J.3_Laboratory_Test_Procedure_for_New_Car_Assessment_Program_Rear_Seat_Research_Testing_2018-05.pdf

U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC

SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FOR

NEW CAR ASSESSMENT PROGRAM REAR SEAT

RESEARCH TESTING

May 2018

RULEMAKING

Office of Crashworthiness Standards Mail Code: NVS-111

1200 New Jersey Avenue, SE Washington, DC 20590

Note: This test procedure is to be supplemented with and serves as an addendum to related NCAP test procedures. This document addresses only the rear seat ATDs and the data collection associated with them. The procedures for carrying out individual NCAP tests remain unchanged.

Attachment J.3

LABORATORY TEST PROCEDURE FOR NCAP REAR SEAT RESEARCH TESTING

TABLE OF CONTENTS

1. PURPOSE AND APPLICATION

2. GENERAL REQUIREMENTS

2.1 APPLICABILITY

2.2 APPLICABLE TESTS

3. MISCELLANEOUS REQUIREMENTS

4. DEFINITIONS

5. PHOTOGRAPHIC DOCUMENTATION

5.1 DIGITAL PHOTOGRAPHS

5.2 PHOTOGRAPHIC VIEWS

5.3 REAL-TIME DOCUMENTATION VIDEO

5.4 HIGH-SPEED VIDEO DOCUMENTATION

5.5 COLORING REQUIREMENTS for PHOTOGRAPHIC PURPOSES

5.6 DUMMY QUALIFICATION

5.7 INSTRUMENTATION

5.8 DUMMY CLOTHING REQUIREMENTS

5.9 DUMMY and REAR SEAT INTERIOR TARGETING

6. PRE-TEST REQUIREMENTS

6.1 TEST and QUALITY CONTROL PROCEDURES

7. TEST EXECUTION

7.1 GENERAL TEST CONDITIONS

7.2 IN-HOUSE REAR SEAT RESEARCH TEST PROCEDURE

7.3 GENERAL NCAP REAR SEAT RESEARCH TEST GUIDELINES

7.4 TEST WEIGHT CALCULATION

7.5 DUMMY MEASUREMENT GUIDELINES

7.6 SEAT BELT PERFORMANCE ASSESSMENT

8. REPORTS

8.1. NOTICE of TEST ANAMOLY

8.2. DELIVERABLE REQUIREMENTS

8.3. TEST REPORT REQUIREMENTS

DATA SHEET NO. 1 – CRASH TEST SUMMARY AND POST-TEST OBSERVATIONS26

DATA SHEET NO. 2 – SEAT POSITIONING DATA

DATA SHEET NO. 3 – REAR SEAT DUMMY LONGTITUDINAL AND TRANSVERSE

CLEARANCE DIMENSIONS

DATA SHEET NO. 4 - SEAT BELT POSITIONING AND ASSESSMENT DATA

DATA SHEET NO. 5 – REAR SEAT CAMERA LOCATIONS

APPENDIX A: REAR SEAT DUMMY SEATING PROCEDURES ........................................ A2

NCAP REAR 1

1. PURPOSE AND APPLICATION

This is a supplemental laboratory test procedure provided by the National Highway Traffic Safety Administration (NHTSA), Office of Crashworthiness Standards (OCWS) for the purpose of presenting guidelines for a uniform testing data and information recording format, and providing suggestions for the use of specific equipment and procedures for contracted testing laboratories. The data correspond to information gathered from rear seat research testing that may be conducted in conjunction with New Car Assessment Program (NCAP) full frontal rigid barrier crash tests. The OCWS test procedure is not intended to limit or restrain a contractor from developing or utilizing any testing techniques or equipment that will assist in procuring the required test data. The laboratory test procedure does not constitute an endorsement or recommendation for use of any particular product or testing method. However, applicability of any such testing technique or equipment is subject to prior approval by the Contracting Officer’s Representative (COR).

If any contractor views any part of the OCWS laboratory test procedure to be in conflict with accepted testing techniques or observes deficiencies in the laboratory test procedure, the Contractor is required to advise the COR and resolve the discrepancy prior to the start of testing or as soon as practicable.

NOTE: This OCWS Laboratory Test Procedure, prepared for the limited purpose of use by independent laboratories under contract to conduct research tests for the New Car Assessment Program (NCAP), are not rules or regulations. In addition, the laboratory test procedure may be modified by the OCWS at any time without notice, and the COR may direct or authorize contractors to deviate from these procedures, as long as the tests remain within the scope of the contract.

2. GENERAL REQUIREMENTS

This laboratory test procedure provides guidelines for the rear seat placement of Anthropomorphic Test Devices (ATDs) and the collection of information regarding their testing in NCAP vehicles for the purposes of research only. There are no minimum performance requirements or any Federal Motor Vehicle Safety Standard (FMVSS)-related requirements associated with the information specifically collected during this testing besides FMVSS qualification requirements related to the specific dummies, if instrumented. In the absence of instrumentation, visual inspection of the dummy parts per the qualification procedure is still required.

2.1 APPLICABILITY

This procedure is applicable to tests where belted ATDs are installed in the rear seats of vehicles otherwise being tested for NCAP rating purposes, at the discretion of the COR.

2.2 APPLICABLE TESTS

NCAP REAR 2

Vehicles will be tested to the requirements contained herein in conjunction with the dynamic requirements for frontal barrier NCAP tests. The rear seat-related research testing may not interfere with the laboratory’s ability to meet the requirements set forth in the related procedures for any of the governing NCAP tests. The test facility must also be able to conduct the governing NCAP dynamic test as described in the rest of this test procedure. The facility must meet ALL the minimum requirements set forth in the main frontal NCAP test procedure regarding weighing capability, speed measurement systems, test surface, tow-road, abort system, barriers, and all other requirements, regardless of the addition of rear seat ATDs for research testing.

