach the lower neck bracket assembly (420-2070) to the lower mount plate of the neck with four 1/4"-28 x 1" SHCS (9000567). The neck bracket has two dowel pins of different size that align with holes in the lower mounting plate of the neck. Insert nodding blocks (420-2023) into the forward and rearward cavities on the nodding joint assembly and fix them in place by press-fitting the cylindrical pegs into the holes on the periphery of the circle. Make sure the blocks are not placed upside-down (Figure 8). At this point, the neck may be attached to the upper neck load cell (SA572-S11) or its structural replacement (420-383X) with the neck transducer pivot pin (420-1005) (see item #12 in Figure 5) and two nodding joint washers (420-2022). Position the two washers on each side of the hole located on the nodding joint. Carefully lower the head assembly so that the holes at the occipital condyle position of the upper neck load cell or structural replacement align with the washers and nodding joint hole. The thickness of the washers may have to be modified to assure a snug fit. To ease alignment and relieve the load on the pivot pin, compress the neck and head together with a nodding block compression tool. It is advantageous to assure alignment to prevent damage to the nodding joint washers when the pivot pin is inserted. After loosening the two #8-32 x 1/4” SSCP (9000452) on the upper neck load cell or structural replacement, start the pointed end of the pivot pin into one side of the hole, with the flat portion of the pin facing the rear of the head to provide a mating surface for the SSCP. Carefully tap the pivot pin through the hole until the cylindrical portion of the pin is clearly visible on the opposite side of the load cell/structural replacement (Figure 10). Tighten the two #8-32 x 1/4" SSCP.

Figure 10. Connecting the head to the neck using the pivot pin and washers

5.2.2. Disassembling the Neck • In order to disassemble the neck completely, it is necessary to remove the neck assembly

from the head. Loosen the two #8-32 x 1/4" SSCP and carefully tap the pivot pin out of the nodding joint. Pull the head off the top of the neck, making sure that the nodding washers are accounted for and not damaged.

• To gain access to the neck cable jam nuts, remove the neck assembly from the lower neck

structural replacement or load cell, by taking out four 1/4"-28 x 1" SHCS.

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• With the neck separated from the upper and lower neck transducers or their structural replacements, the neck assembly can be further disassembled. After checking the cable torque, loosen and remove the two jam nuts at the bottom of the neck cable.

• Separate the nodding joint from the neck assembly by taking out four #10-24 x 5/8" FHCS. • Slide the neck cable out of the top of the neck and remove the bushings from the top and

bottom of the neck, respectively. 5.2.3. Inspecting the Neck Assembly • 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 condition of the strands. If they are not tightly

wound, if frays are visible, or the cable appears larger in diameter on one end, replace the cable. If the cable is permanently bent or if it cannot be properly torqued, replace the cable.

5.3. Upper Torso The components in Tables 7, 8, 9 and 10 list the parts that are included in the torso assembly. The torso has been separated into the upper torso, shoulder, chest deflection transducer, and lower torso assemblies in this section for organizational purposes. Figures 11 and 12 show a photograph and a drawing, respectively, of the upper torso assembly components with parts labeled as shown in Table 7.

Table 7. Upper Torso Assembly Components

Part Description Quantity Part Number Figure # Item # Upper Rib Stop Assembly, Left 1 (420-3900-1) 11,12 3 Front Rib End Stiffener Plate 2 (420-3240) 11,12 4 #8-32 x 5/8" BHCS 24 (9002421) 11,12 7 Bib Assembly 1 (420-3750) 11,12 8 Upper Rib Stop Assembly, Right 1 (420-3900-2) 11,12 9 Chest Flesh Assembly 1 (420-3560) 12 10 Spine Box Weldment 1 (420-3011) 11,12 11 #10-32 x 1/2" SHCS 4 (9000147) 11,12 12 Back Accel. Mount, Lower 1 (420-3660) 11, 12 14 Ribs #1 - #6 6 (420-3610-#) 11,12 18, 19, 21-24 Rib Threaded Strip 4 (420-3230) 11,12 20 Rib Rear Support 6 (420-3200) 11,12 25 Transducer Arm Slider 1 (420-3212) 11 26 #8-32 x 3/8" BHCS 12 (9000345) 11,12 27 Upper Stop Sternum 1 (420-3690) 12 32 Lower Stop Sternum 2 (420-3680) 12 34 #6-32 x 1/4" SHCS 6 (9000242) 12 35

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Figure 11. Photograph of upper torso assembly components

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9

3

12

11 20

7

18, 19, 21-24

27

25

4

7

10

26 20

14

14

Figure 12. Drawing of upper torso assembly with chest potentiometer and shoulder assembly

5.3.1. Assembling the Upper Torso Begin by fastening the upper (420-3690) and lower (420-3680) sternum stops to the spine box weldment (420-3011) using six #6-32 x 1/4" SHCS (9000242). Four of these screws attach the

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two lower sternum stops and two screws fasten the upper sternum stop to the spine box (Figure 13).

Figure 13. Attachment of the lower sternum stops

to the spine box

Attach the left and right upper rib stop assemblies (420-3900-1,2) to the sides of the spine box just below the neck attachment area using four #10-32 X 1/2" SHCS (9000147). Attach the chest accelerometer assembly to the instrumentation mount (420-3035) as described in the Instrumentation Installation section, and fasten the mount to the spine box with four #10-32 x 3/8" FHCS (9000249). The six rib assemblies (420-3610-#) and six rear rib supports (420-3200) may now be attached to the rear of the spine box using two #8-32 x 3/8" BHCS (9000345) per rib. Rib assembly #1 (420-3610-1) goes at the top of the spine box, rib assembly #2 (420-3610-2) goes below rib assembly #1, and so on. Each rib assembly is stamped with the rib assembly # to identify its position on the dummy. One rear rib support fits over each rib at its attachment to the spine box for reinforcement against bending stresses as shown in Figure 14.

Figure 14. Attaching rib assemblies and rear rib supports to spine box weldment

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Place the transducer arm slider (420-3212) with the track on the inside through the slot in the bib and align the holes in the slider (also called “sternum”) with the holes closest to the center of the bib. Secure the slider to the bib using twelve #8-32 x 5/8" BHCS (9002421) (Figure 15) with two threaded strip, rib (420-3230) positioned behind the bib as shown in Figure 16. If the accelerometers (SA572-S4) are to be used on the sternum, they are to be installed at this time. For proper assembly and accelerometer orientation, see Instrumentation Installation. The bib assembly (420-3750) may now be attached to the front of the ribs with a front rib end stiffener plate (420-3240) on the front of the bib (Figure 17) and two threaded strip, rib (420-3230) on the back of the rib. One #8-32 x 5/8" BHCS (9002421) goes through the stiffener plate, bib, and rib (in that order) and fastens to the threaded strip at each end of each rib. The ribs use the column of holes in the bib furthest out from the center of the bib for their attachment (Figure 18).

Figure 15. Attach transducer arm slider and threaded rib strip to bib assembly (front)

Figure 16. Attach transducer arm slider and threaded rib strip to bib assembly (rear)

Figure 17. Position bib to front of ribs

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Figure 18. Attach front rib end stiffener plate, ribs and bib, to front rib threaded strip The shoulder, chest deflection transducer, and lower torso assemblies need to be installed before positioning the abdomen (420-4300) in the torso. Then the chest flesh assembly (420-3560) can be fitted over the torso, completing the torso assembly. 5.3.2. Disassembling the Upper Torso With the chest flesh assembly, or jacket, and abdomen removed, the following steps describe the disassembly of the upper torso. • Remove the two sternum accelerometers, if installed. • Remove the twenty-four #8-32 x 5/8" BHCS and separate the sternum, rib stiffeners, and

threaded strips from the bib assembly. • Remove the two spine accelerometers, if installed. • Remove the rear rib supports by removing the six #8-32 x 3/8" BHCS from the rear of the

spine box. • With the rib assemblies detached, separate them from the spine box. • Remove four #10-32 x 3/8" FHCS and separate the instrumentation mount from the spine

box, taking care not to tear the chest accelerometer cables or lower spine box accelerometer cable, if installed.

• Remove the chest accelerometers, if installed. • Remove the upper rib stop assemblies and upper and lower sternum stops.

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5.3.3. Inspecting the Upper Torso • Check to see that the zipper attachment to the chest flesh assembly is secure and that the

zippers work appropriately. Check the jacket for tears, cuts, or other damage. Replace if damaged.

• Check to ensure that the rib damping material is securely bonded to the rib steel and that the

rib steel is not permanently deformed. The ends of the ribs at the sternum are especially subject to damage, so these shall be inspected closely. Replace entire rib set if any deformation or damage is observed.

• Check to ensure that the rear rib supports are not bent. Replace if damaged. • Check to ensure that the front end rib stiffener plates and front rib end / sternum threaded

strips are not bent. Replace if damaged. • Check to ensure that the chest deflection transducer arm slider is not badly gouged or

damaged along the path of the transducer ball travel. Replace if damaged. • Check to ensure that the bib assembly is not cut or damaged. Replace if necessary. • While fully assembled, measure the horizontal distance from the threaded rib strip to the rear

edge of the spine box between ribs 1-2 and ribs 5-6 (Figure 19). This is best accomplished using a depth gauge that fits between the ribs and lies flush against the back of the spine box. Replace ribs if the rib 1-2 measurement is less than 5.414 inches or the rib 5-6 measurement is less than 5.303 inches. Note that the measurement is made to the rib strip between ribs and not to the end of the bib/sternum attachment bolt at rib level.

Figure 19. Measurement of internal chest depth

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5.3.4. Assembling the Neck to the Upper Torso Assembly The lower neck bracket assembly (420-2070) is the interface piece between the neck and upper torso assemblies. Position the bracket into the compartment at the top of the spine weldment, and rotate the neck to the desired 0, 8, 16, or 23 degree adjustment by first fastening the back side loosely in place with two 3/8-16 x 5/8" BHCS (9001160) and then aligning the relevant hole on the neck bracket with that of the spine weldment (Figure 20).

Figure 20. Assembling the neck to the upper torso assembly (set in position SP-16 as shown

unless otherwise specified)

To fix the neck in place, feed the modified 5/16 x 2" SHSS (420-0011) with washer, flat 1/4 (.257) x 5/8 (9000175) through the front neck adjustment hole (Figure 20). Put another washer, flat 1/4 (.257) x 5/8 (9000175) on the opposite side and tighten a nut, hex jam 1/4-20 x 5/32 thk. (9002934) against it. Finally, tighten the two 3/8-16 x 5/8" BHCS on the rear side. Note that the neck must be adjusted and attached prior to assembling the shoulders. 5.3.5. Shoulder The components in Table 8 list the parts of the shoulder assembly that are included in the torso assembly. Figures 21, 22, 23, and 24 show exploded views of the shoulder assembly components, as well as front and side views of the assembled shoulder on the dummy, with parts labeled as shown in Table 8.

