Attachment_J.1_-_TP_208-14_Sections_1-14.pdf

TP208-14

April 16, 2008

U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FOR

FMVSS 208, Occupant Crash Protection

FMVSS 212, Windshield Mounting

FMVSS 219, Windshield Zone Intrusion

FMVSS 301F, Fuel System Integrity – Frontal

ENFORCEMENT

Office of Vehicle Safety Compliance Mail Code: NVS-220

1200 New Jersey Ave. SE Washington, DC 20590

OVSC LABORATORY TEST PROCEDURE NO. 208

TABLE OF CONTENTS

PAGE

1. PURPOSE AND APPLICATION

2. GENERAL REQUIREMENTS

3. SECURITY

4. GOOD HOUSEKEEPING

5. TEST SCHEDULING AND MONITORING

6. TEST DATA DISPOSITION

7. GOVERNMENT FURNISHED PROPERTY (GFP)

8. CALIBRATION OF TEST INSTRUMENTS

9. PHOTOGRAPHIC DOCUMENTATION

10. DEFINITIONS

11. PRETEST REQUIREMENTS

12. COMPLIANCE TEST EXECUTION

13. POST TEST REQUIREMENTS

14. REPORTS

14.1. MONTHLY STATUS REPORTS

14.2. APPARENT TEST FAILURE

14.3. FINAL TEST REPORTS

14.3.1. COPIES

14.3.2. REQUIREMENTS

14.3.3. FIRST THREE PAGES

14.3.4. TABLE OF CONTENTS

14.3.5. NON-DATA SHEET SECTION PAGES AND INSTRUCTIONS

FOR THE REST OF THE TEST REPORT

15. DATA SHEETS

APPENDICES

APPENDIX A Part 572E Dummy Performance Calibration Test Procedure

APPENDIX B Part 572O Dummy Performance Calibration Test Procedure

APPENDIX C Part 572N 6-Year Old Dummy Performance Calibration Test Procedure

APPENDIX D Part 572P 3-Year Old Dummy Performance Calibration Test Procedure

APPENDIX E Part 572R 12-Month Old Dummy Performance Calibration Test Procedure

APPENDIX F Dummy Positioning Procedures for Test Dummy Conforming to Subpart E of Part 572

APPENDIX G Dummy Positioning Procedures for Test Dummy Conforming to Subpart O of Part 572

APPENDIX H Procedures for Using Humans in Suppression Tests

APPENDIX I Offset Deformable Barrier

APPENDIX J Indicant Steering Column Displacement

REVISION CONTROL LOG

FOR OVSC LABORATORY

TEST PROCEDURES

TP-208

Occupant Crash Protection

TEST PROCEDURE FMVSS 208

REV.

No.

DATE

AMENDMENT

EFFECTIVE

DESCRIPTION

05 07/10/81

06 05/15/87

07 02/15/88

08 09/08/89

09 03/15/93 Major Revision

10 01/15/98 Minor changes to procedure. New data sheets, revised data sheets, hip flexion dummy calibration, and removal of Hybrid II dummy

11 08/22/02 CFR revised Fed. Reg.

Notice

10/1/2000 12/18/2001

Major Revision – Advance air bag rules from May 2000 and December 2001

12 01/14/03 FR notices1 Major revisions to data sheets based on testing experience plus corrections to dummy calibration appendices

1 66 FR 45777, 8/30/2001,66 FR 64368, 12/13/2001, 67 FR 46400, 7/15/2002, 67 FR 47321, 7/18/2002, 67 FR

59020, 9/19/2002, 68 FR 504, 1/6/2003

TEST PROCEDURE FMVSS 208

REV.

No.

AMENDMENT

EFFECTIVE

DATE

DESCRIPTION

13 07/27/05 FR notices2 Major revisions to data sheets based on testing experience and reg. changes

14 04/16/08 FR notice3 Major revisions to data sheets due to reorganization, reg. change, and testing experience. Throughout the document, changes have also been made to adopt a standardized format.4

2 68 FR 50077, 8/20/2003; 68 FR 65179, 11/19/2003; 69 FR 31034, 06/02/2004; 69 FR 51598, 8/20/2004.

3 69 FR 51598, 8/20/2004; 72 FR 40252, 7/24/2007

4 The Office of Vehicle Safety Compliance is updating its laboratory test procedures, to the extent practicable, with a standardized format.

TP208-14 1

1. PURPOSE AND APPLICATION

This document is a laboratory test procedure provided by the National Highway Traffic Safety Administration (NHTSA), Office of Vehicle Safety Compliance (OVSC) 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 specific requirements of the Federal Motor Vehicle Safety Standard(s) (FMVSS). The OVSC test procedures include requirements that are general in scope to provide flexibility for contracted laboratories to perform compliance testing and are not intended to limit or restrain a contractor from developing or utilizing any testing techniques or equipment which will assist in procuring the required compliance test data. These test procedures do not constitute an endorsement or recommendation for use of any particular product or testing method.

Prior to conducting compliance testing, contracted laboratories are required to submit a detailed test procedure to the COTR to demonstrate concurrence with the OVSC laboratory test procedure and the applicable FMVSS. If any contractor views any part of an OVSC laboratory test procedure to be in conflict with a FMVSS or observes deficiencies in a laboratory test procedure, the contractor is required to advise the Contracting Officer's Technical Representative (COTR) and resolve the discrepancy prior to the start of compliance testing or as soon as practicable. The contractor’s test procedure must include a step-by-step description of the methodology and detailed check-off sheets. Detailed check-off sheets shall also be provided for the testing instrumentation including a complete listing of the test equipment with make and model numbers. The list of test equipment shall include instrument accuracy and calibration dates. All equipment shall be calibrated in accordance with the manufacturer’s instructions. There shall be no contradictions between the laboratory test procedure and the contractor’s in-house test procedure. Written approval of the in-house test procedures shall be obtained from the COTR before initiating the compliance test program.

NOTE: The OVSC Laboratory Test Procedures, prepared for the limited purpose of use by independent laboratories under contract to conduct compliance tests for the OVSC, are not rules, regulations or NHTSA interpretations regarding the meaning of a FMVSS.