3. MISCELLANEOUS REQUIREMENTS

Requirements such as SECURITY, METRIC SYSTEM of MEASUREMENT, GOOD HOUSEKEEPING, TEST SCHEDULING AND MONITORING, TEST

DATA DISPOSITION, and GOVERNMENT FURNISHED PROPERTY, and CALIBRATION OF TEST INSTRUMENTS should be followed per the remainder of the Frontal NCAP test procedure.

4. DEFINITIONS

See main frontal NCAP test procedure, Section 10 for Definitions.

5. PHOTOGRAPHIC DOCUMENTATION

5.1 DIGITAL PHOTOGRAPHS

Clear and properly focused digital, color still photographs shall be taken to document the test. Glare or light from any illuminated or reflective surface should be minimized while taking photographs. A tag, label, or placard identifying the test item, NHTSA number (if applicable), date, and whether the photograph was taken prior to the dynamic NCAP test (pre-impact) or after the dynamic NCAP barrier test (post-impact), shall appear in each photograph and be legible. Photographs that are approximately 4 in. x 6 in. (at a minimum) shall be included in the test reports. Two photographs shall be provided on each page and each photograph shall be labeled as to the subject matter in accordance with the list below.

All digital still photographs provided shall be in color, shall include a time/date stamp, shall have a minimum resolution of 1,600 x 1,200 pixels, shall be in a .JPG format, shall be numbered and properly labeled as specified below, and should be posted to the established FTP site as part of the Quality Control Package .zip file required for the governing frontal NCAP test.

NOTE: The Contractor should consult Appendix N of the frontal NCAP test procedure for further details on the Quality Control Package requirements.

NCAP REAR 3

Additional photographs should be provided, as necessary, to document test details, anomalies, or failures, and should be organized in a logical succession. Such supplemental photographs shall follow the list of required photographs in numerical order. Alternatively, if more than one photograph is taken for any of the requested views required in the list of photographs included below; such additional photographs can be similarly numbered and labeled in accords with the following numbering convention: No.

00X(a), No. 00X(b), No. 00X(c), etc. Any failure to meet test requirements shall be documented by photographs that are taken at various angles to assure complete coverage.

5.2 PHOTOGRAPHIC VIEWS

As a minimum, the following photographs for each ATD positioned in the rear seat of an NCAP vehicle shall be included with the test deliverables as well as in each test report submitted by the Contractor. Additional photographs, in the event of anomalies, etc., should be appended to the end of this list and labeled accordingly.

NOTE: Text in italics is for descriptive purposes and need not be included in the photo title.

No. 001 – Pre-Test P# Dummy and Interior Angled View

(Taken with the rear door open such that the most frontal view of the dummy possible is visible)

No. 002 – Post-Test P# Dummy and Interior Angled View (Taken with the rear door open such that the most frontal view of the dummy possible is visible)

No. 003 – Pre-Test P# Dummy and Interior View (Taken perpendicular to the dummy with the rear door open)

No. 004 – Post-Test P# Dummy and Interior View (Taken perpendicular to the dummy with the rear door open)

No. 005 – Pre-Test P# Window View (Taken perpendicular to the dummy with the rear door closed)

No. 006 – Post-Test P# Window View (Taken perpendicular to the dummy with the rear door closed)

No. 007 – Pre-Test P# Seat Fore-Aft Markings (Taken with the door open and in such a way that any seat positioning marks may be seen)

No. 008 – Post-Test P# Seat Fore-Aft Markings (Taken with the door open and in such a way that any seat positioning marks may be seen)

No. 009 – Pre-Test Frontal View of P# Seat Back Prior to Dummy Positioning (Head restraint should be included in the photograph, along with a visible centerline that is drawn on the seat back and head restraint)

No. 010 – Pre-Test Frontal View of P# Dummy Head and Shoulders in Relation to Head Restraint

No. 011 – Pre-Test Overhead View of P# Seat Pan Prior to Dummy Positioning (Show a visible centerline that is drawn onto the seat pan)

NCAP REAR 4

No. 012 – Pre-Test Overhead View of P# Dummy Thighs on Seat Pan (Show the centerline on the seat cushion between the dummy’s legs, if possible)

No. 013 – Pre-Test View of P# Dummy’s Neck Showing Position of Adjustable Neck Bracket

No. 014 – Pre-Test View of P# Dummy’s Head Showing Dummy’s Head is Level (Level should be shown)

No. 015 – Pre-Test Close-Up Side View of P# Seat Back (Show the test position of the seat back, detent or millimeter markings should be shown and labeled, if applicable)

No. 016 – Pre-Test Close-Up View of P# Seat Back or Head Restraint (Show the test position and include a level, placed at the manufacturer’s designated location, to show the angle of the test position.)

No. 017 – Pre-Test Opposite Side View of P# Dummy and Rear Seat Occupant Compartment (Through the vehicle with the opposite side door open.)

No. 018 – Post-Test Right Side View of P# Dummy and Rear Seat Occupant Compartment (Taken through the vehicle with the opposite side door open.)

No. 019 – Pre-Test P# Lower Leg and Foot Positioning (Position with respect to the front seat and vehicle floor should be shown)

No. 020 – Post-Test P# Lower Leg and Foot Positioning (Position with respect to the front seat and vehicle floor should be shown)

No. 021 – Pre-Test View of P# Belt Anchorage (Detent or millimeter markings should be shown and labeled, if applicable)

No. 022 – Pre-Test View of P# Shoulder Belt (Perpendicular view to the front of the dummy to document should belt location)

No. 023 – Pre-Test View of P# Outboard Lap Belt (View to document the outboard lap belt location on the dummy. The picture shall be taken with the door open. The picture shall be taken 25 degree from the front of the dummy. The camera height should be 15 degree above the femurs. The top of the field of view should not go above the bottom of the dummies sternum. The left side field of view shall show the back of the dummies pelvis. The photo should include the left leg where attached it attached to the pelvis, below the inboard part of the pelvis (try to include belt anchor).)