5.3.5.1. Assembling the Shoulder After the neck is fixed in the desirable position, the left and right shoulder supports (420-3583) can be fastened to the spine box by fitting the rounded portion of the support in the groove behind the neck fitted with two shoulder bumpers (420-3550) (Figure 25). The supports can then be fixed in place by routing the modified screw (420-3591) through the following parts in order (from the back of the spine box): flat 7/16” x 1” x 3/32” washer (9000098), spine box, shoulder pivot washer (420-3576), shoulder support, another shoulder pivot washer, clavicle link pivot washer (420-3277), and clavicle link pivot nut (420-3400) recessed in the other side of the spine box (Figure 26). Two more shoulder bumpers (420-3590) should be press-fit into the cavity inside the shoulder supports (Figure 27).

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Table 8. Shoulder Assembly Components

Part Description Quantity Part Number Figure # Item # Shoulder Assembly, Left 1 (420-3800-1) 12 2 Shoulder Assembly, Right 1 (420-3800-2) 12 1 Clavicle Link Assembly, Right 1 (420-3391-2) 21, 22 1 Shoulder Yoke Pivot Bushing 4 (420-3480) 21, 22 2 Shoulder Yoke Assembly 2 (420-3430) 21, 22 3 Retaining Washer 2 (420-3500) 21, 22 4 Shoulder Joint Spring Washer 2 (420-3510) 21, 22 5 Flat 0.25 x 1.0 x 0.06 Washer 2 (9000169) 21, 22 6 Nut, Lock Nut ¼-20 Nylon Collar, 7/32 Height

2 (9005216) 21, 22 7

Steel Stop 2 (420-3460) 21, 22 8 #4-40 x 1/4” SHCS 4 (9000528) 21, 22 9 Stop Assembly, Shoulder 2 (420-3470) 22 10 Shoulder Stop Bracket 2 (420-3410) 21, 22 11 Shoulder Rotation Stop Assembly 2 (420-3440) 21, 22 12 #8-32 x 1/4” SHCS 2 (9002418) 21, 22 13 #6-32 x 3/8” BHCS 4 (9001213) 21, 22 14 Pivot Nut 2 (420-3588) 12, 21 26 Modified Screw 2 (420-3591) 12, 21 28 Flat 7/16 x 1 x 3/32 Washer 2 (9000098) 12, 21 29 Shoulder Pivot Washer 4 (420-3576) 12, 21 30 Clavicle Link Pivot Washer 2 (420-3277) 12, 21 31 Clavicle Link Pivot Nut 2 (420-3400) 12, 21 33 Shoulder Support Assembly 2 (420-3583) 12, 21 39 Shoulder Bumper 2 (420-3590) 12, 21 40 5/16” x 1” SHSS 2 (9000652) 12, 21 41 Flat Washer 21/64” ID x 9/16” OD x 1/16”

2 (9000022) 12, 21 42

Shoulder Pivot Washer II 4 (420-3587) 12, 21 43 Shoulder Washer 2 (420-3586) 12, 21 44 Shoulder Bumper 2 (420-3550) 12, 21 45

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Figure 21. Photograph of shoulder assembly components (only left shoulder shown here)

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6

5

4

2 39

3

31

9

8

1

10

2

26

30

28

29

41

42

43

44 13

12

11

14

30

44

33

40

45

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Figure 22. Drawing of right shoulder assembly

Figure 23. Front view of the assembled right shoulder on the spine box

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Figure 24. Side view of the assembled left shoulder on the spine box

Figure 25. Positioning and fitting of the left shoulder support into spine box

24

Figure 26. Fastening the right shoulder support to the spine box behind the neck

Figure 27. Fitting the shoulder bumper into the right shoulder support

To assemble the shoulder, begin with the shoulder yoke assembly (420-3430). If the shoulder stop assembly (420-3470) is not already attached, use adhesive compound to fix it in the counter-sink hole with chamfered surface aligning with edge of hole through the yoke. Connect the steel stop (420-3460) to the periphery of the yoke with two #4-40 x 1/4” SHCS (9000528) (Figure 28). Fit the small-diameter side of the yoke with a shoulder yoke pivot bushing (420-3480) with the large-diameter side to the outside. Feed the yoke assembly, lining up the bushing holes with the dowel pins, through the hole in the clavicle link assembly (420-3391-1,2), Figure 29, or the load cell, (SA572-S41). Complete the shoulder assembly by fastening the yoke on the

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inside of the clavicle link in the following order: another shoulder yoke pivot bushing (large diameter to the inside this time), retaining washer (420-3500), shoulder joint spring washer (420-3510), flat 1/4" x 1" x 1/16" washer (9000169), and Nut, Lock Nut 1/4"-20 Nylon Collar, 7/32" Height (9005216) (Figure 30). Tighten the lock nut to the torque specification shown in Table 2. Finally, attach the shoulder rotation stop assembly (420-3440) and shoulder stop bracket (420-3410) to the back side of the interface of the yoke and clavicle link using one #8-32 x 1/4" SHCS (9002418) and two #6-32 x 3/8" BHCS (9001213) (Figure 31).

Figure 28. Attaching the shoulder and steel stops to the shoulder yoke

Figure 29. Fitting the shoulder yoke bushing to the shoulder yoke

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Figure 30. Fastening the shoulder yoke assembly to the right clavicle link

Figure 31. Attaching the shoulder rotation stop to the yoke at the right clavicle link interface

The left and right clavicle link assemblies can then be fastened to the shoulder supports by fitting the rounded portion of the link into the groove of the shoulder bumper. Align the hole in the clavicle with the hole in the shoulder support, and fasten the two together by routing the 5/16" x 1" SHSS (9000652) through the following parts in order (from top to bottom): flat washer (9000022), shoulder support, shoulder pivot washer II (420-3587), clavicle link assembly, shoulder pivot washer II, shoulder support, shoulder washer (420-3586), and pivot nut (420-3588) recessed in the other side of the shoulder support (Figure 32). Assure that the torque on this screw adheres to the torque specification found in Table 2.

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Figure 32. Connection of clavicle link assembly to right shoulder support

5.3.5.2. Disassembling the Shoulder • Remove the left and right shoulder assemblies from the shoulder supports by removing the

following from each shoulder assembly: (1) 5/16" x 1" SHSS, (1) flat washer, (2) shoulder pivot washer II, (1) shoulder washer, and (1) pivot nut. Take care not to tear the instrumentation cables coming out of the load cells if installed.

• Remove the shoulder stop assembly and bracket from each clavicle and yoke by taking out

the #8-32 x 1/4" SHCS and two #6-32 x 3/8" BHCS. • Slide the shoulder yoke out of each clavicle by first removing the 1/4"-20 hex jam nut, flat

1/4" x 1" x 1/16" washer, shoulder joint spring washer, retaining washer, and two shoulder yoke pivot bushings.

• Remove each shoulder support from the spine box by removing the modified screw, flat

7/16" x 1" x 3/32" washer, two shoulder pivot washers, clavicle link pivot washer, and clavicle link pivot nut.

5.3.5.3. Inspecting the Shoulder • Check to ensure that the shoulder bumpers are not torn or damaged. Replace if damaged. • Check to ensure that the shoulder stops are not broken. Replace if damaged.

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• Check to ensure that the shoulder pivot washers, modified screws, or 5/16" x 1" SHSS are

not cracked. Replace if broken. • Check to ensure that the shoulder stops are securely bonded to the left and right shoulder

yoke assembly. Reglue with adhesive compound if necessary. 5.3.6. Chest Potentiometer The components in Table 9 list the parts of the Chest Deflection Transducer Assembly that are included in the Torso Assembly. Figures 33 and 34 show a photograph and a drawing, respectively, of the chest deflection transducer assembly components with parts labeled as shown in Table 9.

Table 9. Chest Deflection Transducer Assembly Components Part Description Quantity Part Number Figure # Item # Left Lower Rib Stop 1 (420-3640-1) 12, 33 5 Right Lower Rib Stop 1 (420-3640-2) 12, 33 6 #10-32 x 1/2" FHCS 3 (9000208) 39 19 Flat Washer 9/32" ID x 1/2" OD x 1/16" 4 (9000553) 12 16 1/4"-20 x 1/2" SHCS 4 (9000121) 12, 33 17 Lumbar Thoracic Adaptor Assembly 1 (420-3530) --- --- Mounting Plate Adaptor Assembly 1 (420-3520) 33 3 Mounting Plate Adaptor 1 (420-3270) 33 3 Thorax Potentiometer Mount 1 (420-3271) 33 8 Thorax Stop 2 (420-3577) 33 35 #6-32 x 1/2" SHCS 4 (9000119) 34 36 Bearing SR6553 Barden or Equal 1 (9001179) 33, 34 2 Transducer Assembly 1 (420-3710) --- --- Machined Potentiometer Bracket 1 (420-3711) 33 11 Bearing 5/16" OD x 1/8" ID 2 (9001257) 33 12 Arm Connector 1 (420-3712) 33 13 O-Ring 5/8" OD x 1/2" ID x 1/16" Thick 1 (9001309) 33 14 Chest Rotary Potentiometer 1 (SA572-S50) 33 15 Transducer Arm 1 (420-3730) 33 19 #2-56 x 3/8" SHCS 1 (9000675) 33 20 Six-Year-Old Transducer Ball 1 (420-3721) 33 21 #4-40 x 1/8" SSCP 4 (9000154) 33 22 Flat #10 x 1/2" x .049 Washer 1 (9000054) 33 23 #10-32 x 5/16" BHCS 1 (9001369) 33 24 Transducer Arm Slider 1 (420-3212) 33, 34 4

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Figure 33. Photograph of chest deflection transducer assembly components

Figure 34. Drawing of chest deflection transducer assembly

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13

21

14

15

11

24

23 22

12

20 19

35

2

8

6

17

3

5

4

36

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5.3.6.1. Assembling the Chest Potentiometer Figures 35 and 36 show the chest deflection transducer assembly (420-3540) in detail to assist in its assembly. The machined potentiometer bracket, or “pot bracket” (420-3711), has two 5/16" O.D. x 1/8" I.D. bearings (9001257) which fit tightly into the bracket. If the fit of these two bearings is not sufficiently tight, replace the pot bracket. Slide the bottom end of the transducer arm (420-3730) into the arm connector (420-3712) and secure in place with two #4-40 x 1/8" SSCP (9000154) as shown in Figure 35. Then align the arm connector hole with the holes of the potentiometer bracket. Slide the 5/8" OD x 1/2" ID x 1/16" thick o-ring (9001309) over the shaft of the chest deflection potentiometer (SA572-S50), and insert the potentiometer shaft through the hole in the potentiometer bracket (Figure 35). The shaft of the potentiometer goes through the potentiometer bracket, arm connector, and into the bracket again. When sliding the potentiometer shaft into place, be sure to line up the locator pin on the potentiometer with the corresponding hole in the bracket. This will keep the potentiometer housing from rotating. Once the potentiometer is in place, secure its shaft to the arm connector with two more #4-40 x 1/8" SSCP (9000154). Finally, the o-ring shall be positioned into the crevice between the potentiometer and the bracket by gently pushing or poking the o-ring into place. The Allen wrench used to fasten the #4-40 x 1/8" screws is a good tool for this.