The laboratory test procedures are not intended to limit the requirements of the applicable FMVSS(s). In some cases, the OVSC laboratory test procedures do not include all of the various FMVSS minimum performance requirements. Recognizing applicable test tolerances, the laboratory test procedures may specify test conditions that are less severe than the minimum requirements of the standard. In addition, the laboratory test procedures may be modified by the OVSC at any time without notice, and the COTR may direct or authorize contractors to deviate from these procedures, as long as the tests are performed in a manner consistent with the standard itself and within the scope of the contract. Laboratory test procedures may not be relied upon to create any right or benefit in any person. Therefore, compliance of a vehicle or item of motor vehicle equipment is not necessarily guaranteed if the manufacturer limits its certification tests to those described in the OVSC laboratory test procedures.

TP208-14 2

2. GENERAL REQUIREMENTS

2.1 FMVSS 208

This test procedure is used to determine whether a vehicle meets the conditions, requirements, and injury criteria specified in Federal motor vehicle safety standard (FMVSS) No. 208, “Occupant crash protection.” The requirements of this test procedure are those specified in Standard 208 sections S4, “General requirements,” S14, “Advanced air bag requirements,” and in section S7, “Adjustments,” for seat belt assembly systems.

Passenger cars, trucks, and multipurpose passenger vehicles, with GVWR of 3,855 kilograms (8,500 lb) or less and an unloaded vehicle weight of 2,495 kilograms (5,500

lb) or less, must have frontal/angular protection in the front outboard designated seating positions with air bags and lap/shoulder belts. Lap/shoulder belts are required in each rear seating position. Lap belts are the minimum requirement for the front center-seating positions.

Occupant crash protection requirements are specified in terms of head and chest accelerations, chest displacement, neck forces and moments, and upper leg axial forces measured on laboratory calibrated Part 572 anthropomorphic test dummies in barrier impact collisions and applicable low risk deployment tests. When applicable, passenger air bag system suppression must be demonstrated for child dummies or human children, with and without child restraint seats, and passenger air bag system reactivation must occur with 5th percentile female dummies or humans of a similar size.

METRIC SYSTEM OF MEASUREMENT

Section 5164 of the Omnibus Trade and Competitiveness Act (Pub. L. 100-418) establishes that the metric system of measurement is the preferred system of weights and measures for trade and commerce in the United States. Executive order 12770 directs Federal agencies to comply with the Act by converting regulatory standards to the metric system after September 30, 1992. In a final rule published on March 15, 1990 (60 FR 13639), NHTSA completed the first phase of metrication, converting English measurements in several regulatory standards to the metric system. Since then, metrication has been applied to other regulatory standards (63 FR 28912).

Accordingly, the OVSC laboratory test procedures include revisions to comply with governmental directives in using the metric system. Regulatory standards converted to metric units are required to use metric measurements in the test procedures. For any testing equipment that is not available for direct measurement in metric units, the test laboratory shall calculate the exact metric equivalent by means of a conversion factor carried out to at least five significant digits before rounding consistent with the specified metric requirement.

All final compliance test reports are required to include metric measurements for standards using metrication.

NOTE: The methodology for rounding measurement in the test reports shall be made in accordance with ASTM E29-06b, “Standard Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications.”

TP208-14 3

2. GENERAL REQUIREMENTS....Continued

TABLE 1 - OCCUPANT CRASH PROTECTION INJURY CRITERIA

5 Calculated on data recorded for 300 ms after the vehicle strikes the barrier or from time zero in the sled test. (S4.11(a)) 6 Calculated on data recorded for 125 ms after the initiation of the final stage of air bag deployment designed to deploy in any full frontal rigid barrier crash up to 26 km/h. (S4.11(d)) 7 Calculated on data recorded for 125 ms after the initiation of the final stage of air bag deployment designed to deploy in any full frontal rigid barrier crash up to 64 km/h. (S4.11(c)) 8 Calculated on data recorded for 100 ms after the initial deployment of the air bag. (S4.11(b))

Injury Criteria

Dummies

50th male certified to S5.1.1(b)(1) 0-48 kmph belted, & S5.1.1(b)(2)0-56 kmph belted, & S5.1.2(a)(2), S5.1.2(b) 32- 40 kmph (±30o) unbelted5

5th female barrier S16.1(a)(1) 0-48 kmph belted, S16.1(a)(2) 0-56 kmph belted, S16.1(b) 32- 40 kmph unbelted, & S18.1 offset 0-40 kmph belted5

5th female low risk deployment S25.36

12-month –old low risk deployment S20.47

3-year-old low risk deployment S22.48

6-year-old low risk deployment S24.48

HIC 15 700

S6.2(b)(2)

S15.3.2(b)

S15.3.2(b)

S19.4.2(a)

S21.5.2(b)

S23.5.2(b)

Nij 1.0 (Critical Values 6806 N tens.

6160 N comp.

310 Nm flex.

135 Nm ext.)

S6.6(a)

1.0 (Critical Values 4287 N tens.

3880 N comp.

155 Nm flex.

67 Nm ext.)

S15.3.6(a)

1.0 (Critical Values 3880 N tens.

3880 N comp.

155 Nm flex.

61 Nm ext.)

S25.4(a)

1.0 (Critical Values 1460 N tens.

1460 N comp.

43 Nm flex.

17 Nm ext.)

S19.4.4(a)

1.0 (Critical Values 2120 N tens.

2120 N comp.

68 Nm flex.

27 Nm ext.)

S21.5.5

1.0 (Critical Values 2800 N tens.

2800 N comp.

93 Nm flex.

37 Nm ext.)

S23.5.5(a)

Neck Extension

N/A N/A N/A N/A N/A N/A

Neck Flexion N/A N/A N/A N/A N/A N/A Neck Tension 4170 N

S6.6(b) 2620 N S15.3.6(b)

S25.4(b)

780 N S19.4.4(b)

1130 N S21.5.5(b)

1490 N S23.5.5(b)

Neck Compress.