No. 024 – Pre-Test View of P# Inboard Lap Belt (View to document the inboard lap belt location on the dummy. The picture shall be taken from inside the vehicle. The picture shall be taken 25 degree from the front of the dummy. The camera height should be 15 degree above the femurs. The top of the field of view should not go above the bottom of the dummies sternum. The right side field of view shall show the back of the dummies pelvis. The photo should include the left leg where attached to the pelvis, below the outboard part of the pelvis (try to include belt anchor).)

No. 025 – Post-Test View of P# Dummy Contact with ______ (As applicable, include and label pictures of all dummy chalk marks transferred to the front seat back, headrest, vehicle interior, etc.)

NCAP REAR 5

NOTE: The numbering convention shown above must be maintained. It is deliberate and intended to keep the photographs in a specific order when sorting photographs electronically. For the Quality Control Package file, photographs should be labeled with a minimum of the numbering convention shown here; when the final deliverables are submitted, however, the photographs should also be labeled with the text descriptions provided.

NOTE: The test laboratory’s name or logo shall not appear in any photographs.

5.3 REAL-TIME DOCUMENTATION VIDEO

As part of the real-time documentation video required for each NCAP frontal barrier test, any rear seat ATDs should be made visible before and after the impact, with the doors both open and closed. See the main frontal NCAP test procedure, Sections 9.7 and 9.8, for specific documentation video requirements.

5.4 HIGH-SPEED VIDEO DOCUMENTATION

Camera locations will be at the discretion of the COR and may change depending on the type and locations of ATDs. Footage MUST BE collected at a minimum rate of 1000 fps. In most cases, if two outboard ATDs are positioned in the rear seat, cameras will be mounted on each rear outboard window sill such that the movement of the ATD installed on the opposite side of the vehicle can be seen. If only one dummy is used, such as behind the right front passenger, the high speed onboard camera to document the rear passenger’s motion during the event should be positioned opposite the dummy on the driver’s side of the vehicle. The following, along with Figure 1 below, describes the required field of view when capturing each rear seat ATD:

• The right side field of view shall start 15 cm (6 in) behind the dummy’s back and the top field of view shall start at the intersection of the roof and the side header at the center of the B-pillar.

• The left side field of view shall be as close as possible to the front of the B-pillar.

• The bottom field of view shall be as close as possible to the H-point of the dummy.

• The camera shall show the dummy’s inboard femur and upper body in all frames during the event.

• The centerline of the camera shall be perpendicular to the dummy.

The contractor shall provide adequate lighting to ensure adequate exposure. If the contractor has another strategy for better capturing the movement of the ATDs from the vehicle’s interior, that strategy should be shared with the COR for approval prior to use in NCAP testing.

NCAP REAR 6

Figure 1: Rear Seat Camera Position and Field of View

In addition, two off-board cameras that would otherwise be positioned for frontal NCAP testing, , as long as they are capable of capturing film at a rate of 1000 fps, can be positioned so that they also capture the movement of each rear seat ATD from an off-board perspective. Prior to the test, the COR will discuss with the Contractor which cameras should be moved to capture this view. If only one ATD is positioned in the rear seat, only one off-board camera is needed.

This high-speed camera covers the rear seat passenger interaction with the interior looking across the vehicle.

• The longitudinal position of the camera shall be at the center of the front door window.

• The C-pillar and B-pillar shall be in each frame of the event.

• The bottom field of view shall have the front and rear window sills in each frame during the event.

• The top field of view shall include the center line of the vehicle at impact.

• The camera shall be positioned at a height and angle such that the inboard shoulder of the rear dummy is in view.

Shall start at the intersection of roof and side header at center B-pillar

Shall start 6 inches behind dummies back

Front of B-pillar (as close as possible)

Bottom of dummy pelvis (as close as possible)

Note: The camera shall be perpendicular to the dummy

NCAP REAR 7

Figure 2: Typical Offboard Camera View for Rear Seat ATD

5.5 COLORING REQUIREMENTS for PHOTOGRAPHIC PURPOSES

A. The governing NCAP test procedure describes the painting requirements for both the vehicle interior and underbody. Rear seat vehicle interior surfaces (including front seat backs) can be painted with flat white paint to better view ATD contact locations. Air bag covers should NOT be painted.

B. Parts of the anthropomorphic testing devices shall be coated with colored chalk/water solutions to show contact points with the vehicle's interior, with their own components (such as head to knee contact), and with each other. The chalk/water solution shall be applied after final dummy positioning. Because the types and locations of ATDs tested during research in NCAP will vary, the following color schemes are simply suggestions. The laboratory should have a minimum of four (4) chalk colors available for use. Discretion should be used when painting ATD body parts that have the potential to come in contact with one another or a common surface during an event. The following color schemes should be adjusted accordingly.

SAMPLE CHALKING SCHEME FOR REAR SEAT ATDs

NCAP REAR 8

Dummy Part ATD 1 ATD 2

Nose Red Yellow Lips Red Yellow

Face* Blue Green Top of Head Yellow Blue Back of Head Green Red

Left Knee Red Yellow Right Knee Green Red Right Tibia Yellow Blue Left Tibia Blue Green

*Face chalk shall be extended below the chin and the side of the head

5.6 DUMMY QUALIFICATION

The belted ATDs used in the rear seat of frontal NCAP tests shall be qualified prior to their test program, and before and after every research test they are used in. ATDs must also be qualified if injury levels exceed any established Injury Assessment Reference Value (IARV) limits, or the dummy has been in storage for longer than the time allowed between qualifications as set forth by the main test procedure. The dummy part or parts exceeding the injury limit will be re-qualified prior to the next test. The dummies will be visually inspected prior to each test. If instrumentation is provided and to be used in these research tests, dummy qualification shall be conducted according to the following frontal NCAP requirements:

Dummy Size NCAP Qualification Procedure Hybrid III 5th Percentile Female Appendix B Hybrid III 50th Percentile Male Appendix A 10 Year Old or Other Child ATD To Be Provided by COR

5.7 INSTRUMENTATION

Unless otherwise instructed, the contractor should record data from all instrumentation the ATDs are supplied with. In some cases, ATDs may arrive uninstrumented. The following table contains channels the most commonly used NCAP research ATDs are most likely to have.