Figure 35. Attach the transducer arm to the arm connector

It is important to obtain a secure fit between the potentiometer and the bracket so that the potentiometer housing does not rotate. It is possible to first position the o-ring into the crevice and then slide the potentiometer shaft into the bracket. However, obtaining proper fit of the locator pin on the pot into the hole of the bracket can be quite difficult with the o-ring already in the crevice. It has been found that it is easier to position the o-ring last, by sliding it over the potentiometer housing into the crevice. Next, the transducer ball (420-3721) shall be attached to the transducer arm with one #2-56 x 3/8" SHCS (9000675) as shown in Figure 36. The distance between the outer edge of the ball and the outer edge of the transducer arm is 0.45 +/- 0.01 inches (see drawing 420-3720). Once

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the ball is attached at the appropriate distance from the arm, secure it in place using adhesive compound. The Barden bearing (9001179) shall be press-fit into the appropriate hole of the thorax potentiometer mount (420-3271) of the lumbar thoracic adaptor assembly (420-3530) as shown in Figure 33. It is important that the bearing fit is tight. Then slide the round portion of the pot bracket through the bearing in the thorax potentiometer mount and secure with one #10 x .500" x .049" thick flat washer (9000054) and one #10-32 x 5/16" BHCS (9001369). Fasten the two thorax stops (420-3577) to the thorax potentiometer mount using two each #6-32 x 1/2" SHCS (9000119) as shown in Figures 33, 34, and 37. Attach the left and right lower rib stops (420-3640-1, 2) to the top of the mounting plate adaptor assembly (420-3520) using two each 1/4"-20 x 1/2" SHCS (9000121), see Figure 33. With the curved portion of the rib stop toward the outside of the dummy, the longer straight edge of the rib stop is oriented toward the top of the dummy, while the shorter straight edge is facing the back of the dummy (Figure 37).

Figure 36. Connecting ball to transducer arm

Figure 37. Attach the transducer assembly to the mounting plate adaptor assembly (bottom view) The next step is to attach the lumbar thoracic adaptor assembly, with chest deflection transducer assembly attached, to the molded lumbar assembly (420-4100) using three #10-32 x 1/2" FHCS (9000208). However, before this can be done, the lumbar assembly must be put together as described in the Lower Torso Assembly section.

Front of Dummy

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5.3.6.2. Disassembling the Chest Potentiometer • Remove the three #10-32 x 1/2" FHCS from the lumbar thoracic adaptor assembly and

separate the chest deflection transducer assembly from the Lower Torso Assembly. • Remove the four 1/4"-20 x 1/2" SHCS to remove the left and right lower rib stops. • Remove the four #6-32 x 1/2" SHCS to remove the thorax stops. • Remove the #10-32 x 5/16" BHCS and flat washer to separate the chest deflection transducer

assembly from the thorax potentiometer mount. • Remove two #4-40 x 1/8 SSCP and separate the transducer arm from the arm connector. • Remove two #4-40 x 1/8 SSCP and separate the potentiometer shaft from the potentiometer

bracket and arm connector. • Remove the o-ring from the potentiometer bracket. 5.3.6.3. Inspecting the Chest Potentiometer • Inspect the chest deflection potentiometer by rotating its shaft. The motion should feel

smooth and free of restrictions; if it does not feel smooth, have it inspected by an electronics technician. Replace the potentiometer if damaged.

• Check that the distance between the outside edge of the transducer ball and the outer edge of

the transducer arm is 0.45 +/- 0.01 inches. • Check to ensure that the transducer ball is securely bonded to the transducer arm. Secure

with an epoxy resin if necessary. • Check to ensure that the transducer arm is not bent out of its original shape. Replace if

damaged. • Check to ensure that the set screw threads in the arm connector are not worn causing the

transducer arm or potentiometer shaft to become unfastened. Replace set screws or re-thread arm connector if damaged.

• Check that the potentiometer locator pin is installed into the hole of the machined

potentiometer bracket for appropriate fit. • Check that the o-ring is properly installed over the potentiometer housing into the machined

potentiometer bracket for tight fit. Otherwise, the potentiometer housing may be able to rotate.

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• Check to ensure a tight press-fit between the Barden bearing and the transducer mount weldment. Press-fit a new bearing into the weldment if necessary.

• Check to ensure that the thorax stops are not broken. Replace if damaged. • Check to ensure that the left and right lower rib stops are not cracked or broken. Replace if

damaged. 5.4. Lower Torso The components in Table 10 list the parts of the Lower Torso Assembly that are included in the complete Torso Assembly. Figures 38 and 39 show a photograph and a drawing, respectively, of the lower torso assembly components with parts labeled as shown in Table 10.

Table 10. Lower Torso Assembly Components

Part Description Quantity Part Number Figure Item Molded Lumbar 1 (420-4100) 38, 39 1 Lumbar Attachment 1 (420-4121) 38, 39 2 Modified Screw 1 (420-4122) 38, 39 3 Lumbar Cable 1 (420-4130) 38, 39 4 Lumbar Adjustment Bracket 1 (420-4200) 38, 39 5 Adjustment Bracket Nut 1 (420-4210) 38, 39 6 Abdomen 1 (420-4300) 38, 39 7 Molded Pelvis 1 (420-4400) 38, 39 8 Femur Assembly, Left and Right 1 ea. (420-4500-1,2) 38, 39 9 Lumbar Load Cell Simulator 1 (420-4401) 38, 39 10 ASIS Load Cell Replacement, Left 1 (420-4505-1) 38, 39 11 ASIS Load Cell Replacement, Right 1 (420-4505-2) 38, 39 12 Nylon Shoulder Bushing for 5/16" x 1/4" Screw 1 (420-4509) 38, 39 13 Square Sleeve 2 (420-4411) 38, 39 14 1/4-20 x 7/8" SHCS 4 (9000086) 38, 39 15 #10-32 x 1/2" SHCS 4 (9000147) 38, 39 16 1/4-28 x 1 1/4" SHCS 2 (9000141) 38, 39 17 Mounting Plate Insert 1 (420-4507) 38, 39 18 #10-32 x 1/2" FHCS 3 (9000208) 38, 39 19 5/16-24 Hex Jam Nut 2 (9001336) 38, 39 20 1/4-20 x 1/2" SHCS 2 (9000121) 38, 39 21 1/4-28 x 3/4" SHCS 4 (9000453) 38, 39 22 #10-24 x 1/2" SHCS 6 (9000624) 38, 39 23 5/16" x 1" SHSS 2 (9000652) 38, 39 24 Friction Plunger Assembly 2 (420-4508) 38, 39 25

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Figure 38. Photograph of lower torso assembly components

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22 19 18 4

20 13

1

21

2 3

5

11

12

25

16 10

15

23

6 17

8

14

9

24

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Figure 39. Drawing of lower torso assembly

5.4.1. Assembling the Lower Torso Beginning with the molded lumbar assembly (420-4100), place the mounting plate insert (420-4507) and nylon shoulder bushing for 5/16" x 1/4" screw (420-4509) into the upper and lower plates of the lumbar assembly, respectively. Then, after assuring that the lumbar cable (420-4130) is not damaged (see Inspecting the Lower Torso), thread it through the hole in the middle of the lumbar spine and secure using one 5/16" - 24 jam nut (9001336) torqued to 6 - 10 in-lbs (0.68 - 1.13 N-m). In order to tighten the nut, it is necessary to hold the bottom of the cable with a flathead screw driver in the slot so that the cable doesn’t twist around preventing proper torque to be applied. Once the first jam nut has been installed at the appropriate torque, a second jam nut is screwed onto the end of the cable to keep the first jam nut in place. Once the lumbar assembly is complete, attach the lumbar attachment bracket (420-4121) to the bottom of the lumbar assembly using two 1/4-20 x 1/2" SHCS (9000121) and one modified screw (420-4122) in the countersunk hole found in the underside of the attachment as shown in Figure 40.

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36

Figure 40. Attaching lumbar attachment to lumbar assembly

Beginning with the lumbar load cell simulator (420-4401) (or lumbar load cell SA-572-S9), route four #10-32 x 1/2" SHCS (9000147) from the bottom through the holes that form a circular pattern. Take the lumbar adjustment bracket (420-4200) and fasten it to the top of the simulator or load cell using those SHCS, making sure that the teeth on the bracket are facing the rear of the dummy (Figure 41). Now, take the molded pelvis assembly (420-4400) and position the lumbar load cell simulator or load cell on the flat surface inside the pelvis cavity with the base holes aligned with the pelvis holes. Using four 1/4"-20 x 7/8" SHCS (9000086), fasten the simulator to the pelvis. The front two SHCS can be fed through the top of the simulator, while the rear two SHCS should be fastened in the opening in the pelvis occupied by the pelvis accelerometers (Figure 42).

Figure 41. Attach lumbar adjustment bracket to lumbar load cell simulator

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Figure 42. Attach load cell simulator to molded pelvis assembly

Take the left and right femur assemblies (420-4500-1,2) and position the femur ball in the acetabular socket in the machined pelvis. Align the holes in the femur ball retaining ring (420-4513) portion of the femur assembly with the holes circumventing the socket. Using an Allen wrench, tighten three #10-24 x 1/2" SHCS (9000624) on both femurs (Figure 43). Rotate the femur inward to reach the bottom SHCS.

Figure 43. Attach femur assemblies to molded

pelvis assembly

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If the pelvis accelerometers (SA572-S4) are to be used, they shall be installed at this time. Refer to Instrumentation Installation for installation instructions and proper accelerometer orientation. Next, install both the left and right ASIS load cell replacements (420-4505-1,2) (or ASIS load cells SA572-S13) by positioning them in the sides of the pelvis cavity and fastening in place with four 1/4" – 28 x 3/4" SHCS (two on each side) using an Allen wrench through the back of the pelvis (Figure 44).