4000 N S6.6(c)

2520 N S15.3.6(c)

S25.4(c)

960 N S19.4.4(c)

1380 N S21.5.5(c)

1820 N S23.5.5(c)

Neck Fore-Aft Shear

N/A N/A N/A

Chest g 60 g S6.3

60 g S15.3.3

60 g S15.3.3

50 g S19.4.3

55 g S21.5.3

60 g S23.5.3

Chest Compress.

63 mm S6.4(b)

52 mm S15.3.4

52 mm S15.3.4

N/A 34 mm S21.5.4

40 mm S23.5.4

Femur Load 2250 lbf. (10000 N) S6.5

6805 N S15.3.5

6805 N S15.3.5

TP208-14 4

TABLE 2 - S7. SEAT BELT ASSEMBLY REQUIREMENTS

FMVSS 208

Passenger Cars

Trucks, MPVs, and Buses (GVWR 4,536 kg or less

Required Restraints

Front Outboard

Front Center

Rear

Front Outboard

Front Center

Rear

Adjustment S7.1

Yes S4.1.5.1(a)(3)

Yes S4.1.5.1(a)(2)

Yes S4.1.5.5.1

Yes S4.2.6 S4.1.5.1(a)(3)

Yes S4.2.6 S4.1.5.1(a)(2)

Yes S4.2.7

Lockability S7.1.1.5

Yes S4.1.5.1(a)(3)

Yes S4.1.5.1(a)(2)

Yes S4.1.5.5.1

Yes S4.2.6 S4.1.5.1(a)(3)

Yes S4.2.6 S4.1.5.1(a)(2)

Yes S4.2.7

Movable Anchorage S7.1.2

Yes S4.1.5.1(a)(3)

Yes S4.1.5.1(a)(2)

Yes S4.1.5.5.1

Yes S4.2.6 S4.1.5.1(a)(3)

Yes S4.2.6 S4.1.5.1(a)(2)

Yes S4.2.7

Belt Intersection S7.1.3

Yes S4.1.5.1(a)(3)

Yes S4.1.5.1(a)(2)

Yes S4.1.5.5.1

Yes S4.2.6 S4.1.5.1(a)(3)

Yes S4.2.6 S4.1.5.1(a)(2)

Yes S4.2.7

Latch Mechanism S7.2

Yes S4.1.5.1(a)(3)

Yes S4.1.5.1(a)(2)

Yes S4.1.5.5.1

Yes S4.2.6 S4.1.5.1(a)(3)

Yes S4.2.6 S4.1.5.1(a)(2)

Yes S4.2.7

Seat Belt Warning S7.3

Yes S4.1.5.1(a)(3) Driver ONLY

N/A S7.3

N/A S7.3

Yes S4.2.6 S4.1.5.1(a)(3) Driver ONLY

N/A S7.3

N/A S7.3

Belt Contact Force S7.4.3

NO

S7.4 (b)(1)

YES

S7.4 (b)(1)

YES

S7.4 (b)(1)

YES

S7.4 (b)(2)(ii)

YES

S7.4 (b)(2)(ii)

YES

S7.4 (b)(2)(ii)

Latch Plate Access S7.4.4

NO

S7.4(b)(1)

YES

S7.4 (b)(1)

YES

S7.4 (b)(1)

YES

S7.4 (b)(2)(ii)

YES

S7.4 (b)(2)(ii)

YES

S7.4 (b)(2)(ii)

Retraction S7.4.5

NO

S7.4(b)(1)

YES

S7.4 (b)(1)

YES

S7.4 (b)(1)

YES

S7.4 (b)(2)(ii)

YES

S7.4 (b)(2)(ii)

YES

S7.4 (b)(2)(ii)

Seat Belt Guides and Hardware S7.4.6

NO

S7.4(b)(1)

YES

S7.4 (b)(1)

YES

S7.4 (b)(1)

YES

S7.4 (b)(2)(ii)

YES

S7.4 (b)(2)(ii)

YES

S7.4 (b)(2)(ii)

TP208-14 5

TABLE 3 - S7.1. – SEAT BELT FIT AND ADJUSTMENT

Designated

Seating Position

Seat Belt Type

Fit

Adjustment Driver Type 2 5th% Female to 95th % Male

(S7.1.1.1)

Lap belt – emergency locking retractor (S7.1.1.3) Torso belt – emergency locking retractor or manual adjusting device (S7.1.1)

Type 1 50th % 6-year-old to 95th% Male (S7.1.1)

ELR or ALR (S7.1.1)

Lap - 50th % 6-year-old to 95th% Male (S7.1.1)

ELR or ALR (S7.1.1.2(a))

Center

Type 2

Torso – 5th% Female to 95th % Male

ELR or ALR or manual adjusting device (S7.1.1.2(a))

Lap - 50th % 6-year-old to 95th% Male (S7.1.1)

Lap belt – emergency locking retractor (S7.1.1.3)

Front Row

Passenger Outboard

Type 2

Torso – 5th% Female to 95th % Male

Torso belt – emergency locking retractor or manual adjusting device (S7.1.1)

Lap - 50th % 6-year-old to 95th% Male (S7.1.1)

Lap belt – emergency locking retractor (S7.1.1.3)

Outboard Type 2

Torso – 5th% Female to 95th % Male

Torso belt – emergency locking retractor or manual adjusting device (S7.1.1)

Lap - 50th % 6-year-old to 95th% Male (S7.1.1)

ELR or ALR (S7.1.1.2(a))

2nd Row (rear)

Center Type 2

Torso – 5th% Female to 95th % Male

ELR or ALR or manual adjusting device (S7.1.1.2(a))

Lap - 50th % 6-year-old to 95th% Male (S7.1.1)

Lap belt – emergency locking retractor (S7.1.1.3)

Outboard Type 2

Torso – 5th% Female to 95th % Male

Torso belt – emergency locking retractor or manual adjusting device (S7.1.1)

Lap - 50th % 6-year-old to 95th% Male (S7.1.1)

ELR or ALR or manual adjusting device (S7.1.1)

Other Rear Rows

Center Type 2

Torso – 5th% Female to 95th % Male

Torso belt – emergency locking retractor or manual adjusting device (S7.1.1)

NOTE: Front seat belt fit data shall be obtained with the seat in both the forward most and rearward most positions and the seat back in the manufacturer’s nominal design riding position. Movable anchorages are required for some outboard designated seating positions with Type 2 seat belts (S7.1.2). All the lap belt parts of a seat belt assembly, except for the driver must be lockable for child safety seats. (S7.1.5)

TP208-14 6

2. 2. GENERAL REQUIREMENTS....Continued

TABLE 4

S7.3(a). Warning system for seat belt assembly provided at Driver's position, EITHER S7.3 (a)(1) or S7.3 (a)(2) —

S7.3(a)(1)

S7.3(a)(2)

Belt unlatched & Key on9

Belt latched & Key on

Belt unlatched & Key on9

Warning light10

60 sec.

minimum

4 to 8 sec. 4 to 8 sec.