Dummy Size Potential Channels

Hybrid III 5th Female

Head Acceleration: X,Y,Z Primary and Redundant Accelerations Head Angular Rate X, Y, Z Upper Neck: X,Y,Z Forces and X,Y,Z Moments Lower Neck: X,Y,Z Forces and X,Y,Z Moments Chest Acceleration: X,Y,Z Primary and Redundant Accelerations Chest deflection

NCAP REAR 9

Pelvis: X, Y, Z Accelerations Femur: Z Force Primary and Redundant (if equipped)

Hybrid III 50th Male

Head: X,Y,Z Primary and Redundant Accelerations Upper Neck: X,Y,Z Forces and X,Y,Z Moments Chest: X,Y,Z Primary and Redundant Accelerations and Deflection Pelvis: X, Y, Z Accelerations Femur: Z Force Primary and Redundant (if equipped)

10 Year Old or Other Child ATD Varies, COR will provide list of channels to record

Any belted rear seat dummy

Shoulder Belt Force Lap Belt Force

In addition to recording ATD responses, the COR may direct the Contractor to install restraint-related instrumentation during the research test. These may include the following:

Belt Payout (electrical and mechanical measurements are required) Belt Elongation

5.8 DUMMY CLOTHING REQUIREMENTS

If more than one ATD is used in the rear seat, their clothing should be in contrasting colors so that their movement can best be documented.

5.9 DUMMY and REAR SEAT INTERIOR TARGETING

Photographic targets are required to identify the movement of dummy reference points.

Adhesive-backed paper or fabric targets having a pattern that facilitates identifying and tracking of reference points in high speed movies are required. ATD and interior targeting requirements per the following should typically be used in NCAP research tests.

Additional targeting per the COR may also be suggested.

The contractor shall place a target at the CG of the head and shall place another target forward of CG in the longitudinal direction (Figure 1). The distance between these two

(C) should be recorded. The contractor shall place two targets on the rear door. The distance between these targets (A) shall be recorded in the appropriate data sheet. The front seat targets are not required.

NCAP REAR 10

Figure 3: Rear Seat Interior Targeting

6. PRE-TEST REQUIREMENTS

Prior to conducting an NCAP rear seat research test, the Contractor shall:

A. Verify the training of technicians for performance of this test, B. Verify the calibration status of test equipment, C. Review applicable revisions of the related Frontal NCAP test procedure, D. Review the vehicle Owner’s Manual and any additional equipment mfg.

instructions that may have been provided by the COR.

6.1 TEST and QUALITY CONTROL PROCEDURES

Prior to conducting the research test, if requested by the COR, the Contractor may be required to submit a detailed in-house test procedure (to the COR) which should include:

A. A step-by-step description of the methodology to be used.

B. A written Quality Control (QC) Procedure which shall include equipment calibrations, ATD qualifications, the data and report review process, and the people assigned to perform QC on each task.

C. A complete listing of test equipment with instrument accuracy and calibration dates.

D. Detailed check-off lists to be used before, during, and after the test as well as during data review. These lists shall include all test procedure requirements and any additional requirements pertaining to the positioning of the ATDs in the rear seat. Each separate check-off sheet shall identify the laboratory, test date, vehicle, B A

C D

NCAP REAR 11

and test technicians. These sheets shall be used to document that all requirements and procedures have been complied with. If requested, these sheets shall be submitted with the test report.

E. There shall be no contradiction between the OCWS Laboratory Test Procedure and the Contractor's in-house test procedure.

7. TEST EXECUTION

7.1 GENERAL TEST CONDITIONS

Unless otherwise specified in this procedure or by the COR, all tests and measurements conducted throughout the course of NCAP rear seat research testing shall follow the related frontal NCAP test procedure. No NCAP test conducted with the addition of rear seat dummies for research purposes should contain practices that contradict or interrupt the intent of the original test being conducted for consumer information purposes.

7.2 IN-HOUSE REAR SEAT RESEARCH TEST PROCEDURE

Prior to conducting any rear seat research test, contractors may be required to submit a detailed in-house test procedure to the COR which should include a step by step description of the methodology to be used as described in Section 7.1 of this procedure.

This document may simply be a supplement to the contractor’s existing in-house frontal NCAP test procedure. Written approval may be required from the COR before initiating the research program so that all parties are in agreement.

7.3 GENERAL NCAP REAR SEAT RESEARCH TEST GUIDELINES

The types of ATDs, and/or their placement position in the rear seats of NCAP vehicles for research purposes will vary depending on the needs of the agency and will be at the discretion of the COR. Any ATDs currently or in consideration of being incorporated in Part 572 may be provided to the Contractor for use in NCAP rear seat research. ATDs may be provided with or without instrumentation. The Contractor must be able to qualify and/or otherwise maintain whatever ATDs the COR provides in a manner consistent with the requirements for ATDs currently used in the NCAP and other guiding documents such as qualification procedures published under FMVSS.

A seating procedure for the placement of the Hybrid III 5th percentile female ATD in the rear seat of NCAP vehicles is included as Appendix A of this supplemental procedure.

Procedures for seating other ATDs will be provided by the COR as needed.

7.4 TEST WEIGHT CALCULATION

The contractor should follow the general method for determining the target test weight calculation when using dummies in the rear seat of frontal NCAP tests (Section 11 of the main frontal procedure).

NCAP REAR 12

Measured Parameter Units Value Total Delivered Weight kg

Weight of 1 P572E ATD & 1 P572O ATD Rated Cargo/Luggage Weight (RCLW) Calculated Vehicle Target Weight (TVTW) kg

7.5 DUMMY MEASUREMENT GUIDELINES

The following measurements pertaining to rear seat ATD positioning should be taken and recorded on the appropriate data sheet(s). Contractors should continue to follow guidance in the main frontal NCAP test procedure for measurements pertaining to the front seat ATDs. If the center rear position in the vehicle is used, the Contractor should still attempt to take measurements in the Y-Z plane and indicate which side of the vehicle those measurements are taken to.

