2 - V3332101 - SOW.pdf

Statement of Work

Sled Tests Using Different Hybrid-III Anthropomorphic Test

Devices in APTA’s Passenger Rail Seat Tests

1. Introduction

The American Public Transportation Association (APTA) publishes passenger rail industry safety standards that are supported by the commuter and intercity railroads in the U.S. The construction and structural standard for passenger rail seats (APTA-PR-CS-S-016-99, Rev. 3.1 [1]) was created with technical support from the Federal Railroad Administration (FRA) and Volpe National Transportation

Systems Center (Volpe Center). The standard currently specifies dynamic sled tests with anthropomorphic test devices (ATDs), i.e., crash test dummies, seated in passenger rail seats. The sled is a rigid test fixture that is used to attach the seats as a surrogate for a carbody. The sled is either rapidly accelerated or decelerated in a simulated crash pulse with a magnitude of 8g on a linear track. In the forward-facing version of the test, the ATDs are thrown out of the seats they are sitting in and impact the row of seats in-front of them. In the rear-facing version, the ATDs are accelerated backwards into their seatbacks. The performance requirements for the seats are such that they must (1) compartmentalize the

ATDs between the rows of seats, (2) remain attached to the sled, and (3) mitigate the human injury criteria measured by the ATDs to an acceptable level.

Figure 1 shows a schematic for the forward-facing human injury test (left) and the rearward-facing seat attachment and human injury test (right) that are specified in the APTA seat standard with

Hybrid-III 50th percentile male (H3-50M) ATDs. The seat standard also specifies a forward-facing seat attachment test with Hybrid-III 95th percentile male (H3-95M) ATDs that is not shown in Figure 1.

Figure 1. Schematic of APTA Passenger Rail Forward-facing (Left) and Rearward-facing (Right)

Seat Sled Test [1]

The human injury performance tests in the APTA seat standard are currently limited in that they only evaluate human injury criteria for H3-50M ATDs. However, the full frontal 35 mph crash test specified in the U.S. New Car Assessment Program (NCAP) utilizes a Hybrid-III 5th percentile female

(H3-5F) ATD in the front passenger seat to better represent the U.S. population (73 FR 40016). Also, 50th percentile male occupants do not represent a worst-case scenario for the evaluation of the performance of a seat. For example, a 5th percentile female occupant would be more likely to suffer serious injury from an overly stiff seatback. Additionally, the rearward-facing seat test does not represent a worst-case scenario because it uses H3-50M instead of H3-95M ATDs while evaluating seat attachment.

Preliminary results from finite element (FE) analyses performed at the Volpe Center indicate that currently available passenger rail seats may be able to meet residual space/compartmentalization [2] and equivalent human injury [3] performance requirements for 5th percentile female and 95th percentile male

Hybrid-III ATDs. The equivalent injury criteria that have been applied to H3-5F and H3-95M ATDs are summarized in Table 1, and the injury criteria for H3-50M ATDs are included for comparison.

Table 1. Human Injury Performance Requirements for Hybrid-III Anthropomorphic Test Devices

Injury Criteria 5th Female 50th Male 95th Male

Head Injury Criterion (HIC) 700 700 700

Neck Injury Criterion (Nij) 1 1 1

Neck Axial Tension 2.62 kN 4.17 kN †

Neck Axial Compression -2.52 kN -4 kN †

Resultant Chest Acceleration, 3ms exceedance 60g 60g 55g

Femur Axial Load 6.805 kN 10 kN 12.7 kN

† Volpe Center researchers were not able to identify injury criteria for neck axial loads for the H3-95M ATD

The head injury criterion (HIC) performance requirements for the different sized Hybrid-III

ATDs are the same. However, even though neck injury criterion (Nij) performance requirements are all listed as 1, the intercepts (also referred to as constants) used to calculate Nij are not the same for the different sized ATDs. The Nij equation is shown in Equation 1, and the Nij intercepts are shown in Table

2.