Audible signal11

4 to 8 sec. 4 to 8 sec.

9 At the manufacturer’s option, the driver's belt NOT IN USE (unbelted) is defined as either the belt latch mechanism is not fastened or the belt is not extended at least 4 inches from the stowed position.

10 Continuous or flashing warning light visible to the driver consisting of the symbol for the seat belt telltale. Instead of the continuous or flashing warning light, the manufacturer, if permitted by FMVSS 101, may display the words "FASTEN SEAT BELTS" or "FASTEN BELTS.

11 Continuous or intermittent audible signal. Note, 49 USC Section 30124 does NOT allow an audible signal to operate for more than 8 seconds. A voluntary audible signal after the 4 to 8 second required signal may be provided. It must be differentiated from the required signal (See May 25, 2001, legal interpretation to Longacre and Associates).

TP208-14 7

2.2 FMVSS 212, Windshield Mounting

This standard establishes windshield retention requirements for motor vehicles during crashes.

After they are subjected to a full frontal (the line of travel of the vehicle is perpendicular to the barrier) barrier impact test at any speed up to and including 48 kmph, vehicles equipped with passive restraints must retain not less than 50 percent of the portion of the windshield periphery on each side of the vehicle longitudinal centerline.

2.3 FMVSS 219, Windshield Zone Intrusion -- Partial

This standard specifies limits for the displacement of vehicle components into the windshield area during a frontal barrier impact test at any speed up to and including 48 kmph.

TABLE 5

In "Protected Zone" Below "Protected Zone"

Vehicle Component Penetration

Maximum of 6 mm into template (571.219 S5)

Must not penetrate inner surface of windshield within the Daylight Opening (DLO) (571.219 S5)

2.4 FMVSS 301

This standard specifies requirements for the integrity of motor vehicle fuel systems in frontal crash tests at speeds up to and including 48 kmph.

A. Frontal, Oblique, Lateral, and Rear Impact —

TABLE 6

TIME MAX. FLUID SPILLAGE

From impact until vehicle motion ceases

28 g (571.301 S5.5)

For 5 minute period after vehicle motion ceases

142 g (571.301 S5.5)

For the next 25 minutes 28 g/minute (571.301 S5.5)

TP208-14 8

B. Static Rollover

TABLE 7

TIME MAX. FLUID SPILLAGE

For 5 minute period from onset of rotation at each 90o position

142 g (571.301 S5.6)

For 6th minute 28 g (571.301 S5.6)

For 7th minute (if required) 28 g (571.301 S5.6)

For 8th minute (if required) 28 g (571.301 S5.6)

3. SECURITY

The contractor shall provide appropriate security measures to protect the OVSC test vehicles and Government Furnished Property (GFP) from unauthorized personnel during the entire compliance testing program. The contractor is financially responsible for any acts of theft and/or vandalism which occur during the storage of test vehicles and GFP. Any security problems which arise shall be reported by telephone to the Industrial Property Manager (IPM), Office of Acquisition Management, within two working days after the incident. A letter containing specific details of the security problem shall be sent to the IPM (with copy to the COTR) within 48 hours.

The contractor shall protect and segregate the data that evolves from compliance testing before and after each vehicle test. No information concerning the vehicle safety compliance testing program shall be released to anyone except the COTR, unless specifically authorized by the COTR or the COTR's Division Chief.

NOTE: No individuals, other than contractor personnel directly involved in the compliance testing program or OVSC personnel, shall be allowed to witness any vehicle or equipment item compliance test or test dummy calibration unless specifically authorized by the COTR.

4. GOOD HOUSEKEEPING

Contractors shall maintain the entire vehicle compliance testing area, dummy calibration laboratory, test fixtures and instrumentation in a neat, clean and painted condition with test instruments arranged in an orderly manner consistent with good test laboratory housekeeping practices.

5. TEST SCHEDULING AND MONITORING

The contractor shall submit a test schedule to the COTR prior to conducting the first compliance test. Tests shall be completed at intervals as required in the contract. If not specified, the first test shall be conducted within 6 weeks after receiving the first delivered unit.

Subsequent tests shall be completed in no longer that 1 week intervals unless otherwise specified by the COTR.

TP208-14 9

5. TEST SCHEDULING AND MONITORING….Continued

Scheduling of tests shall be adjusted to permit vehicles (or equipment, whichever applies) to be tested to other FMVSSs as may be required by the OVSC. All compliance testing shall be coordinated with the COTR in order to allow monitoring by the COTR and/or other OVSC personnel if desired. The contractor shall submit a monthly test status report and a vehicle status report (if applicable) to the COTR. The vehicle status report shall be submitted until all vehicles are disposed of. The status report forms are provided in the forms section.

6. TEST DATA DISPOSITION

The Contractor shall make all preliminary compliance test data available to the COTR on location within 30 minutes after the test. Final test data, including digital printouts and computer generated plots, shall be available to the COTR in accordance with the contract schedule or if not specified within two working days. Additionally, the Contractor shall analyze the preliminary test results as directed by the COTR.

All backup data sheets, strip charts, recordings, plots, technicians’ notes, etc., shall be either sent to the COTR or destroyed at the conclusion of each delivery order, purchase order, etc.

The contractor shall protect and segregate the data that evolves from compliance testing before and after each test.