When a level is to be used, it is to ensure that the line containing the two points described is either parallel or perpendicular to the ground. If a measurement to be made is less than 25 cm (10 in.), ignore the directions to use a level and approximate a level measurement.

Also, when a measurement is to be taken to or from the center of a bolt on the dummy, take the measurement from the center of the bolt hole if the bolt is recessed.

Figure 4: Rear Seat ATD Measurements in the X-Z Plane

The following measurements of the rear seat ATD are to be made within a vertical longitudinal plane:

NCAP REAR 13

HZ – Head to Roof Taken from the point where the dummy's nose meets his forehead (between his eyes) to the point on the roof directly above it. Use a level.

NB – Nose to Rear of Front Seat Taken from the tip of the dummy's nose to the closest point on the rear of the front seat.

CB – Chest to Rear of Front Seat Place a tape measure on the tip of the dummy's chin and rotate five inches of it downward toward the dummy to the point of contact on the transverse center of the dummy's chest. Then measure from this point to the closest point on the rear of the front seat.

SH, SK, ST – Striker to Hip, Knee, and Head These measurements are to be taken in the X-Z plane measured from the forward most center point on the striker to the center of the H-point, outer knee bolt, and head target. When taking this measurement, a firm device that can be rigidly connected to the striker should be used. Use a level. The angles of these measurements with respect to the horizontal should also be recorded. The measurement in the Y (transverse) direction from the striker to the H-point should also be taken (see SHY below).

KB – Knee to Seat Back (not shown in diagram) Taken from the dummy’s knee to the closest point on the rear of the front seat.

The following angles are to be measured and recorded:

SBA - Seat Back Angle Find this angle using the instructions provided by the COR via the manufacturer.

If the manufacturer instructions aren’t clear enough contact the COR.

PA – Pelvic or Femur Angle Taken by inserting the pelvic angle gauge into the H-point gauging hole on the Hybrid III dummies and taking this angle with respect to the horizontal.

NA - Nose Angle Measure the angle made when taking the measurement NB with respect to the horizontal.

TA - Tibia Angle Use a straight edge to connect the dummy's knee and ankle bolts. Then place an inclinometer on the straight edge and measure the angle with respect to the horizontal.

NCAP REAR 14

Figure 5: Rear Seat ATD Measurements in the Y-Z Plane

The following measurements are to be made within a vertical transverse plane:

HR – Head to Side Header eyes) to the side roof header.

HS – Head to Side Window eyes) to the outside of the side window. To make this measurement, use a level and roll the window down to the exact height which allows a level measurement.

AD – Arm to Door Using a level, measure from the outer surface of the bolt on the outboard bicep to the closest point on the vehicle door.

HD – H-point to Door Using a level, measure from the H-point on the dummy to the closest point on the vehicle door.

SHY – Striker to H-point Using a level and a rod rigidly connected to the forward-most center point on the striker, measure between the striker and the H-point.

KK – Knee to Knee Measure the distance between the outboard knee clevis flange surfaces. This measurement may not be exactly transverse.

NCAP REAR 15

7.6 SEAT BELT PERFORMANCE ASSESSMENT

If directed by the COR, the Contractor shall measure the belt system spool-out, retractor lock-up time, belt webbing stretch, and belt lengths for every ATD tested in the rear seat of frontal NCAP tests. The contractor shall use at least 1 electronic method and 1 mechanical method.

A. Webbing Spool-Out

NOTE: The Contractor SHALL NOT REMOVE ANY TEST VEHICLE SEAT

BELT RESTRAINT SYSTEM ANCHORAGES which includes 'D' ring, retractor housing, buckle and cable, etc., attachments to the vehicle body. DO NOT REMOVE INTERIOR TRIM MOLDINGS FROM VEHICLE to expose the belt system's retractor unit. DO NOT CUT SHEET METAL STRUCTURAL SUPPORTS OR PANELS to gain access.

Webbing spool-out may be determined as follows:

(1) Mark white lines approximately ¼-inch wide and spaced 1-inch apart on the belt webbing starting at the retractor reel and extending for 5 inches of webbing outside of the reel. This marking process takes place AFTER

THE RESTRAINT SYSTEM HAS BEEN FITTED AROUND THE

DUMMY. Typewriter correction fluid has been successfully used in the past for marking the belt webbing. The line adjacent to the retractor or the line closest to the D-ring (whichever is in the onboard camera view) should be delineated by a dashed vs. solid line.

(2) Two high-speed cameras shall be focused on the marked portion of the belt webbing and the two front outboard retractor units to record webbing spool-out using the white lines as reference points.

(3) “Time zero” for the impact event shall be indicated by a strobe light or taped flash bulb within the field-of-view of both cameras to assess the time delay for retractor lock-up after impact.

(4) A linear potentiometer, such as the Bournes Model No. 5194 with an 8” range, shall be attached to the seat belt webbing for spool-out measurement. As a redundant backup measurement system, a 2-inch cube of Styrofoam shall be attached to the vehicle's 'B' post trim molding or at the base of the vehicle's 'B' post as shown in Figure 6. Thread shall be used with the foam to determine webbing spool-out. Tape can be used to retain the thread if unable to use the foam cube.

B. Webbing Stretch

Shoulder belt webbing elongation shall be determined by the use of a linear position transducer recommended with a 3/16” to 7/16”range.

NCAP REAR 16

Belt stretch shall be measured as close as possible to the shoulder belt load cell (between load cell and 'D' ring) and NOT between the retractor reel and the 'D' ring. For each rear seat ATD prior to the crash test (seats and dummies in “final position'), the Contractor shall record the length of seat belt webbing. Using the transducer data, the PERCENT WEBBING ELONGATION at maximum belt load shall be calculated and recorded. The appropriate maximum belt load shall be reported with this data even if it is reported elsewhere in the final test report.