Figure 44. Attach ASIS load cell simulators to molded

pelvis assembly

Next, attach the lumbar assembly to the molded pelvis by positioning the lumbar attachment on the lumbar adjustment bracket in the desired lumbar angle (0 – 24 degrees in 4 degree increments) (Figure 45). Position “SP-12” indicates “Standard Posture”, which aligns the upper torso perpendicular to the dummy’s seating surface. Position “SS-0” indicates “Standard Slouch”, which reclines the upper torso 12 degrees back from perpendicular. SP-12 should be used unless otherwise specified. Fix the lumbar in place by positioning the nut, adjustment bracket (420-4210) so that the teeth mesh with the teeth of the lumbar adjustment bracket. Route two 1/4-28 x 1.25” SHCS (9000141) through the nut and bracket and tighten, making sure that the desired angle indicator on the lumbar attachment remains aligned with the notch on the adjustment bracket (Figure 46).

Figure 45. Positioning lumbar attachment on lumbar adjustment bracket

39

Figure 46. Fasten lumbar attachment to lumbar adjustment bracket

5.4.2. Disassembling the Lower Torso • Remove the pelvis accelerometers if installed. • Remove the two 1/4-28 x 1 1/4" SHCS which hold the lumbar to the pelvis. • Remove the abdomen if present, taking care not to tear it. • Remove the ASIS load cell simulators or load cells by taking out the four 1/4" – 28 x 3/4"

SHCS, taking care not to tear the cables. • Remove the six #10-24 x 1/2" SHCS from the acetabular socket and take out the femur

assemblies. • Remove the lumbar load cell simulator or load cell (if installed) by taking out four 1/4"-20 x

7/8" SHCS. • Detach the lumbar adjustment bracket from the load cell simulator or load cell (if installed)

by removing four #10-32 x 1/2" SCHS. • Detach the lumbar attachment from the bottom lumbar plate by removing the two 1/4" – 20 x

1/2" SCHS and one modified screw. • Remove the two jam nuts at the end of the lumbar cable. • Remove the cable from the molded lumbar spine. • Remove the mounting plate insert and nylon shoulder bushing from the lumbar spine.

40

5.4.3. Inspecting the Lower Torso • Check the abdomen for tears or other damage in the foam. Solder minor tears or replace if

damage is extensive. • Check the lumbar cable by observing the condition of the strands. If they are not tightly

wound, if frays are visible, or the cable appears larger in diameter on one end, replace the cable. If the cable is permanently bent or if it cannot be properly torqued, replace the cable.

• Check the lumbar for deformation, tears, or breaks in the rubber. Replace the lumbar if any

damage is observed. • Check the hardness of the lumbar in several locations near the middle of the rubber segment

with a durometer. If the lumbar is too hard or too soft, as specified in the drawing, replace it. • Check the mounting plate insert and nylon shoulder bushing for cracks. Replace if broken or

damaged. Check to make sure the lumbar remained in the same angular position. If not, check the

adjustment nut and bracket for stripping of the teeth. 5.4.4. Assembling the Upper and Lower Torso Assemblies Once the lower torso is assembled, the mounting plate adaptor of the lumbar thoracic adaptor assembly can be attached to the top of the lumbar assembly with three #10-32 x 1/2" FHCS (9000208) as shown in Figure 47. Once the chest deflection transducer and lower torso assemblies have been fastened together, the upper and lower torso assemblies can be attached. Slide the transducer ball (420-3721) into the track of the transducer arm slider (420-3212). Place the bottom plate of the spine box weldment (420-3011) onto the lumbar thoracic adaptor and align the mounting holes. Thread four 1/4"-20 x 1/2" SHCS (9000121), each with a flat washer, 9/32 ID x 1/2 OD x 1/16 (9000553) through the bottom of the adaptor into the weldment to secure the upper and lower torso assemblies together as shown in Figure 48.

Figure 47. Attaching the chest potentiometer and lower torso assemblies together

41

Figure 48. Fastening the upper and lower torso assemblies together

The “positioning guides” protruding from the sides of the abdomen are to be positioned above the iliac “wings” at the front of the pelvis assembly as shown in Figure 49. It should be pressed as far down into the pelvis cavity as possible, with the top edge underneath the chest potentiometer mounting plate adaptor. Fit the entire torso assembly into the chest flesh assembly (420-3560) or “jacket,” after positioning the abdomen (420-4300) within the abdominal region of the pelvis cavity. Fasten the zipper in the back of the jacket (Figure 50). This completes the torso assembly.

Figure 49. Proper positioning of abdominal insert

Figure 50. Fitting jacket over torso assembly

42

5.5. Arms The components in Table 11 list the parts used in assembling the left and right Upper Arm Assemblies and attaching them to the Torso Assembly as well as the parts used in assembling the left and right Lower Arm-Hand Assemblies and attaching them to the Upper Arm Assembly. Figures 51 and 52 show a photograph of the upper and lower arm assembly components and drawing with parts labeled as shown in Table 11.

Table 11. Upper / Lower Arm and Hand Assemblies with Attachment Hardware

Part Description Quantity

(Total L/R)

Part Number Figure Item

Upper Arm Molded Assembly 2 (420-7001) 51, 52 1 Upper Arm, Lower Part Weldment 2 (420-7050) 51, 52 2 1/4” x 1 1/4” SHSS 2 (9000289) 51, 52 3 Upper Arm and Elbow Pivot Washer 4 (420-7080) 51, 52 4 Upper Arm and Elbow Pivot Bushing 4 (420-7090) 51, 52 5 Molded Arm Lower 2 (420-7120) 51, 52 6 Shoulder Joint Spring Washer 4 (420-3510) 51, 52 7 Upper Arm Pivot Nut 4 (420-7100) 51, 52 8 Washer, 21/64 ID x 9/16 OD x 1/16 4 (9000022) 51, 52 9 5/16" x 7/8" SHSS 4 (9002587) 51, 52 10 Wrist Rotation Weldment 2 (420-7180) 51, 52 11 1/4" x 5/8" SHSS 2 (9000619) 51, 52 12 Hand Molded, Left and Right 2 (420-7230-1, 2) 51, 52 13 5/16" x 5/8" SHSS 2 (9001021) 51, 52 14

43

Figure 51. Drawing of arm assembly

5.5.1. Assembling One Arm Begin by inserting the upper arm lower part weldment (420-7050) into the bottom side of the upper arm molded assembly (420-7001), and fasten by inserting one 1/4” x 1 1/4" SHSS (9000289) into the hole on the side of the upper arm molded assembly (Figure 53). Place the upper arm and elbow pivot washer (420-7080) and bushing (420-7090) into opposite sides of the elbow hole of the lower part weldment, and place the shoulder joint spring washer (420-3510) in the bushing side of this assembly. Locate the grooves on the bushing and washer with the lower arm stops located on the lower molded arm (420-7120) as indicated in Figure 54. Position the upper arm pivot nut (420-7100) on the spring washer side of the lower molded arm, and feed the 5/16" x 7/8" SHSS (9002587) with flat washer (9000022) through the joint starting on the opposite side of the pivot nut (Figure 55). Next, attach the wrist rotation weldment (420-7180) to the lower molded arm using a 1/4" x 5/8" SHSS (9000619), and attach the molded hand (420-7230-1, 2) to the wrist weldment with a 5/16" x 5/8" SHSS (9001021) (Figure 56). Tighten the elbow and wrist according to the torque requirements stated in Appendix B. Repeat these steps for the opposite arm.

44

Figure 52. Photograph of arm assembly components

Figure 53. Attach the upper arm lower weldment

to the upper arm molded assembly

1

2

3

4

5

6

7 8

9

10

11

12

14

13

45

Figure 54. Locate the grooves on the bushing and washer with the lower arm stops

Figure 55. Attach the upper arm lower weldment to the lower arm at the elbow

Figure 56. Attach the hand to the lower arm via the wrist

46

5.5.2. Assembling the Upper Arm to the Torso Place the upper arm and elbow pivot washer (420-7080) and bushing (420-7090) into opposite sides of the shoulder hole of the upper arm, and place the shoulder joint spring washer (420-3510) in the bushing side of this assembly. Locate the grooves on the bushing and washer with the dowel pins located on inside of the shoulder yoke assembly (420-3430) as indicated in Figure 57. Position the upper arm pivot nut (420-7100) on the spring washer side of the shoulder yoke, and feed the 5/16" x 7/8" SHSS (9002587) with flat washer (9000022) through the joint starting on the opposite side of the pivot nut (Figure 58). Adjust the shoulder joint torque as described in Appendix B. Repeat these steps for the opposite arm.

Figure 57. Align the grooves on the bushing and washer with the shoulder yoke dowel pins

Figure 58. Attach the upper arm to the shoulder yoke assembly

47

5.5.3. Disassembling the Arm • Remove the 5/16 x 7/8" SHSS from the shoulder pivot and separate the arm assembly from

the torso. • Remove the hand (9001021), wrist (9000619), elbow (9002587), and upper arm (9000289)

SHSS from the arm. Be sure not to lose the two washers, two bushings, two pivot nuts, or two spring washers when disassembling each arm.

5.5.4. Inspecting the Arm • Check that the bushings are present and are not cracked or damaged. Replace if damaged. • Check that the washers are present. Secure in place if necessary. If the washers are cracked

or damaged, replace them. • Repair any torn flesh as described in Appendix A. Check that the joint torques are at the 1 G setting as described in Appendix B. 5.6. Legs The components in Table 12 list the parts used in assembling the left and right Leg Assemblies and attaching them to the Torso Assembly. Figures 59 and 60 show a photograph of the leg assembly components and drawing with parts labeled as shown in Table 12, respectively. 5.6.1. Assembling One Leg Starting with the upper leg weldment (420-5110) and flesh (420-5120), attach the femur load cell simulator (420-5121) or femur load cell (SA572-S10) to the weldment with a 1/4-20 x 1 1/4 SHCS (9001170) (Figure 61). Take the machined kneecap (420-5210) and fit the knee flesh (420-5220) and knee insert (420-5230). Attach the assembled knee to the femur load cell simulator or load cell with 1/4"-20 x 1 1/2" SHSS (9005003), as shown in Figure 62. Take the lower leg upper weldment (420-5310) and attach it to the knee assembly using the same method as was used for the shoulder and elbow (see Figures 55 and 58), and apply a 1 g torque. Insert the lower leg rotation stop assembly (420-5405) and tighten until contact with the machined knee is present (Figure 63). Repeat these steps for the opposite leg.