TEST DATA LOSS

A. INVALID TEST DESCRIPTION

An invalid compliance test is one, which does not conform precisely to all requirements/specifications of the OVSC Laboratory Test Procedure and Statement of Work applicable to the test.

B. INVALID TEST NOTIFICATION

The Contractor shall notify NHTSA of any test not meeting all requirements/specifications of the OVSC Laboratory Test Procedure and Statement of Work applicable to the test, by telephone, within 24 hours of the test and send written notice to the COTR within 48 hours or the test completion.

C. RETEST NOTIFICATION

The Contracting Officer of NHTSA is the only NHTSA official authorized to notify the Contractor that a retest is required. The retest shall be completed within 2 weeks after receipt of notification by the Contracting Officer that a retest is required.

D. WAIVER OF RETEST

NHTSA, in its sole discretion, reserves the right to waive the retest requirement. This provision shall not constitute a basis for dispute over the NHTSA's waiving or not waiving any requirement.

TP208-14 10

6. TEST DATA DISPOSITION….Continued

E. TEST VEHICLE

NHTSA shall furnish only one vehicle for each test ordered. The Contractor shall furnish the test vehicle required for the retest. The retest vehicle shall be equipped as the original vehicle.

The original vehicle used in the invalid test shall remain the property of NHTSA, and the retest vehicle shall remain the property of the Contractor. The Contractor shall retain the retest vehicle for a period not exceeding 180 days if it fails the test. If the retest vehicle passes the test, the Contractor may dispose of it upon notification from the COTR that the test report has been accepted.

F. TEST REPORT

No test report is required for any test that is determined to be invalid unless NHTSA specifically decides, in writing, to require the Contractor to submit such report. The test data from the invalid test must be safeguarded until the data from the retest has been accepted by the COTR. The electronic data, draft final test report, dummy calibration report, and video shall be submitted within 14 days of the final test. The final test report, dummy calibration report, and video shall be submitted 7 days after receiving comments from the COTR.

G. DEFAULT

The Contractor is subject to the default and subsequent reprocurement costs for nondelivery of valid or conforming test (pursuant to the Termination For Default clause in the contract).

H. NHTSA'S RIGHTS

None of the requirements herein stated shall diminish or modify the rights of NHTSA to determine that any test submitted by the Contractor does not conform precisely to all requirements/specifications of the OVSC Laboratory Test Procedure and Statement of Work applicable to the test.

7. GOVERNMENT FURNISHED PROPERTY (GFP)

GFP consist of test vehicles and test dummies. The GFP is authorized by contractual agreement. The contractor is responsible for the following.

A. ACCEPTANCE OF TEST VEHICLES

The contractor has the responsibility of accepting each GFP test vehicle whether delivered by a new vehicle dealership or another vehicle transporter. In both instances, the Contractor acts on behalf of the OVSC when signing an acceptance of the GFP test vehicle delivery order.

When a GFP vehicle is delivered, the contractor must verify:

1. All options listed on the "window sticker" are present on the test vehicle.

2. Tires and wheel rims are new and the same as listed.

3. There are no dents or other interior or exterior flaws in the vehicle body.

TP208-14 11

7. GOVERNMENT FURNISHED PROPERTY (GFP)….Continued

4. The vehicle has been properly prepared and is in running condition.

5. The glove box contains an owner's manual, warranty document, consumer information, and extra set of keys.

6. Proper fuel filler cap is supplied on the test vehicle.

7. Spare tire, jack, lug wrench and tool kit (if applicable) is located in the vehicle cargo area.

8. The VIN (vehicle identification number) on the vehicle condition report matches the VIN on the vehicle.

9. The vehicle is equipped as specified by the COTR.

A Vehicle Condition form will be supplied to the Contractor by the COTR when the test vehicle is transferred from a new vehicle dealership or between test contracts. The upper half of the form is used to describe the vehicle as initially accepted. The lower half of the Vehicle Condition form provides space for a detailed description of the post-test condition. The contractor must complete a Vehicle Condition form for each vehicle and deliver it to the COTR with the Final Test Report or the report will NOT be accepted for payment.

If the test vehicle is delivered by a government contracted transporter, the contractor should check for damage which may have occurred during transit.

GFP vehicle(s) shall not be driven by the contractor on public roadways unless authorized by the COTR.

B. NOTIFICATION OF COTR

The COTR must be notified within 24 hours after a vehicle (and/or equipment item) has been delivered. In addition, if any discrepancy or damage is found at the time of delivery, a copy of the Vehicle Condition form shall be sent to the COTR immediately.

C. TEST DUMMIES

Part 572 test dummies will be furnished to the contract laboratory by the OVSC. For low risk deployment and crash tests that are performed with Part 572, Subpart O, 5th percentile female dummies, the tests shall be performed using dummies manufactured by either Denton or First Technology Safety Systems. The COTR will direct the testing laboratory on which 5th female dummy to use taking into consideration the manufacturer’s selection for its certification testing.

The Subpart E (50th male), O (5th female), and N (6-year old) dummies shall be stored in an upright sitting position with the weight supported by the internal structure of the pelvis. The dummies shall be held upright by using a strap around the chest or the base of the neck so that the neck is not supporting the weight of the dummy. The Subpart P (3-year-old), and R (12-month-old) dummies shall be stored in a hanging position using the bracket and positioning shown in Figures 1 and 2. The dummies shall be stored in a secured room, which

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is kept between 55oF and 85oF and 10-70% relative humidity. The Contractor shall check the dummy components for damage after each crash test or low risk deployment test and complete a Dummy Damage Checklist that shall be included with the posttest dummy calibration. The COTR shall be kept informed of the dummies condition in order that replacement parts can be provided. The Contractor shall calibrate the test dummies before every dynamic test and check the calibration after every dynamic test.

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FIGURE 1

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FIGURE 2

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8. CALIBRATION AND TEST INSTRUMENTATION

Before the Contractor initiates the vehicle safety compliance test program, a test instrumentation calibration system must be implemented and maintained in accordance with established calibration practices. The calibration system shall include the following as a minimum:

A. Standards for calibrating the measuring and test equipment shall be stored and used under appropriate environmental conditions to assure their accuracy and stability.