For redundancy, two 2-inch sections of shoulder belt webbing located along the dummy's chest area shall be fitted with thread configuration as shown in Figure 7 during the pre-test operations. The amount of webbing stretch (thread movement) shall be measured after the frontal crash event, and the frontal crash event, and the percent webbing elongation shall be calculated using the thread measurement data.

C. Belt Length and Documentation

Measurement of lap and shoulder belt is to be performed and included in the final test report on Data Sheet No. 4.

The location of the shoulder belt on the upper torso of each dummy shall be found by measuring the distance from the top surface of an aluminum plate placed across the topmost surfaces of the dummy's upper legs upward to the top and bottom edges of the shoulder belt at the dummy's midsagittal plane.

Detailed descriptions of the occupant restraint system characteristics including the number of retractors, retractor locations, pre-tensioning devices, continuous system, adjustable D-rings, motorized, 2 point, 3 point, etc. are to be provided in the test report.

NCAP REAR 17

Figure 6: Method to Measure Belt Webbing Spool-Out

NCAP REAR 18

Figure 7: Method to Determine Belt Webbing Stretch

8. REPORTS

8.1. NOTICE of TEST ANAMOLY

Any indication of a test anomaly shall be communicated by telephone to the COR within 24 hours with written notification mailed within 48 hours (Saturdays and Sundays excluded). In the event of a test anomaly, a post-test calibration check of some critically sensitive test equipment and instrumentation may be required for verification of accuracy.

The necessity for the calibration shall be at the COR's discretion and shall be performed without additional costs to the OCWS.

8.2. DELIVERABLE REQUIREMENTS

Required deliverables for rear seat testing are discussed in this section. The TEST DELIVERABLES section of the governing frontal NCAP test procedure should be consulted for further details on deliverable requirements and schedules. Information on the FTP Website as well as submission timelines for the QuickLook Report, Quality Control Package, Draft Test Report, and Final Test Report and Deliverables is found in the frontal NCAP test procedure.

B. QuickLook Report

A separate QuickLook report is not needed for the rear seat-related data. In addition, no rear seat-related information is needed on the standard frontal NCAP QuickLook Report.

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C. Quality Control Package

All required rear seat-related information should be included within the Quality Control Package .zip file required to contain the frontal NCAP test deliverables. It serves as a summary of the governing frontal NCAP test and the accompanying rear seat research results, if applicable. In addition to the deliverable requirements specified for the frontal NCAP test, it shall include all dummy qualifications, photographs, videos, and any computer-generated plots (if applicable) from the related rear seat research.

Photographs included as part of the Quality Control Package should be numbered, at a minimum, and preferably also labeled, and should be arranged such that they are in the same order as they appear in the draft version of the Test Report. See the PHOTOGRAPHIC DOCUMENTATION section of this procedure to determine proper photo order and labeling requirements. Additional photographs, which may be taken to document a test concern, anomaly, etc., may be included as part of the Quality Control Package, but should appear in order after all required photos.

The Contractor should consult Appendix N of the main frontal NCAP procedure for more details on the Quality Control Package requirements.

D. Draft Test Report

The draft version of the rear seat research report should be submitted as the final Appendix to the frontal NCAP test’s draft report. Further instructions on the submission of the test report may be found in the frontal NCAP test procedure.

As with the frontal NCAP test, the Contractor shall use detailed descriptions of all test events. Any events during the frontal NCAP test that are specifically associated with the rear seat ATDs or that are otherwise of technical interest shall also be included.

Contractors are required to review and proofread all test reports before submittal to the COR. The OCWS will not act as a report quality control office for Contractors. Reports containing a significant number of errors will be returned to the Contractor for correction. The OCWS will alert the Contractor to minimal corrections that should be made prior to submission of the Final Test Report.

E. Final Test Report and Deliverables

The final version of the rear seat research report and associated documentation, including test data, test videos, and properly labeled and numbered photographs, are relied upon as the chronicle of any NCAP test. For these reasons, each rear seat research Final Test Report must be a complete document capable of standing by itself, even though it should be submitted as the last Appendix to the

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frontal NCAP test report. The Contractor should use DETAILED descriptions of all test events. Any events that are not directly associated with the NCAP rear seat research test, but that are of technical interest, should also be included.

The Final Test Report for the frontal NCAP test, as well as deliverables associated with the rear seat research, will be released to the public domain after review and acceptance by the COR. For these reasons, all deliverables must be complete and error-free. Final Test Reports containing errors will be returned to the Contractor for correction and a hold will be placed on invoice payment for the particular test.

Instructions for the preparation of the NCAP rear seat research test report, submitted as the final Appendix to the frontal NCAP test report, are provided in the below sections. To maintain report standardization, the format outlined below should be adhered to.

8.3. TEST REPORT REQUIREMENTS

A. Cover Page

The cover page for the test report shall contain the following information:

(a) Final Report Number such as NCAPREAR-ABC-XX-001, where –

REAR denotes the research test conducted ABC are the initials for the laboratory XX is the last two numbers of the Fiscal Year of the test program 001 is the Group Number (001 for the 1st test, 002 for the 2nd test, etc.)

(b) Final Report Title and Subtitle such as:

NEW CAR ASSESSMENT PROGRAM (NCAP)

Rear Seat Research Test World Motors Corporation 20XX SafeRider 4-door Sedan NHTSA No. M20XX0000

(c) Contractor's Name and Address such as:

ABC Laboratories, Inc.

4335 West Main Street Detroit, Michigan 48070-1234

NOTE: DOT SYMBOL SHALL BE PLACED BETWEEN ITEMS (C) AND (D)

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(d) Date of Final Report completion

(e) The words "FINAL REPORT"

(f) The sponsoring agency's name and address as follows:

U. S. DEPARTMENT OF TRANSPORTATION

National Highway Traffic Safety Administration Office of Rulemaking Mail Code: NVS-111 1200 New Jersey Avenue, SE Room W43-410 Washington, DC 20590

D. Table of Contents

The Final Test Report Table of Contents shall include the following:

Section

1 Test Purpose and Procedure 2 Summary of Test Results 3 Data Sheets

Data Sheets

1 Crash Test Summary and Post-Test Observations 2 Seat Positioning Data 3 Rear Seat Dummy Longitudinal and Transverse Clearance

Dimensions 4 Seat Belt Positioning and Assessment Data 5 Rear Seat Camera Locations

Appendix

A Photographs B Dummy Response Data C Other Documentation (if applicable) D ATD Qualification (if requested) E Test Equipment List and Calibration Information (if requested)

E. Test Purpose and Procedure

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This section briefly describes the purpose for conducting the NCAP rear seat research test and states the appropriate test procedure followed during the test.