Equation 1. Neck Injury Criterion (Nij)

𝑁𝑖𝑗 =

𝐹𝑍

𝐹𝑍𝐶

𝑀𝑂𝐶,𝑌

𝑀𝑌𝐶

Table 2. Nij Intercepts (Constants)

Nij Constant 5th Female 50th

Male

95th

Male

FZC, when Fz > 0 4.287 kN 6.806 kN 8.18 kN

FZC, when Fz < 0 -3.88 kN -6.16 kN -7.48 kN

MYC, when MOC,Y > 0 155 N-m 310 N-m 405 N-m

MYC, when MOC,Y < 0 -67 N-m -135 N-m -177 N-m

2. Objectives

The objective of the testing described in this document is to evaluate whether modern commercially available passenger rail seats can meet the structural and equivalent human injury performance requirements in the APTA passenger rail seat standard (APTA-PR-CS-S-016-99, Rev. 3.1) with different ATDs than those currently specified in the standard. The goal of using different ATDs in the standard is to improve passenger safety by (1) better representing the U.S. population with different

ATDs and (2) testing worse-case scenarios in the human injury and seat attachment tests. It will be more difficult for a given seat design to meet all of the performance requirements for 5th percentile female, 50th percentile male, and 95th percentile male ATDs because of tradeoffs on arresting the motion of heavier occupants versus limiting injuries to lighter occupants. This testing will demonstrate to passenger rail stakeholders the feasibility of utilizing the H3-5F ATD in the forward-facing human injury test and H3-

95M ATDs in the rearward-facing seat attachment test.

3. Scope

The scope of this effort is to plan, execute, and document sled tests per the APTA passenger rail seat standard with different sized ATDs than those currently specified in the standard. Slight modifications must be made to the test procedure in the APTA standard to accommodate the different sized ATDs. In the base contract, two 2-person seat designs will be tested, and options will allow for tests of two additional 2-person seat designs. Each seat design will be tested three times: (1) forward-facing with H3-50M and H3-5F ATDs, (2) forward-facing with 2x H3-50M ATDs, and (3) rearward-facing with

2x H3-95M ATDs. The H3-5F and H3-50M ATDs will be instrumented to collect injury data in the forward-facing sled tests. The uninstrumented H3-95M ATDs will be used to evaluate seat attachment, compartmentalization, and residual space in the rearward-facing sled tests.

4. Tasks

4.1. Plan sled tests

4.1.1. The Contractor shall define the procedures required to prepare for, set up and conduct the sled tests. Where necessary, the Contractor shall also determine if any special fixtures are needed, define areas requiring modification, if any, define required working tools, and specify the test set-up and procedure.

4.1.2. The Contractor shall prepare a detailed Test Implementation Plan (TIP) that may reference sections in APTA-PR-CS-S-016-99, Rev. 3.1 where appropriate. The TIP shall be developed in coordination with the Volpe Center Technical Point of Contact (TPOC).

The TIP shall be descriptive enough to conduct the sled tests and shall include:

• planned layouts for the seats and ATDs in each test along with necessary dimensions for seat installation and test setup

• description of test conditions and pre- and post-test measurements

• description of test instrumentation, data post-processing, and high speed video system

4.1.3. In advance of testing, the contractor shall conduct a test run(s) with a ballasted test sled to demonstrate that that specified acceleration pulse can be achieved, ideally within the allowable parameters of APTA S-016

4.1.4. A draft TIP shall be submitted to the TPOC at least 14 days before the planned test date.

The final TIP is subject to approval by the TPOC before the execution of the sled test.

4.2. Implement sled tests

4.2.1. The contractor shall implement six sled tests in the base contract. In the base contract

(CLIN0100), the TPOC will solicit two seat manufacturers (A and B) to donate three identical 2-person seats for a total of 6 seats. In the first option (CLIN0200), an additional seat manufacturer (C) will donate three identical 2-person seats bringing the total to 9 seats. In the second option (CLIN0300), a final seat manufacturer (D) will donate three identical 2-person seats bringing the total to 12 seats. Each set of identical seats will be tested in three sled tests with different ATD configurations. An optional additional fourth seat will be requested from each seat manufacturer as a backup for testing. Table 3 summarizes the planned sled test matrix across the base contract and 2 options. It is expected that the launch seat can remain attached and be reused after the forward-facing sled tests if it is not deformed by the rebounding ATDs; however, all other seats will be plastically deformed during the tests.