48

Table 12. Upper / Lower Leg and Foot Assemblies with Attachment Hardware

Part Description Quantity (Total L/R) Part Number Figure Item

Upper Leg, Upper Assembly 2 (420-5100) 60 1 Upper Leg Weldment 2 (420-5110) 59 35 Upper Leg Flesh 2 (420-5120) 59 17 Femur Load Cell Simulator 2 (420-5121) 59 18 1/4" – 20 x 1 1/4 SHCS 2 (9001170) 59 19 Knee Assembly 2 (420-5200) 60 2 Machined Knee Cap 2 (420-5210) 59 21 Knee Flesh 2 (420-5220) 59 22 Knee Insert 2 (420-5230) 59 20 1/4"-20 x 1 1/4" SHCS 2 (9005003) 59,60 9 Lower Leg Assembly 2 (420-5300) 60 3 Lower Leg, Upper Weldment 2 (420-5310) 59 23 Lower Leg, Lower Weldment 2 (420-5320) 59 24 Lower Leg Flesh 2 (420-5330) 59 25 1/4"-20 x 1 1/4" BHCS 4 (9001200) 59 26 5/16" x 1 3/4" SHSS 2 (9002391) 59, 60 11 Washer Bushing 2 (420-5515) 59, 60 12 Spring Washer Yoke 2 (420-5516) 59, 60 13 Nut 2 (420-5517) 59, 60 14 Knee Bushing 2 (420-5340) 59, 60 15 Lower Leg Rotation Stop Assembly 2 (420-5405) 59, 60 6 Ankle Assembly 2 (420-5400) 60 5 Ankle Bumper Assembly 2 (420-5408) 59,60 7 Screw, SHSS 1/4 x 5/8 2 (9000619) 59, 60 8 Ankle Attachment Bolt 2 (420-5518) 59,60 16 #6-32 x 1/2" BHCS 8 (9000247) 56, 60 10 Ankle Shell 2 (420-5410) 59 27 Ankle Shaft 2 (420-5420) 59 28 Lower Ankle Shell 2 (420-5402) 59 29 Stop Pin Retainer 2 (420-5403) 59 30 Ankle Friction Pad 2 (420-5401) 59 31 #6-32 x 1/2" FHCS 6 (9001279) 59 32 5/16-18 x 3/8" SSCP 2 (9000073) 59 33 #8-32 x 1/4" SSCP 4 (9000452) 59 34 Foot Molded, Left and Right 2 (420-5500-1, 2) 59, 60 4

49

Figure 59. Photograph of leg assembly components

34

33

32

31

30

29

28

27

10 7

8

4

6

15

35

12

14 11

26

25

23

24

18

21

22

17

9

19

16

20

13

50

Figure 60. Drawing of leg assembly

Figure 61. Attach the femur load cell or simulator to upper leg

51

Figure 62. Attach the knee assembly to the femur load cell or simulator

Figure 63. Insert the lower leg rotation stop assembly

Attach another femur load cell (SA572-S10) or femur load cell simulator (420-5121) to the lower leg weldment with a 1/4-20 x 1 1/4 BHCS (9001200), and connect the lower leg lower weldment (420-5320) with another 1/4-20 x 1 1/4 BHCS (Figure 64).

Figure 64. Assemble the lower leg bone

52

5.6.2. Assembling the Ankle and Foot Beginning with the ankle shell (420-5410), press fit the ankle friction pad (420-5401) into the hole leading from the ball joint area to the lower leg weldment attachment area (Figure 65). Take the ankle shaft (420-5420) and insert the ball end into the joint area of the ankle shell. Insert the 3/16 x 3/8 dowel pin (9000044) through the slot along the outside edge of the ankle shell and align it with the slot in the ball (Figure 66). Push the stop pin retainer (420-5403) into the slot, and place the lower ankle shell (420-5402) onto the shell and tighten down with three #6-32 x 1/2" FHCS (9001279) (Figure 67). Insert two #8-32 x 1/4" SSCP (9000452) and tighten until the stop pin is snug. Put the 5/16-18 x 3/8” SSCP (9000073) in the same hole as the friction pad and tighten the joint to the desired torque. To complete the ankle assembly, position the ankle bumper assembly (420-5408) and fasten with four #6-32 x 1/2" BHCS (9000247) (Figure 68). Attach the ankle assembly to the lower leg weldment with one ankle attachment bolt (420-5518) (Figure 69). Finally, attach the bottom of the ankle assembly to the molded foot assembly (420-5500-1, 2) with one 1/4 x 5/8" SHSS Screw (9000619) (Figure 70). Finally, put the lower leg flesh (420-5330) on the lower leg, with the zipper in back. Repeat these steps for the opposite leg.

Figure 65. Fit the ankle friction pad into the ankle shell

Figure 66. Insert the dowel pin into the ankle shaft

53

Figure 67. Insert the stop pin retainer and fasten the lower ankle shell

Figure 68. Attach the lower shell and ankle bumper assembly

Figure 69. Attach the ankle assembly to the lower leg weldment

54

Figure 70. Attach the ankle assembly to the foot

5.6.3. Assembling the Leg to the Lower Torso Guide the top of the upper leg upper weldment into the machined femur, aligning the pins on both sides of the weldment with the femur slots. Fasten the two parts together with a 5/16 x 1 SHSS (9000652), as shown in Figure 71.

Figure 71. Attaching the leg to the lower torso

5.6.4. Disassembling the Leg • Remove the 5/16 x 1 SHSS from the hip pivot and separate the leg assembly from the lower

torso. • Remove the knee and ankle screws, as well as the lower leg rotation stop screws from the

knee, and carefully separate the lower leg from the upper leg and foot, taking care not to tear the knee and ankle stops. Be sure not to lose the washers, bushings, or screws when disassembling each leg.

• Remove lower leg flesh.

55

5.6.5. Inspecting the Leg • Check that the knee and ankle stops are present and not destroyed, causing specification

problems with the range of motion of the lower leg or foot or possibly causing metal-to-metal contact. Replace if damaged.

• Check that the bushings, washers, or screws are not cracked or damaged. If damaged,

replace them. • Repair any torn flesh as described in Appendix A. • Inspect the load cells if installed. Check that the joint torques are at the 1 G setting as described in Appendix B.

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6. INSTRUMENTATION INSTALLATION All instruments required for compliance testing or otherwise specified are to be installed in the dummy as described herein. Installation of all other instruments is optional. 6.1. Head Accelerometers The accelerometers in the head are used to measure accelerations in the x, y and z directions occurring at the center of gravity of the head. Table 13 shows the parts needed for installing the instrumentation in the head.

Table 13. Head Instrumentation Parts

Part Description Quantity Part Number Figure Item

Head Accelerometer 3 Axis Mounting Block 1 (420-1006) or (420-9121) 72 1

#10-24 x 3/8" SHCS 4 (9000487) 72 2 Triaxial Mount Block 1 (SA572-S80) 72 3

#2-56 x 5/8" SHCS 2 (9000531) 72 4 Uniaxial Piezoresistive Accelerometer 3 (SA572-S4) 72 5 #0-80 x 1/8" SHCS 6 (9000152) 72 6

Mount the three uniaxial piezoresistive accelerometers (SA572-S4) onto the triaxial mount block (SA572-S80) with two each #0-80 x 1/8" SHCS (9000152) so that their seismic masses all point to the back left corner of the block. Attach the triaxial block to the head accelerometer 3 axis mounting block (420-1006) or head mounting block with tilt sensor (420-9121) using two #2-56 x 5/8" SHCS (9000531) as shown in Figure 72. Place the 3 axis mounting block onto the upper neck load cell or structural replacement and attach with four #10-24 x 3/8" SHCS (9000487) as shown in Figure 73.

Figure 72. Head accelerometers shown in correct orientation

1

2

3

4

5

6

Front

Back

57

Figure 73. Accelerometers mounted in the head

6.2. Sternum Accelerometers The sternum accelerometers are used in conjunction with the spine box accelerometers and the x-accelerometer of the chest accelerometer assembly to measure relative acceleration between the sternum and spine in the x-direction. The accelerometer on the upper part of the sternum is in line with the upper spine box accelerometer; and the accelerometer on the lower part of the sternum is in line with the lower spine box accelerometer. These accelerometer pairs were developed to supplement the Chest Deflection Transducer Assembly and the Chest Accelerometer Assembly in determining sternum displacement, velocity and acceleration. Table 14 shows the parts needed for installing the accelerometers on the sternum.

Table 14. Sternum Accelerometer Parts

Part Description Quantity Part Number Figure Item

Uniaxial Piezoresistive Accelerometer 2 (SA572-S4) 74 1

#0-80 x 1/8" SHCS 4 (9000152) 74 2

Transducer Arm Slider 1 (420-3212) 74 3

Mount the two uniaxial piezoresistive accelerometers (SA572-S4) onto the outside of the transducer arm slider (420-3212) with two each #0-80 x 1/8" SHCS (9000152) as shown in Figure 74. The seismic masses of the upper and lower accelerometers point toward the top and bottom of the sternum, respectively, so that the accelerometer cables can be routed in the groove toward the center of the sternum.

58

Figure 74. Accelerometers mounted on the sternum

6.3. Spine Box Accelerometers The accelerometers on the lower spine box are used along with the accelerometers on the sternum to measure acceleration of the sternum relative to the spine. Table 15 shows the parts needed for installing these accelerometers.

Table 15. Spine Box Accelerometer Parts

Part Description Quantity Part Number Figure Item Uniaxial Piezoresistive Accelerometer 2 (SA572-S4) 75 1 #0-80 x 1/8" SHCS 4 (9000152) 75 2 Upper Back Accelerometer Mount 1 (420-3741) 75 3

Mount the uniaxial piezoresistive accelerometer (SA572-S4) onto the upper back accelerometer mount (420-3741) with two #0-80 x 1/8" SHCS (9000152). The seismic mass is pointed upward so that the cable can be routed out of the rib cage, as shown in Figure 75.

Figure 75. Spine accelerometers mounted at ribs 6 and 1

1

1

2 3

1

2

3

59

6.4. Chest Accelerometers The accelerometers in the chest are used to measure accelerations in the x, y and z directions occurring at the T-4 location of the spine. These accelerometers are essentially placed inside the “chest cavity” of the dummy and are referred to as either “chest” or “T-4” accelerometers. Table 16 shows the parts needed for installing the accelerometers in the chest.

Table 16. Chest Accelerometer Parts

Part Description Quantity Part Number Figure Item

Uniaxial Piezoresistive Accelerometer 3 (SA572-S4) 76 1 Triaxial Mount Block 1 (SA572-S80) 76 2 #0-80 x 1/8" SHCS 6 (9000152) 76 3 Chest Mount 1 (420-9211) 76 4 #2-56 x 9/16" SHCS 2 (9000550) 76 5 Instrumentation Mount with SA572-S42 Tilt Sensor 1 (420-3035) 76 6

#4-40 x 1/4" SHCS 4 (9000528) 76 7 Mount the three uniaxial piezoresistive accelerometers (SA572-S4) onto the triaxial mount block (SA572-S80) with 2 each #0-80 x 1/8" SHCS (9000152) so that their seismic masses all point to one corner of the block. Attach the triaxial mount block to the chest mount (420-9211) with two #2-56 x 9/16" SHCS (9000550). Then attach the chest mount to the Instrumentation Mount with SA572-S42 Tilt Sensor (420-3035) with four #4-40 x 1/4" SHCS (9000528) as shown in Figure 76. When the accelerometers are installed, the seismic masses are all pointing forward and/or leftward with respect to the dummy.