B. All measuring instruments and standards shall be calibrated by the Contractor, or a commercial facility, against a higher order standard at periodic intervals not exceeding 12 months for instruments and 12 months for the calibration standards except for static types of measuring devices such as rulers, weights, etc., which shall be calibrated at periodic intervals not to exceed two years. Records, showing the calibration traceability to the National Institute of Standards and Technology (NIST), shall be maintained for all measuring and test equipment.

Accelerometers shall be calibrated every twelve months or after a test failure or after any indication from calibration checks that there may be a problem with the accelerometer whichever occurs sooner.

C. All measuring and test equipment and measuring standards shall be labeled with the following information:

1. Date of calibration

2. Date of next scheduled calibration

3. Name of the technician who calibrated the equipment

D. A written calibration procedure shall be provided by the Contractor, which includes as a minimum the following information for all measurement and test equipment:

1. Type of equipment, manufacturer, model number, etc.

2. Measurement range

3. Accuracy

4. Calibration interval

5. Type of standard used to calibrate the equipment (calibration traceability of the standard must be evident)

6. The actual procedures and forms used to perform the calibrations.

E. Records of calibration for all test instrumentation shall be kept by the Contractor in a manner that assures the maintenance of established calibration schedules.

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8. CALIBRATION AND TEST INSTRUMENTATION….Continued

F. All such records shall be readily available for inspection when requested by the COTR.

The calibration system shall need the acceptance of the COTR before vehicle safety compliance testing commences.

G. Test equipment shall receive a system functional check out using a known test input immediately before and after the test. This check shall be recorded by the test technician(s) and submitted with the final report.

H. Anthropomorphic test devices shall be calibrated before and the calibration checked after each crash and low risk deployment test. The calibrations and calibration check shall be submitted with the final report.

Further guidance is provided in the International Standard ISO 10012-1, “Quality Assurance Requirements for Measuring Equipment” and American National Standard ANSI/NCSL Z540- 1, “Calibration Laboratories and Measuring and Test Equipment General Requirements.”

NOTE: In the event of a failure to meet the standard's minimum performance requirements additional calibration checks of some critically sensitive test equipment and instrumentation may be required for verification of accuracy. The necessity for the calibration will be at the COTR's discretion and shall be performed without additional cost.

9. PHOTOGRAPHIC DOCUMENTATION

The contractor shall document the crash event or low risk deployment with high-speed and real time digital color video cameras. The contractor shall report all camera locations along with camera speeds and lens focal lengths on the appropriate final report data sheets. Camera locations shall be referenced to the barrier face and monorail centerline with the X, Y, and Z coordinate for each camera.

The video footage shall be transferred to a compact disc (CD) or DVD as AVI or MPEG files with any standard or generally available “codec” compatible to Microsoft Windows. All video footage should be saved in a “read only” format before sending to the COTR to verify that the evidence has not been altered from its original condition. Video footage may only be saved using other types of file formats if approved by the COTR.

High-Speed Digital Video Cameras

High-speed digital video cameras shall operate at 1000 frames per second for at least 10 ms before barrier contact or the air bag is fired for low risk deployment and for at least 310 ms after barrier contact or after the air bag is fired for low risk deployment.

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9. PHOTOGRAPHIC DOCUMENTATION….Continued

The minimum resolution for these cameras shall be 1536 CMOS sensors per every two rows of pixels, with 80% of the horizontal distance of the two rows covered by effective light sensors. There shall be a minimum of 1024 rows of sensors. Some camera views may not need to meet these specifications. Cameras that do not meet these specifications may be used if approved by the COTR.

A time zero impact mark must be registered in a frame to indicate when contact with the barrier is made in the crash test or when the air bag is fired in a low risk deployment test. Each frame shall contain the camera speed and the frame number beginning with the time zero frame labeled as “Frame 0.” The frame numbers prior to time zero shall be negative numbers.

Real Time Camera

The contractor shall use a “real time” color digital camera that minimally operates at 24 frames per second. It shall be used to record pretest and posttest vehicle set-up, the installation of the fuel filler cap onto the filler neck and the rotation of the cap to the installed position, any fluid spillage and its collection after the impact or during static rollover, and to record a side view of the low risk deployment tests and left side of the vehicle or moving barrier as it travels down the tow road and through the impact event. The installation of the filler cap shall appear in the final version of the real-time crash video or as a single video file.

9.1 CAMERAS REQUIRED

9.1.1 OFFSET AND CRASH TESTS

CAMERA 1 Real-time (24 fps) left side view camera to follow the test vehicle down the tow road, across the photographic pit, and into the barrier face.

CAMERA 2 High-speed left side view camera to cover the vehicle's left side from the barrier face to a point rearward of the vehicle's front seat backs. The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle.

CAMERA 3 High-speed left side view camera positioned adjacent to the vehicle's A-post to document the driver dummy's head movement during the impact event in the windshield area and windshield zone intrusion area. The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle.

CAMERA 4 High-speed left side view camera positioned adjacent to the vehicle's B-post or center post to document the movement of the driver dummy during the impact event.

CAMERA 5 High-speed left side view camera positioned adjacent to the vehicle's B-post to document the movement of the vehicle's steering column/wheel assembly relative to the roof targets and the rear sill target during the impact event. (This camera is also used for steering column displacement analysis.) The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle.

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CAMERA 6 High-speed left side view camera positioned adjacent to the vehicle's left front door and underneath CAMERA 5 to document the movement of the vehicle's steering column/wheel assembly relative to the roof target and the rear sill targets during the impact event. (This camera is also used for steering column displacement analysis.) The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle.

CAMERA 7 High-speed right side view camera to cover the entire right side of the test vehicle during the impact event. The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle.

CAMERA 8 High-speed right side view camera positioned adjacent to the vehicle's A-post to document the passenger dummy's head movement in the windshield area during the impact event and windshield zone intrusion. The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle.