Table 3. Sled Test Matrix

Test # Seat Design ATDs Direction Injury? CLIN

1 A H3-5F & H3-50M Forward Yes 0100

2 A H3-50M x2 Forward Yes 0100

3 A H3-95M x2 Rearward No 0100

4 B H3-5F & H3-50M Forward Yes 0100

5 B H3-50M x2 Forward Yes 0100

6 B H3-95M x2 Rearward No 0100

7 C H3-5F & H3-50M Forward Yes 0200

8 C H3-50M x2 Forward Yes 0200

9 C H3-95M x2 Rearward No 0200

10 D H3-5F & H3-50M Forward Yes 0300

11 D H3-50M x2 Forward Yes 0300

12 D H3-95M x2 Rearward No 0300

4.2.2. The Contractor shall implement the ATD experiments described in the approved TIP.

The Contractor shall install the sled equipment, including all elements of the donated seats. The Contractor shall prepare the data acquisition system, required lighting, and high speed video cameras. The Contractor shall instrument the sled and ATDs as described in this document. The Contractor shall position the ATDs according to the requirements in APTA-PR-CS-S-016-99, Rev. 3.1. The Contractor shall define, set-up, and conduct pre-test checks on the instrumentation and camera triggers. The Contractor shall be responsible for documenting all aspects of the test, including pre- and post-test photos and high-speed videos.

4.2.3. The Contractor shall analyze and organize the videos, measurements, and test data to prepare test(s) report as part of this effort. Either a separate report for each test or a larger report for all of the tests may be provided. Where appropriate, the test report(s) shall include:

1. test number

2. test date

3. summary of the test setup and conditions

4. evaluation of emergency egress space in the forward-facing tests per APTA S-016

5. evaluation of residual space in the rearward-facing tests per Appendix L of

GMRT2100, Issue 6.2 [4]

6. evaluation of seat attachment

7. evaluation of ATD compartmentalization

8. table of pre- and post-test seat measurements

9. table of measured injury criteria for H3-50M and H3-5F ATDs

10. plots of the processed data signals

4.3. Data collection

4.3.1. Instrumentation – The H3-50M and H3-5F ATDs shall be instrumented to measure data per 49 CFR Part 572. Table 4 summarizes the instrumentation requirements. Targets shall be applied to the ATD, seats, and sled in locations to be determined by the TPOC and the Contractor for the video evaluation of compartmentalization and residual space.

Table 4. Instrumentation requirements for H3-50M and H3-5F

ATD/Object Transducer Measurement Channel

Count

ATD Triaxial accelerometer Head (x, y, z) acceleration 3

ATD Triaxial accelerometer Chest (x, y, z) acceleration 3

ATD 6-axis load cell Upper neck forces (Fx, Fz) and extension/flexion moment (My)

ATD Uniaxial load cell Femur, left, axial load (Fz) 1

ATD Uniaxial load cell Femur, right, axial load (Fz) 1

Sled Accelerometer Sled (x) acceleration (redundant) 2

Total 13

4.3.2. Test measurements – The following forces and accelerations shall be measured and processed for the H3-5F and H3-50M ATDs and sled, in accordance with SAE J211/1 and SAE J1727:

– Triaxial head acceleration-time history

– Triaxial chest acceleration-time history

– Axial left and right femur force-time history

– Upper neck extension/flexion bending moment

– Upper neck axial force, Fz

– Upper neck shear force, Fx

4.3.3. Injury criteria - The following injury criteria shall be computed in accordance with 49

CFR 571.208, SAE-J211, and SAE J1727, where applicable:

– HIC15

– Nij

– Peak upper neck axial tension/compression forces

– Resultant chest acceleration, 3ms exceedance

– Peak axial femur load

4.3.4. Test Data Format – The Contractor shall provide the TPOC with raw and processed

ASCII data files from the instrumentation listed in Table 4. The qualification/calibration documentation from the instrumented ATDs shall also be provided upon request.