Figure 76. Chest accelerometers mounted in the spine box weldment (front view)

1

3 2 5

4

7

6

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6.5. Pelvis Accelerometers The accelerometers in the pelvis are used to measure accelerations in the x, y and z directions occurring in the pelvis. Table 17 shows the parts needed for installing the accelerometers in the pelvis.

Table 17. Pelvis Accelerometer Parts

Part Description Quantity Part Number Figure Item

Uniaxial Piezoresistive Accelerometer 3 (SA572-S4) 77 1

Triaxial Mount Block 1 (SA572-S80) 77 2 #0-80 x 1/8" SHCS 6 (9000152) 77 3 Pelvis-Accel Mount with SA572-S42 Tilt Sensor 1 (420-9321) 77 4

#2-56 x 5/8" SHCS 2 (9000531) 77 5 Pelvic Bone- Machined 1 (420-4410) 77 6 #10-32 x 3/4" SHCS 2 (9000151) 77 7

Mount the three uniaxial piezoresistive accelerometers (SA572-S4) onto the triaxial mount block (SA572-S80) with 2 each #0-80 x 1/8" SHCS (9000152) so that their seismic masses all point to one corner of the block. Attach the triaxial block to the Pelvis-Accel Mount with SA572-S42 Tilt Sensor (420-9321) with two #2-56 x 5/8" SHCS (9000531). Then mount the assembly to the pelvic bone, machined (420-4410) with two #10-32 x 3/4” SHCS (9000151) as shown in Figure 77. When the accelerometers are installed, the seismic masses are all pointing upward and/or leftward with respect to the dummy and the notch in the pelvis adaptor plate matches the notch in the pelvic bone weldment.

Figure 77. Accelerometers mounted in the pelvis

6

7

7

4 1

3

5 2

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6.6. Tilt Sensor The HIII-10C dummy design allows for a tilt sensor (SA572-S42) with accompanying mounting blocks with holes for the head, chest, and pelvis to measure orientation about the X and Y-axis (Table 18 and Figure 78) during positioning of the dummy prior to use in a test.

Table 18. Tilt Sensor Parts Part Description Quantity Part Number Figure Item 2-Axis Tilt Sensor 1-3 (SA572-S42) 78 18 Chest Accelerometer Mount 1 (420-9211) 78 20 Pelvis Accelerometer Mount 1 (420-9321) 78 21 Head Accelerometer Mount 1 (420-9121) 78 22

Figure 78. Tilt sensor assembly drawings 6.7. IR-Tracc The HIII-10C dummy design allows for thoracic instrumentation with mechanical and electrical capabilities equivalent to the IR-Tracc (420-8000) (Table 19). This assembly is used in lieu of 420-3540, chest deflection transducer assembly, only when specified.

Table 19. IR-Tracc Parts Part Description Quantity Part Number Figure Item IR-Tracc Assembly 1 (420-8000) 79 --- Transducer Arm Slider 1 (420-8014) 79 1 IR-Tracc Displacement Sensor Assembly, H3-10YO

2 (SA572-S43) 79 2

Dowel Pin, 1/8” x 1 1/2” 2 (9002415) 79 3 Sleeve I 2 (420-8015) 79 4 Sleeve III 1 (420-8012) 79 5 Screw, SSCP #4-40 x 1/4” 2 (9000218) 79 6 Swivel Pin 4 (420-8030) 79 7 Dowel Pin, 1/8” x 5/8” 4 (9000004) 79 7 Modified Screw 4 (420-8031) 79 7 Sleeve II 1 (420-8009) 79 8 Instrumentation Mount 1 (420-3281) 79 9 Sternum Threaded Strip, Left 1 (420-8040-1) 79 10 Sternum Threaded Strip, Right 1 (420-8040-2) 79 11 Chest Rotary Potentiometer 2 (SA572-S50) 79 12

62

Figure 79. IR-Tracc Assembly Drawing

Figure 80. IR-Tracc Assembly

6.8. Load Cells The load cells available to the HIII-10C dummy use the same threaded fasteners as their corresponding structural replacements (Upper Neck (SA572-S11), Lower Neck Load Cell (SA572-S40), Shoulder Load Cells (SA572-S41L & SA572-S41R) containing Shoulder Load Cell Yoke Assembly (420-3435), Lumbar Load Cell (SA572-S9), ASIS Load Cells (SA572-S13L & SA572-S13R), Femur Load Cells (SA572-S10)). When installing the lumbar load cell, position the load cell so that the cables are to the rear of the dummy. There are no special

63

installation instructions concerning any other load cells. However, instrumentation cable routing is critical in prevention of cable damage and is discussed in the Cable Routing section. 7. INSTRUMENTATION CABLE ROUTING The dummy contains provisions for mounting numerous electronic instruments (Table 3) 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 that ensures 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 Hybrid III 10 Year Old dummy that indicates some of the instrumentation and sample cable routing (Figure 81).

Figure 81. Cable routing schematic

64

The upper neck load cell cables are routed up through the base plate of the skull. The head accelerometer and upper neck load cell cables (Figure 82) exit the head between the skull and skull cap and are routed through the channels in the rear of the skull. It is important to leave enough extra cable between the head and torso to allow the head and neck to rotate forward without introducing tension in the instrumentation cables (Figure 83).

Figure 82. Head accelerometer and upper neck load cell cables

Figure 83. Cable slack to allow for head motion

65

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 (Figure 84). The cables exit the rib cage just below rib number 3 and next to the lumbar spine, 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.

Figure 84. Rear view of cable routing

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 skull and the spine (Figure 85). Attach one end of the grounding cable under one of the rear #10-32 x 5/8" SHCS which attaches the head accelerometer mounting plate to the skull. Attach the opposite end of the grounding cable with a #8-32 fastener to the thorax instrument cavity rear face. Next, attach one end of a second, longer length of cable at this same location (at the thorax instrument cavity rear face) 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.

66

Figure 85. Grounding cable

If the sternum mounted accelerometers are installed, route them along the bib assembly 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 (Figure 86). From there, route the cables to the rear of the thoracic cavity and then down along the spine box.

Figure 86. Sternum accelerometer cables

If the lower neck load cell is used, route the cables down through the top of the spine box and then out through the thorax instrument cavity rear face (Figure 87). Then route the cables inside the thoracic cavity and down along the sides of the spine box. If the T-1 spine accelerometers are used, route the cables down into the thoracic cavity and along the side of the spine. The chest accelerometer cables and the lower spine box accelerometer cable are routed internally of the spine box, down to just below the third rib. At this point, the cables exit the lower rear portion of the spine box and can be combined with the other cables into the umbilical. If the shoulder load cells are used, route the cables inside the thoracic cavity down to the lower rear portion of the spine and combine them with the other cables into the umbilical (Figure 88). The cables can exit either the bottom of the load cell or the rear side. Either way, the cable

67

should be routed down through the thorax cavity. The cables for the lumbar load cell and the T-12 spine accelerometers, if used, will all be located in close proximity to the umbilical. Simply route these cables directly into the umbilical. The anterior superior iliac spine (A.S.I.S.) load cells and lumbar load cell are also located in the pelvic region and these cables are simply routed back to the rear of the dummy and into the umbilical (Figure 89).

Figure 87. Lower neck load cell cables

Figure 88. Shoulder load cell cables with (left) rear and (right) bottom cable exit

68

Figure 89. ASIS and lumbar load cell cables

The cables for the pelvis accelerometers will be located in the bottom of the pelvic region (Figure 90). These cables can be routed directly up the back side of the pelvis and into the umbilical. Place the jacket on the dummy, being careful not to pinch any of the cables in the jacket zipper. The cable bundle should exit through the hole provided in the jacket (see Figure 91). 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.

Figure 90. Pelvic accelerometer cables

Figure 91. Umbilical exiting through jacket

69

8. EXTERNAL DIMENSIONS These measurements shall be taken prior to testing with the dummy in order to verify key external dimensions and identify possible deficiencies in the dummy molded parts or problems with the internal structural configuration. These dimensions shall be checked without any instrumentation cabling coming from the rear of the dummy as this bundle may affect the measurements. 1. Check that the torque on the 5/16 - 24 jam nut closest to the lumbar spine on the lumbar

cable and the 5/16 - 24 jam nut closest to the neck on the neck cable are 0.68-1.13 N-m (6-10 in-lbs). Adjust the torque if necessary.

2. Reassemble the dummy, except for the chest jacket and abdominal insert. Refer to Assembly sections of the PADI for instruction. The lumbar spine and neck angles should be 12 and 0 degrees, respectively.

3. Seat the dummy on a flat, rigid, smooth, clean, dry, horizontal surface as shown in Figure 92. The seating surface must be at least 406 mm (16 in) wide and 221 mm (8 11/16 in) deep, with a vertical section at least 406 mm (16 in) wide and 610 mm (24 in) high attached to the rear of the seating fixture. The dummy’s midsagittal plane is vertical and centered on the test surface.

4. Secure the dummy to the test fixture so that the upper torso and buttocks are against the rear vertical surface of the fixture.

5. The horizontal distance forward from the square lifting hole to the dummy’s H-point is 58.3 mm (2.295 in) and the vertical distance is 39.3 mm (1.546 in). Position the dummy’s hip pivot so that it is 84.0 +/- 5.1 mm (3.31 +/- 0.2 in) above the horizontal seating surface and 138.2 +/- 5.1 mm (5.44 +/- 0.2 in) forward of the rear vertical surface of the fixture.

6. The D-plane of the pelvis bone is set to 18 ± 2 degrees with respect to horizontal. 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 rearmost surface of the head should be 48.3 +/- 2.5 mm (1.9 +/- 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. The centerline between the knee pivot and the ankle pivot is parallel to the rear vertical surface of the fixture.

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 shoulder and elbow pivot is parallel to the rear vertical surface of the fixture.

11. Position the lower arms horizontally so that the centerline of the lower arm-hand is parallel to the seat surface.

12. Measure and record the dimensions listed in Table 20, except for dimensions X, Y and Z, as these measurements are best taken while the dummy is free from the seating fixture.

13. Mark the locations AA and BB and record the measured dimensions Y and Z as specified in Table 20. Measure and record dimension X.

14. Note any measurements that are not within the specifications listed in Table 21 and resolve discrepancies prior to testing with the dummy.