The following is provided as an example.

A belted occupant rear seat research test in conjunction with a frontal NCAP impact test was conducted on the subject 20XX SafeRider 4-door sedan. The anthropomorphic test device used in this research was one Hybrid III X percentile dummy location in position P#.

The research test was conducted in accordance with the Office of Crashworthiness Standards Laboratory Test Procedure, dated __________, for the purpose of collecting information on belted occupant performance in the rear seat of vehicles.

This rear seat research test is part of the FY__ New Car Assessment Program Test Program, sponsored by the National Highway Traffic Safety Administration (NHTSA), under contract number _______________.

F. Summary of Test Results

This section gives a summary of the rear seat research test. The following is an example of the content needed in this section. The Contractor should amend this language so that it is relevant to the actual test conducted. For example, if only one ATD is used in rear seat of a frontal NCAP test, the language below should be amended to reflect that

An NCAP frontal barrier impact test was performed by ABC Laboratories, Inc. on a 20XX SafeRider 4-door Sedan on {insert date}. Belted ATDs were installed in the rear seat of this vehicle: a {insert ATD type} was seated in position P3 and a {insert ATD type} was seated in position P4.

Data sheets, along with pre-test and post-test measurements and photographs of the ATDs, are included in this report to document the test.

Dummies were placed in the right and left rear designated seating positions according to instructions specified in the Laboratory Test Procedure for NCAP Rear Seat Research Testing, dated ____________.

APPENDIX A contains the photographs. APPENDIX B contains the vehicle and dummy response data.

Dummy injury readings were recorded as follows:

ATD

Position

HIC15 HIC36 Nij Neck

Tension

Neck

Compression

3ms Chest Clip (Gs)

Chest Disp.

(mm)

Left Femur (N)

Right Femur (N)

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(Type) (N) (N)

P3 (50th

Male)

P4 (5th

Female)

Supplemental restraint information for the rear seat is given below:

Restraint Type Right Rear Position, P3 Left Rear Position, P4 Mounted Deployed Mounted Deployed

Side Airbag 1 (Type or n/a) Side Airbag 2 (Type or n/a) Side Airbag 3 (Type or n/a) Seat Belt Pretensioner Seat Belt Load Limiter Other

TEST NOTES

(Indicate any additional information deemed important.)

G. Data Sheets

This section requires the reporting of all information found in the following data sheets. Data sheet examples can be found later in this document. The Contractor may expand upon the data sheets if desired; however, the required data must be presented in the order listed below.

DATA SHEET NO. 1 – CRASH TEST SUMMARY AND POST-TEST

OBSERVATIONS

DATA SHEET NO. 2 – SEAT POSITIONING DATA

DATA SHEET NO. 3 – REAR SEAT DUMMY LONGTITUDINAL AND

TRANSVERSE CLEARANCE DIMENSIONS

DATA SHEET NO. 4 - SEAT BELT POSITIONING AND ASSESSMENT

DATA

DATA SHEET NO. 5 – REAR SEAT CAMERA LOCATIONS

H. Appendix A - Photographs

Photographs shall be included for each ATD belted in the rear seat of the frontal NCAP test. Photo numbers as well as position installed in the vehicle should be adjusted accordingly for any subsequent ATDs. All additional

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photographs taken for clarification or to document a test anomaly related to the rear seat research should be added after the last required photograph. The Contractor should present two photographs per page according to the guidelines set forth by Section 6 of this document.

I. Appendix B – Dummy Response Data

If the research test series uses instrumented dummies, the contractor should provide Appendix B, which will contain data plots pertaining to relevant ATD response data. The Contractor should publish multiple data plots per page as well as a table of plots containing appropriate page numbers. The following is a typical list of figures that the Contractor may use. Figures pertaining to a single ATD should be grouped together with one ATD’s response data listed after another.

Fig. No. List of Data Plots Provided In The Test Report Page No.

1 P# Head X Acceleration vs. Time Primary B-1 2 P# Head Y Acceleration vs. Time Primary B-1 3 P# Head Z Acceleration vs. Time Primary B-1 4 P# Head Resultant Acceleration vs. Time Primary B-1 5 P# Chest X Acceleration vs. Time Primary B-2 6 P# Chest Y Acceleration vs. Time Primary B-2 7 P# Chest Z Acceleration vs. Time Primary B-2 8 P# Chest Resultant Acceleration vs. Time Primary B-2 9 P# Upper Neck Force X vs. Time Primary B-3 10 P# Upper Neck Force Z vs. Time Primary B-3 11 P# Upper Neck Moment Y vs. Time Primary B-3 12 P# Nij vs. Time Primary B-3 13 P# Chest X Deflection vs. Time B-4 14 P# Left Femur Force vs. Time B-4 15 P# Right Femur Force vs. Time B-4

The remainder of the rear seat ATD data that is included in the data tape but not provided as traces in the report should also be listed in Appendix B of the rear seat research Appendix with a statement such as the following:

The following additional dummy and vehicle response data can be found in the R&D section of the NHTSA website at www.nhtsa.dot.gov

This additional data may include some or all of the following:

P# Head X Acceleration Redundant http://www.nhtsa.dot.gov/

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P# Head Y Acceleration Redundant P# Head Z Acceleration Redundant P# Upper Neck Force Y P# Upper Neck Moment X P# Upper Neck Moment Z P# Chest X Acceleration Redundant P# Chest Y Acceleration Redundant P# Chest Z Acceleration Redundant P# Pelvis X P# Pelvis Y P# Pelvis Z P# Left Femur Redundant P# Right Femur Redundant P# Shoulder Belt Force P# Lap Belt Force P# Shoulder Belt Pullout/Spool-off P# Shoulder Belt Elongation

J. Appendix C – Other Documentation

All other documentation that is deemed necessary to properly convey the test results, including applicable pages from the vehicle Owner’s Manual, should be provided in this section. Any events that are not directly associated with the test, but that are of technical interest, should also be included.