CAMERA 9 High-speed right side view camera positioned adjacent to the vehicle's B-post (or center) to document the movement of the passenger dummy during the impact

CAMERA 10 High-speed right side view camera positioned adjacent to the vehicle's right front door to document the movement of the passenger dummy during the impact

CAMERA 11 High-speed overhead camera positioned directly above the vehicle's windshield centerline to cover the windshield area during the entire crash event. A polarizing filter may be used to eliminate windshield glare.

CAMERA 12 High-speed front view camera mounted above the barrier face to document the movement of the driver dummy during the impact event and windshield zone intrusion.

CAMERA 13 High-speed front view camera mounted above the barrier face to document the movement of the passenger dummy during the impact event and windshield zone intrusion.

CAMERA 14 High speed overhead camera positioned directly above the barrier to record the contact of the vehicle with the barrier.

CAMERA 15 High-speed photographic pit camera positioned beneath the vehicle's engine compartment to record the vehicle structural crush and document any Stoddard solvent spillage.

CAMERA 16 High-speed photographic pit camera positioned beneath the vehicle's fuel tank to document any Stoddard solvent spillage.

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CAMERA POSITIONS FOR FRONTAL IMPACTS

FIGURE 3

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9.1.2 LOW RISK DEPLOYMENT TESTS

CAMERA 1 The real-time camera (24 fps) shall be used to document the pretest and posttest condition of the test vehicle in addition to the pretest and posttest positions of the test dummy.

CAMERA 2 High-speed left side view camera positioned perpendicular to the longitudinal centerline of the vehicle in line with the transverse centerline of the seat cushion to capture the movement of the dummy.

CAMERA 3 High-speed right side view camera positioned perpendicular to the longitudinal centerline of the vehicle in line with the transverse centerline of the seat cushion to capture the movement of the dummy.

CAMERA 4 High-speed front view camera mounted in the midsagittal plane of the dummy to document the movement of the dummy.

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LEFT SIDE VIEW

TOP VIEW

REAL TIME CAMERA1

CAMERA POSITIONS FOR LOW RISK DEPLOYMENTS

CAMERA FRAME RATES:

#1 = 24 fps All Others = 1,000 fps

TEST

VEH.

A1 A2

A1

FIGURE 4

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9.2 COLORING REQUIREMENTS FOR TEST PHOTOGRAPHIC PURPOSES

A. Vehicle underbody components such as the floor pan, frame rail members, steering mechanism, suspension components, engine oil pan, and all fuel system components shall be painted with different colored paint (pink, green, blue, orange, etc.). (Crash tests ONLY.)

B. Parts of the dummies shall be coated with colored chalk 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 solution shall be applied after final dummy positioning for crash tests. If necessary, the chalk solution may be applied prior to final dummy positioning for the low risk deployment tests.

TABLE 8

CHALK COLORS TO BE USED ON TEST DUMMIES

DUMMY PART DRIVER PASSENGER

Nose Red Yellow

Lips Red Yellow

Face Blue Red

Top of Head Yellow Blue

Back of Head Red Yellow

Left Knee Red Yellow

Right Knee Blue Red

Lower Steering Wheel Rim Red

C. In tests with a driver and passenger dummy, the clothes shall be contrasting colors so that the motion of each dummy can be identified during analysis.

9.3 PHOTOGRAPHIC COVERAGE OF FUEL FILLER CAP INSTALLATION

The removal, installation and tightening of the vehicle's fuel filler cap and the cap's rotation to its locked position by Contractor's personnel shall be documented. This color video footage shall appear in the final released video print to show that the filler cap was properly installed and tightened prior to the crash test. (Crash test ONLY.)

9.4 PHOTOGRAPHIC COVERAGE OF STODDARD SOLVENT SPILLAGE

The real-time camera (24 fps) shall be used to record any Stoddard solvent spillage from the test vehicle after the impact event or during the static rollover test. (Crash test ONLY)

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9.5 VEHICLE AND DUMMY PHOTOGRAPHIC COVERAGE

The real-time camera (24 fps) shall be used to document the pretest and post test condition of the test vehicle and the test dummies’ pretest and post test positions (including marks showing the fore and aft seat position) and if applicable, placement of the lap and shoulder belts on these dummies.

9.6 IMPACT EVENT MARKER

Strobe lights or taped photoflash bulbs (cloth tape on bulb exterior to form small slit for light passage) shall be placed in the field-of-view of all cameras to mark the beginning (time zero) of the crash or low risk deployment test. For the low risk deployment tests time zero is when the signal is sent to fire the air bag. Light from the impact detectors SHOULD NOT COVER MORE THAN 3 HIGH-SPEED FRAMES. Suggested locations for impact detectors or "time zero" markers are as follows:

A. Vehicle's roof panel along longitudinal centerline above windshield header B. Top surface of vehicle's instrument panel along longitudinal centerline C. Adjacent to engine oil pan.

D. Adjacent to vehicle's fuel tank.

9.7 REFERENCE TARGETS

Complete the “Photographic Targets” form for reference photographic targets to be used for crash testing. The setup rotation of the resection panel within the motion plane is not critical.

9.8 INFORMATIONAL PLACARDS

Vehicle identification placards shall be positioned so that at least 1 placard will be visible in the field-of-view for each of the cameras. The following information shall be shown:

A. Vehicle's NHTSA Number B. Type of test, e.g., "48 KMPH FRONTAL," “40 KMPH FRONTAL,” “40 KMPH OFFSET

FRONTAL,” etc.

C. Date of test D. Name of contract laboratory E. Vehicle year, make and model

9.9 CRASH VIDEO TITLE AND EDITING

The crash test video shall include the following title frames:

A. "The following [fill in the test type as stated in the informational placard above] test was conducted under contract with the National Highway Traffic Safety Administration by [name and location of test laboratory]"

B. TEST TYPE e.g., "48 KMPH FRONTAL," “40 KMPH FRONTAL,” “40 KMPH OFFSET FRONTAL,” etc.

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TEST VEHICLE MODEL YEAR, MAKE AND MODEL

NHTSA No. CXXXXX

DATE OF TEST

CONTRACT NO.: DTNH22-XX-X-XXXXX

C. The ending frame shall state "THE END"

9.10 VIDEO EDITING

The video shall be edited in the following sequence:

A. Title

B. Pretest Coverage

C. Real Time Pan Coverage

D. All high speed coverage in numerical order as shown in figures 3 and 4. When incorporating the procedures of Appendix J the video shall be edited to include each steering column camera's (5 and 6) "pre-run" of the resection control points panel inserted directly preceding that camera's footage from the actual test.