15. Install the chest jacket and abdominal insert, and measure the dimensions in Table 20 that include these parts.

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Figure 92. Schematic showing external dimension measurement designations

16. Check the flatness of the 2” long belt-interacting lengths of the shoulder portion of the chest

flesh assembly (420-3560) and front surface of the pelvis flesh molded assembly (420-4400) as shown in Figure 93. There should not be any gaps between a straight-edge and the dummy surface greater than 1/8" when measured along mid-sagittal plane of the pelvis or the mid-coronal plane of the shoulder. This step helps to assure that the belt will not artificially slide laterally on the shoulder or vertically on the pelvis due to a “domed” geometry or be artificially held in place by a “cupped” surface.

Figure 93. Check shoulders (left) and pelvis (right) for belt fit & interaction

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Table 20. External Dimension Definitions

Dim. Description Definition A Total Sitting Height Fixture’s seat surface to highest point on top of head B Shoulder Pivot Height Centerline of shoulder pivot bolt to fixture’s seat surface C Hip Pivot Height REFERENCE - set dummy hip pivot height at specified vertical

distance from fixture’s seating surface D Hip Pivot from Back-line REFERENCE - set dummy hip pivot at specified horizontal

distance from fixture’s rear vertical surface E Shoulder Pivot from Back-line with Jacket Center of shoulder pivot bolt to fixture’s rear vertical surface F Thigh Clearance Fixture’s seat surface to highest point on the upper leg segment G Back of Elbow to Wrist Pivot Back of elbow flesh to wrist pivot bolt, in line with the elbow and

wrist centerlines H Head Back from Back-line REFERENCE - rearmost surface of head to the fixture’s rear

vertical surface I Top of Shoulder Yoke to Elbow Length Highest point on top of the shoulder to the lowest part of the flesh

on the elbow, in line with the shoulder and elbow pivot bolts J Elbow Rest Height The flesh below the elbow pivot bolt to the fixture’s seat surface K Back-line to Knee Length Most forward surface of the knee flesh to the fixture’s rear

vertical surface, minus the gap from buttock to fixture L Bottom of Seating Surface to Bottom of Foot 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 Back-line to Rear-most Part of Calf The most forward portion of the crevice between the upper and

lower legs behind the knee to the fixture’s rear vertical surface O Chest Depth without Jacket Measured 342.9 +/- 5.1 mm (13.5 +/- 0.2 in) above seat surface P Foot Length Tip of toe to rear of heel R Backline to Knee Pivot Length Knee pivot bolt to the fixture’s rear vertical surface, minus the

gap from buttock to fixture S Head Breadth Distance across the width of the head at its widest point T Head Depth Distance from the forward most surface of the head to the

rearmost surface of the head, in line with the midsagittal plane U Hip Breadth Distance across the width of the hip at the widest point of the

jacket V Shoulder Breadth – Bone to Bone Distance between outside edges of shoulder yoke, in line with the

shoulder pivot bolts W Foot Breadth The widest part of the foot X Head Circumference At the largest location Y Chest Circumference with Jacket Distance around chest at reference location AA, with jacket on. Z Waist Circumference The distance around waist at reference location BB, with the

jacket on. AA Chest Circumference REFERENCE – 342.9 +/- 5.1 mm (13.5 +/- 0.2 in) above seat

surface BB Waist Circumference REFERENCE – 1 cm below top rear surface of pelvis flesh,

parallel to pelvis rim CC Shoulder belt interaction REFERENCE – No more than 1/8” along midcoronal (see Fig.

93) DD Pelvis belt interaction REFERENCE – No more than 1/8” along midsagittal (see Fig.

93)

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Table 21. External Dimensions of HIII-10C Dummy

Dim. Description Specification (in.)

+/- (in.) Specification (mm)

+/- (mm)

A Total Sitting Height 28.20 0.50 716.3 12.7 B Shoulder Pivot Height 15.55 0.40 395.0 10.2 C Hip Pivot Height (see Note 1) 3.31 0.20 84.1 5.1 D Hip Pivot from Back-line (see Note 1) 5.44 0.20 138.2 5.1 E Shoulder Pivot from Back-line with Jacket 3.55 0.20 90.2 5.1 F Thigh Clearance 4.45 0.30 113.0 7.6 G Back of Elbow to Wrist Pivot 9.25 0.30 235.0 7.6 H Head Back from Back-line (see Note 1 1.90 0.10 48.3 2.5 I Top of Shoulder Yoke to Elbow Length 10.90 0.30 276.9 7.6 J Elbow Rest Height 5.80 0.40 147.3 10.2 K Back-line to Knee Length 18.65 0.40 473.7 10.2 L Bottom of Seating Surface to Bottom of Foot 13.05 0.40 331.5 10.2 M Knee Pivot Height 15.00 0.30 381.0 7.6 N Back-line to Rear-most Part of Calf 14.85 0.40 377.2 10.2 O Chest Depth without Jacket (see Note 2) 6.50 0.30 165.1 7.6 P Foot Length 7.70 0.30 195.6 7.6 R Backline to Knee Pivot Length 16.70 0.40 424.2 10.2 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 10.40 0.30 264.2 7.6 V Shoulder Breadth – Bone to Bone 12.40 0.30 315.0 7.6 W Foot Breadth 3.00 0.30 76.2 7.6 X Head Circumference 21.20 0.40 538.5 10.2 Y Chest Circumference with Jacket 27.70 0.50 703.6 12.7 Z Waist Circumference 27.90 0.50 708.7 12.7

AA Reference Location for Chest Circumference 13.50 0.20 342.9 5.1 BB Reference Location for Waist Circumference Table 20 CC Shoulder belt interaction Table 20 DD Pelvis belt interaction Table 20

Notes: 1) Dimensions C, D, and H are the setup dimensions 2) Dimension BB is 1 cm (0.4 inches) below top rear surface of pelvis flesh, parallel to pelvis rim

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9. SEGMENT WEIGHTS Check the weights of the various dummy segment assemblies. They should conform to the specifications in Table 22. Consult Tables 23-32 which define the contents of each segment.

Table 22. Segment Weights of HIII-10C Dummy

Dummy Body Segment Specification (lbs.)

+/- (lbs.)

Specification (kg)

+/- (kg)

Head Assembly 8.23 0.10 3.73 0.05 Neck Assembly 1.77 0.10 0.80 0.05 Upper Torso Assembly w/ Jacket 17.94 0.30 8.15 0.14 Lower Torso Assembly 19.21 0.30 8.72 0.14 Right Upper Arm 1.78 0.10 0.81 0.05 Left Upper Arm 1.78 0.10 0.81 0.05 Right Lower Arm 1.35 0.10 0.61 0.05 Left Lower Arm 1.35 0.10 0.61 0.05 Right Hand 0.38 0.10 0.17 0.05 Left Hand 0.38 0.10 0.17 0.05 Right Upper Leg 5.90 0.15 2.68 0.07 Left Upper Leg 5.90 0.15 2.68 0.07 Right Lower Leg 4.92 0.15 2.23 0.07 Left Lower Leg 4.92 0.15 2.23 0.07 Right Foot 0.90 0.05 0.41 0.02 Left Foot 0.90 0.05 0.41 0.02 Total Weight 77.61 2.00 35.21 0.91

Table 23. Head Assembly Segment Weight Components

Part Description Quantity Part Number Head Assembly 1 (420-1000) Triaxial Mount Block 1 (SA572-S80) #2-56 x 5/8” SHCS 2 (9000531) Uniaxial Piezoresistive Accelerometer (or mass equivalent)

3 (SA572-S4)

#0-80 x 1/8” SHCS 6 (9000152)

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Table 24. Neck Assembly Segment Weight Components

Part Description Quantity Part Number Neck Assembly 1 (420-2000)

3/8-16 x 5/8" BHCS 2 (9001160) 5/16 x 2 Modified SHSS 1 (420-0011) Nut, Hex Jam 3/8-24 1 (9000130) Washer, 3/4 OD x 13/32 ID x 3/32 2 (9002503)

Table 25. Upper Torso Assembly Segment Weight Components

Part Description Quantity Part Number Upper Torso Assembly 1 (420-3000) Upper Arm & Elbow Pivot Washer 2 (420-7080) Upper Arm & Elbow Pivot Bushing 2 (420-7090) Shoulder Joint Spring Washer 2 (420-3510) Upper Arm Pivot Nut 2 (420-7100) Flat Washer 2 (9000022) 5/16 x 7/8" SHSS 2 (9002587) S4 Triaxial Accelerometer Mounting Block 1 (SA572-S80) Chest Mount (SA572-S4) 1 (420-9211) Uniaxial Piezoresistive Accelerometers (or mass equivalent)

7 (SA572-S4)

0-80 x 1/8" SHCS 14 (9000152) 2-56 x 5/8" SHCS 2 (9000531) 4-40 x 1/4" SHCS 4 (9000528)

Table 26. Lower Torso Assembly Segment Weight Components

Part Description Quantity Part Number Lower Torso Assembly 1 (420-4000) Pelvic Accelerometer Mount with SA572-S41 Tilt Sensor

1 (420-9321)

#10-32 x 3/4" SHCS 2 (9000151) S4 Triaxial Accelerometer Mounting Block 1 (SA572-S80) Uniaxial Piezoresistive Accelerometer (or mass equivalent)

3 (SA572-S4)

0-80 x 1/8" SHCS 6 (9000152) 2-56 x 5/8" SHCS 2 (9000531) 10-32 x 3/4" SHCS 2 (9000151)

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Table 27. Upper Arm Assembly Segment Weight Components (Left and Right)

Part Description

Quantity (Each Left and Right)

Part Number Upper Arm Molded Assembly 1 (420-7001) Upper Arm Lower Part Weldment 1 (420-7050)

1/4" x 1-1/4" SHSS 1 (9000289)

Table 28. Lower Arm Assembly Segment Weight Components (Left and Right)

Part Description

Quantity (Each Left and Right)

Part Number Molded Arm Lower 1 (420-7120) Upper Arm & Elbow Pivot Washer 1 (420-7080) Upper Arm & Elbow Pivot Bushing 1 (420-7090) Shoulder Joint Spring Washer 1 (420-3510) Upper Arm Pivot Nut 1 (420-7100) Flat Washer 1 (9000022) 5/16 x 7/8" SHSS 1 (9002587) Wrist Rotation Weldment 1 (420-7180) 1/4 x 5/8" SHSS 1 (9000619) 5/16 x 5/8" SHSS 1 (9001021)

Table 29. Hand Assembly Segment Weight Components (Left and Right)

Part Description

Quantity (Each Left and Right)

Part Number Hand Molded Assembly 1 (420-7230-1, -2)

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Table 30. Upper Leg Assembly Segment Weight Components (Left and Right)

Part Description

Quantity (Each Left and Right)

Part Number Upper Leg, Upper Assembly 1 (420-5100) 1/4-20 x 1 1/2" SHCS 1 (9005003) Knee Assembly 1 (420-5200)