K. Appendix D– ATD Qualification Information

ATD qualification responses shall be provided by the Contractor according to the guidelines set forth by the governing NCAP procedure.

L. Appendix E – Test Equipment List and Calibration Information

A list of test equipment and related calibration procedures shall be maintained and provided by the Contractor if requested by the COR. There is no need to include this Appendix with each test report.

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DATA SHEET NO. 1 – CRASH TEST SUMMARY AND POST-TEST OBSERVATIONS

Test Vehicle: ______________________________ NHTSA No. _________________ Test Program: _____________________________ Test Date: ___________________

REAR SEAT ATD AND RESTRAINT INFORMATION

Description Position # ATD Position # ATD

ATD Type Serial Number Restraint Pretensioner Yes/No Yes/No Load Limiter Yes/No Yes/No Load Limiter Type If Applicable If Applicable Head SAB Type If Applicable If Applicable Torso SAB Type If Applicable If Applicable

VISIBLE CONTACT POINTS

Description Position # ATD

(Serial #) Position # ATD

(Serial #) Head Contact Chest Contact Abdomen Contact Left Knee Contact Right Knee Contact Left Tibia Contact Right Tibia Contact Left Foot/Toe Contact Right Foot/Toe Contact Other

POST-TEST SEAT DATA

Seating Location Seat Movement (mm) Seat Back Failure Right Rear (P3) Yes/No Left Rear (P4) Yes/No

REAR SEAT ATD INFO AND NUMBER OF DATA CHANNELS

Seating Location ATD Serial # # of ATD Channels

Right Rear (P3) Left Rear (P4)

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DATA SHEET NO. 2 – SEAT POSITIONING DATA

Test Vehicle: ____________________________________ NHTSA No. ___________________ Test Program: ___________________________________ Test Date: _____________________

SCRL ANGLE RANGE

Seating Location SCRL (o)

Max Min Mid

SEAT HEIGHT AND ANGLE

Seating Location

SCRL

Angle

(Mid)(o)

SCRP

Height (mm)

SCRP

Height

Position

SCRP Height (mm)

Rear-most Mid-

Fore/Aft Forward-

Most

Right Rear (P3)

Max Mid Min

Left Rear (P4)

Max Mid Min

SEAT FORE/AFT POSITION

Seating Location Total Fore/Aft Travel Test Position from Forwardmost Position mm Detents* mm Detent* Right Rear (P3)

*If applicable

SEAT BACK ANGLE ADJUSTMENT

*If applicable

HEAD RESTRAINT ADJUSTMENT

Seating

Location Total # of Positions Placed in Position #

Seating Location Total Seat Back Angle Range Test Position from Most Upright Degrees Detents* Degree Detent*

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DATA SHEET NO. 3 – REAR SEAT DUMMY LONGTITUDINAL AND TRANSVERSE

CLEARANCE DIMENSIONS

Code Measurement Description P# Rear Passenger P# Rear Passenger

Length (mm) Angle (°) Length (mm) Angle (°) SBAº Seat Back Angle HZ Head to Roof NA/NB Nose to Seat Back CB Chest to Dash/Seat Back KBL Left Knee to Seat Back KBR Right Knee to Seat Back PAº Pelvic Angle TAº Tibia Angle SK Striker to Knee ST Striker to Head SH Striker to H-point HR Head to Side Header HS Head to Side Window AD Arm to Door HD H-point to Door SHY Striker to H-point KK Knee to Knee

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DATA SHEET NO. 4 - SEAT BELT POSITIONING AND ASSESSMENT DATA

Test Vehicle: ___________________________________ NHTSA No.: ________________ Test Program: __________________________________ Test Date: __________________

SEAT BELT ANCHORAGE ADJUSTMENT

SHOULDER BELT SPOOL-OFF DATA

BELT STRETCH DATA

SEAT BELT POSITIONING

MEASUREMENTS

Measurement Description Units P3 P4 PBU — Top surface of reference to belt upper edge mm PBL — Top surface of reference to belt lower edge mm

BELT LENGTH DATA

Measurement Description Units P3 P4 Retractor reel to “D” ring Shoulder belt length as measured on ATD mm Lap Belt Length as measured on ATD mm Remainder of belt on reel mm Total belt length for continuous webbing systems mm

Right Rear (P3) Left Rear (P4) Total # of Positions)

Placed in Position #

Measurement

Right Rear (P3) in mm

Left Rear (P4) in mm

Total # of Positions)

Placed in Position #

Measurement

Right Rear (P3) in mm

Left Rear (P4) in mm

Electronically btwn load cell and “D” ring

Mechanically

SEAT BELT POSITIONING DATA

DUMMY'S CENTERLINE

TBI

'D' RING

SHOULDER

BELT

PORTION

LAP BELT

PORTION

1/8" THICK

ALUMINUM

PLATE EMERGENCY

LOCKING

RETRACTOR

OUTBOARD

ANCHORAGE

INBOARD

ANCHORAGE

FLOORPAN

BUCKLE

ASSEMBLY

MALE BLADE

REEL

PBU

PBL

FRONT VIEW OF DUMMY

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DATA SHEET NO. 5 – REAR SEAT CAMERA LOCATIONS

Test Vehicle: ___________________________________ NHTSA No. ___________________ Test Program: __________________________________ Test Date: _____________________

**Insert graphic of cameras located to capture rear seat passenger(s)**

Camera No.

View Location (mm) Angle (deg °) Lens (mm)

Spe…