E. Posttest Coverage (All fuel system or windshield failures shall be completely documented.)

F. If applicable, FMVSS 301 Rotating Fixture Coverage (a minimum 10 seconds "burst" during

0 to 90 degree roll)

G. "The End"

9.11 DIGITAL PHOTOGRAPHS

The contractor shall take digital photographs of pretest and posttest condition of entire vehicle deformation and details that pertain to the tested standards. Photographs of all areas of the test vehicle that may be of importance to the frontal barrier impact test should be taken in excess and included in the test report only if the need arises. Photographs shall be taken in color and contain clear images. A tag, label or placard identifying the test vehicle model, NHTSA number and date shall appear in each photograph and must be legible. Each photograph shall be labeled as to the subject matter. The required resolution for digital photographs is a minimum of 1,600 x 1,200 pixels and shall have the same labeling requirements as still photographs. Digital photographs are required to be created in color and in a JPG format. Glare or light from any illuminated or reflective surface should be minimized while taking photographs.

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The test reports should include enough photographs to describe the testing in detailed and shall be organized in a logical succession of consecutive pictures. The digital photographs shall be included in the test report as 203 mm x 254 mm or 215.9 mm x 279 mm (8 x 10 or 8½ x 11 inch) pictures. All photographs are required to be included in the test report in the event of a test failure. Any failure must be photographed at various angles to assure complete coverage. Upon request, the photographs should be sent to the COTR on a CD or DVD and saved in a “read only” format to ensure that the digital photographs are the exact pictures taken during testing and have not been altered from the original condition.

The following digital photographs are required for the OVSC standards enforcement report for vehicles that exceed the FMVSS 208 performance requirements. Those marked with an asterisk are required in reports for vehicles that meet the FMVSS 208 performance requirements.

The underbody views shall include the following vehicle components: fuel pump, fuel lines, sender unit, fuel tank filler pipe and any other visible fuel system components.

9.11.1 Frontal barrier crash tests

*A. Pretest and post test frontal view of test vehicle

*B. Pretest and post test left side view of test vehicle

*C. Pretest and post test right side view of test vehicle

*D. Pretest and post test left front three-quarter view of test vehicle

E. Pretest and post test right rear three-quarter view of test vehicle

F. Pretest and post test windshield view

G. Pretest and post test engine compartment view

H. Pretest and post test fuel filler cap view (Include for FMVSS 301 failures)

*I. Pretest and post test front underbody view

J. Pretest and post test rear underbody view

*K. Pretest and post test driver dummy position with the camera perpendicular to the longitudinal centerline of the vehicle and in line with the markings showing the fore-aft position of the seat.

*L. Frontal pretest and post test driver dummy position with the camera in the same plane as the longitudinal centerline of the dummy.

*M. Pretest and post test passenger dummy position with the camera perpendicular to the longitudinal centerline of the vehicle and in line with the markings showing the fore-aft position of the seat.

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*N. Frontal pretest and post test passenger dummy position view with the camera in the same plane as the longitudinal centerline of the dummy.

*O Dummy contact point(s) vehicle and dummy

*P. Pretest and post test view of the knee bolsters.

*Q. Pretest and post test view of the steering column shear capsule if any part of it is visible.

Do NOT disassemble any parts to take these photographs.

*R. Pretest and post test view of the under hood steering shaft and steering box. Take the best photograph possible without removing any parts.

*S. Pretest and post test view of the steering column intersecting the fire wall from the inside of the vehicle. Take the best photograph possible without removing any parts.

*T. Pretest and post test under hood view of the steering column intersecting the fire wall.

Take the best photograph possible without removing any parts.

U. Photograph of ballast installed in vehicle.

V. Post test Stoddard solvent spillage location view, when leakage occurs.

W. Post test windshield periphery retention loss.

X. Post test windshield intrusion, when intrusion occurs.

*Y. Post test view of test vehicle while vehicle is on static rollover machine.

*Z. Photograph of certification label.

*AA. Photograph of tire placard.

*AB Photograph of vehicle window sticker(s)

AC Photographs of fuel system failures

9.11.2 Offset Deformable Barrier – the above photographs plus the following

*A. Pretest and posttest of the front left side perpendicular to the centerline of the vehicle at the most forward point of the vehicle.

*B. Pretest and posttest of the front of the vehicle.

*C. Pretest and posttest of the vehicle interior to show any intrusion that may occur.

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9.11.3 Suppression tests (For the suppression tests that meet the performance requirements of

FMVSS 208 the contractor shall have 4 photographs per page in the test report. Thus the individual photograph size will not be 203 mm x 254 mm or 215.9 mm x 279 mm (8 x 10 or 8½ x 11 inch)).

*A. Left side view of final position

*B. Right side view of final position

*C. Windshield view of final position

D. Photograph of the suppression telltale if it does not indicate the air bag is suppressed when the suppression test is performed

9.11.4 Low Risk Deployment

*A. Pretest and post test right side view

*B. Pretest and posttest left side view

*C. Dummy contact points

10. DEFINITIONS

The contractor shall check the Code of Federal Regulations for the most recent definitions. A citation is provided after each definition not specified in Standard 208.

10.1 Automatic-locking retractor: A retractor incorporating adjustment hardware by means of a positive self-locking mechanism which is capable when locked of withstanding restraint forces.

(571.209, S3)

10.2 Backless child restraint system: A child restraint, other than a belt-positioning seat, that consists of a seating platform that does not extend up to provide a cushion for the child’s back or head and has a structural element designed to restrain forward motion of the child’s torso in a forward impact. (571.213, S3)

10.3 Belt-positioning seat: a child restraint system that positions a child on a vehicle seat to improve the fit of a vehicle Type II belt system on the child and that lacks any component, such as a belt system or a structural…