Table 31. Lower Leg Assembly Segment Weight Components (Left and Right)

Part Description

Quantity (Each Left and Right)

Part Number Lower Leg Assembly 1 (420-5300) Ankle Assembly 1 (420-5400) Ankle Bumper Assembly 1 (420-5408) Lower Leg Rotation Stop Assembly 1 (420-5405) Knee Bushing 1 (420-5340) Yoke Spring Washer 1 (420-5516) Nut 1 (420-5517)

5/16 x 1 3/4" SHSS 1 (9002391) Bushing Washer Elbow/Shoulder/Knee 1 (420-5515)

Table 32. Foot Assembly Segment Weight Components (Left and Right)

Part Description

Quantity (Each Left and Right)

Part Number Foot Molded Assembly 1 (420-5500-1, -2) 1/4 x 5/8" SHSS 1 (9000619)

A-1

APPENDIX A. FLESH REPAIR Head Skin Repair The HIII 10C head skin can be repaired with a heating iron, however, repairs should not be made in areas that will affect the performance of the head assembly during testing. Therefore, do not attempt to repair flesh damage in the frontal or forehead region of the head. Typically, a heating iron, similar to a standard electronic soldering iron, is used to make flesh repairs. For best results, a variable power supply set between 60 and 90 watts is suggested to control the amount of heat provided by the iron. When repairing flesh, remove all loose material from the damaged areas and clean the flesh with 99% isopropyl alcohol in a well ventilated area. 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. Scrapes can be repaired by rubbing the iron over the affected area. If black flakes of burnt flesh start to appear, the iron is either too hot or has been in the same spot too long. Clean the iron tip (flat paddle or “duck bill” suggested) frequently by quickly tapping it on a buffing wheel or rubbing it with a wire brush. 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. Other Flesh Repairs For small cuts or tears occurring in regions which are not expected to contribute significantly to the dummy’s response (such as the dummy’s extremities), Loctite 406 may be used to repair the damage. If significant damage is sustained, the part should be either replaced or remolded by the manufacturer.

B-1

APPENDIX B. JOINT TORQUE ADJUSTMENTS The joints of the dummy are to be adjusted to a “1G” torque setting. 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 forward and perpendicular to the dummy’s body, the shoulder 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. Upper and Lower Arms

1. Extend the entire arm so that it points forward and is in a horizontal position. Tighten the hex nut (Figure 29) until the shoulder joint torque will support the weight of the arm. 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 bolt. Repeat the procedure of tapping at the wrist and adjusting the shoulder bolt until the 1G-torque requirement is satisfied. Repeat for the lateral direction, with the arm straight out to the side and horizontal instead of forward and horizontal (Figure B1).

2. Rotate the upper arm down so that it is vertical and along the side of the dummy’s torso.

Orient the lower arm so it points forward and is horizontal. Adjust the elbow pivot bolt through the access holes in the lower arm flesh at the elbow until the elbow joint torque is sufficient to support the weight of the lower arm (see Fig. B2). Tap the lower arm near the wrist with a vertical impact. The lower arm should slowly fall back down along the dummy’s side. 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.

3. Repeat steps 1 and 2 for the other arm assembly.

Legs and Feet

1. Place the dummy in a seated position. 2. Remove the ASIS load cells or their structural replacements (see Figure 43).

3. Orient the lower leg at 90 degrees relative to the upper leg. Lift the upper leg assembly

above horizontal. Adjust the friction plunger until the joint torque is sufficient to support the weight of the leg (see Fig. B3). 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 bolt. Repeat the procedure of tapping at the knee and adjusting the femur bolt until the 1G-torque requirement is met.

B-2

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. B4). 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 bolt until the

joint torque is sufficient to support the weight of the foot (see Fig. B5). Tap the foot near the toes with a vertical impact. The foot should slowly fall down. If it does not fall, loosen the ankle bolt. Repeat the procedure of tapping at the toes and adjusting the ankle bolt until the 1G-torque requirement is met.

6. Repeat steps 1 - 4 on the other leg and foot.

Figure B1. Setting the 1g Figure B2. Setting the lg shoulder torque elbow torque

Figure B3. Setting the 1g femur torque

B-3

Figure B4. Setting the 1g knee torque

Figure B5. Setting the 1g ankle torque

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 foolproof solution to documenting the polarity of channels, but will serve to increase the confidence that polarities have been correctly determined. The sign convention used in this document is the same as that 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 Recommended Practice. The standardized coordinate system and polarities for data permits comparison of data from different crash test facilities. There are many ways to affect the polarity of a data channel. NHTSA has required that 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, the polarity of the internal sensors should be 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, then steps must be taken to correct it prior to submitting data to NHTSA, so that data is in accordance with the sign convention. 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.

C-2

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 Hybrid III 10 Year Old dummy. PROCEDURE Table C1 lists the transducers (load cells, accelerometers, and deflection devices) in the CFR Part 572 Anthropomorphic Test Device Subpart T (Hybrid III 10 Year Old Dummy). A separate procedure is defined for each type of transducer (i.e. accelerometer, load cell, displacement transducer). Accelerometer Data Channel 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. Apply a blow to the back of the head with a rubber mallet and record the data channel output and time of event. Figure C1 is an example of a plot used to document the polarity of the dummy’s head x axis accelerometer data channel. The polarity of the dummy channel in Figure C1 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 shows that the polarities of both the y and z axis accelerometer data channels in the head of this dummy are negative. Therefore these polarities must be inverted to agree with the sign convention. It is possible to document the polarity of each dummy data channel by following this approach. 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 results 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 connected 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.

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Figure C1. Polarity of X axis accelerometer data channel

Figure C2. Polarity of Y axis accelerometer data channel

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Figure C3. Polarity of Z axis accelerometer data channel

The procedure for each axis requires placing the accelerometers to be checked perpendicular to the axis of gravity in two orientations each 180 degrees apart. Then the sign and value of the acceleration channel are recorded 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.

Figure C4. Accelerometer perpendicular to gravity in two orientations 180 degrees apart 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’s center. The polarity must agree with the SAE J211 sign convention.

C-6

The data collected should be recorded in the Polarity Check Data Sheet 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 in order to be in accordance with the sign convention. Place a check in the column titled “Channels To Be Reversed” for those channels that will require reversal by the data acquisition software. The channel outputs for all of 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 y-axis 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 “Lean Down.” (Note that the symbol “D” 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 lists recorded output polarities for

C-7

various transducers. The manipulations identified in SAE J211 and those of additional load cells and the deflection sensors are shown in the tables.

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 the Polarity Check Data Sheet For Load Cells and Deflection Transducers and record the resulting data channel output from the data acquisition system. If the polarity of the channel output does not agree with that given in the Data Sheet, then invert 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 ensure that the channel output is in agreement with the J211 requirements listed in the Data Sheet. Sample Polarity Check Data Sheets have been included in this appendix for the various 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 needs to be taken. If, however, the signs are not in agreement, then the channel output must be reversed to agree with the J211 sign convention for positive polarity.

C-8

Polarity Check Data Sheet For X - Axis Accelerometers

Dummy Type:_____________ Serial No._______________ Date:_____________ Component

Channel Output ( g )

Orientation

of Most Positive Value

(FU or FD)

J-211

Orientation for Positive Polarity

Data

channels to have polarity changed

Dummy Orientation

Face Down (FD)

Face Up (FU)

Head FU

Sternum, upper FU

Sternum, lower FU

Spine Box, upper FU

Spine Box, lower FU

Chest FU

Pelvis FU

C-10

Polarity Check Data Sheet For Y - Axis Accelerometers

Dummy Type:_____________ Serial No._______________ Date:_____________ Component

Channel Output ( g )

Orientation

of Most Positive Value

(RSU or RSD)

J-211

Orientation for Positive Polarity

Data channels to have polarity changed

Dummy Orientation

Right Shoulder

Down (RSD)

Right Shoulder Up

(RSU)

Head RSU

Chest RSU

Pelvis RSU

C-10

Polarity Check Data Sheet For Z - Axis Accelerometers

Dummy Type:_____________ Serial No._______________ Date:_____________ Component

Channel Output ( g )

Orientation

of Most Positive Value

(U or D)

J-211

Orientation for Positive

Polarity

Data channels to

have polarity changed

Orientation

Upright (U)

Lean Down (D)

Head D

Chest D

Pelvis D

C-11

Polarity Check Data Sheet For Load Cells and Deflection Transducers

Dummy Part/

Channel

Dummy Type: Dummy Serial No. Date:

Channel Output

J211 Polarity

Channels to be

Reversed Dummy Manipulation for which J211

Polarity is indicated

Upper Neck (Internal)

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 +

Mz chin toward left shoulder +

Lower Neck (Internal) 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 +

Mz chin toward left shoulder +

Lumbar Spine (Internal) 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 +

Mz right shoulder forward, left shoulder rearward +

Left Shoulder (External) Fx shoulder forward, chest rearward +

Fz shoulder down, chest upward +

Right Shoulder (External) Fx shoulder forward, chest rearward +

Fz shoulder down, chest upward +

C-12

Polarity Check Data Sheet For Load Cells and Deflection Transducers

Dummy Part/

Channel

Dummy Type: Dummy Serial No. Date:

Channel Output

J211 Polarity

Channels to be

Reversed Dummy Manipulation for which J211

Polarity is indicated

Femur (Internal) (dummy in seated position, femurs horizontal)

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.) (External)

Fx upper upper iliac spine rearward, chest forward (-)

Fx lower lower iliac spine rearward, chest forward (-)

Chest Deflection

Δx chest rearward, spine forward (-)

Tibia (Internal) (dummy in seated position, tibias horizontal)

Fx ankle forward, knee rearward +

Fy ankle rightward, knee leftward +

Fz femur upward, tibia downward +

Mx ankle leftward, hold tibia in place +

My ankle forward, bottom of knee clevis rearward +

Mz ankle leftward, hold knee in place +

D-1

APPENDIX D. PROCEDURE FOR DETERMINING THE MOMENT OF INERTIA OF PROBES USED FOR DUMMY CERTIFICATION 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 certification 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 · in.· 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 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.

Figure D1. Determination of moment of inertia of probes used for dummy certification

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 4π2L

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. When converting the moment of inertia of a mass from customary units to SI units, keep in mind that the base unit pound used in the derived unit lb · in.· sec2 is a unit of force (not mass) and, therefore, should be converted into Newtons. We have lb · in.· sec2 = (4.448 N)(2.54 cm)(1 sec2) = 11.29792 N cm sec2 = 1129.792 kg cm2.

E-1

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

E-2

Data recording Record the data using a sampling rate at 50 kHz and anti-aliasing filter at 20 kHz. Typical responses 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

E-3

Figure E3. Probe acceleration response (longitudinal axis) between 38 and 41 milliseconds