4.3.5. Video – The Contractor shall provide the TPOC with processed digital high speed video files from each experiment. The digital videos shall be captured using four high-speed cameras (overhead, 2x aisle side views, and wall side view) to evaluate the ATD kinematics, compartmentalization, and residual space.

4.3.6. Chalk - The Hybrid-III ATDs will be chalked in areas where the Contractor expects the

ATDs to contact an impacted seat.

4.3.7. Photographs – Pre- and post-test digital photographs shall be provided to the TPOC to document installation of the ATD and seats, as well as any damage or structural failures that occur during the test.

4.4. List of equipment provided by the Contractor

4.4.1. One Hybrid-III 5th percentile female (H3-5F) ATD in accordance with 49 CFR Part 572

Subpart O with instrumentation installed as described in Table 4

4.4.2. Two Hybrid-III 50th percentile male (H3-50M) ATDs in accordance with 49 CFR Part

572 Subpart E with instrumentation installed as described in Table 4

4.4.3. Two Hybrid-III 95th percentile male (H3-95M) ATDs

4.4.4. Sled and data acquisition system capable of meeting the crash pulse and measurement/recording requirements in APTA-PR-CS-S-016-99, Rev. 3.1

5. SCHEDULE OF DELIVERABLES

Table 5 contains a schedule of deliverables for the base contract CLIN 0100 which includes tests 1-6 in

Table 3.

Table 5. Schedule of Deliverables for CLIN 0100

Task # Deliverable/Event Deliverable Format Due Date

1 Test implementation plan MS Word or PDF 6 weeks1

2 Initial setup including fabricating fixtures N/A 12 weeks1

3 Conduct six dynamic sled tests N/A 16 weeks1

4 Electronic data files:

Test videos, Test photos, Processed test data, Test report

MP4

JPG

ASCII or MS Excel

PDF

4 weeks2

NOTES:

1 After base contract award 2 After completion of sled tests in Task 3

Table 6 contains a schedule of deliverables for the option contracts CLIN 0200 which includes tests 7-9 in

Table 3.

Table 6. Schedule of Deliverables for CLINs 0200

Task # Deliverable/Event Deliverable Format Due Date

5 Conduct three dynamic sled tests N/A 6 weeks1

6 Electronic data files:

Test videos, Test photos, ASCII or MS Excel

PDF

2 weeks2

NOTES:

1 After option award 2 After completion of sled tests in Task 5

Table 7 contains a schedule of deliverables for the option contracts CLIN 0300 which includes tests 10-12 in Table 3.

Table 7. Schedule of Deliverables for CLINs 0300

Task # Deliverable/Event Deliverable Format Due Date

7 Conduct three dynamic sled tests N/A 6 weeks1

8 Electronic data files:

Test videos, Test photos, ASCII or MS Excel

PDF

2 weeks2

NOTES:

1 After option award 2 After completion of sled tests in Task 7

All electronic data files shall be electronically submitted to the TPOC via email or other electronic data transfer method.

The Contractor will promptly notify the COR and TPOC about technical, scheduling, or financial problems encountered and seek guidance.

6. Period of Performance

The period of performance for the work in this purchase order is 20 weeks from the date of base contract award CLIN 0100. The period of performance for the first option is 8 weeks from the option award CLIN 0200. The period of performance for the second option is 8 weeks from the option award

CLIN 0300.

7. References

[1] American Public Transportation Association, "APTA PR-CS-S-016-99, Rev. 3.1 - Standard for

Passenger Seats in Passenger Railcars," Washington, D.C., October 2023.

[2] Federal Railroad Administration, "Finite Element Analysis of APTA Passenger Rail 8G Structural

Seat Test (RR," May 2023. [Online]. Available: https://rosap.ntl.bts.gov/view/dot/67364.

[3] Federal Railroad Administration, "Finite Element Analysis of APTA Passenger Rail 8G Injury Seat

Test (RR 23-07)," May 2023. [Online]. Available: https://rosap.ntl.bts.gov/view/dot/67363.

[4] Rail Safety and Standards Board, "GMRT2100 Issue 6.2 - Rail Vehicle Structures and Passive

Safety," March 2023.