Attachment-J.5-FrontalTest procedureSept2020_v1.pdf

Atachment‐J.5

OVSR Draft Frontal Test Procedure September 2020 2

September 2020

U .S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FOR FRONTAL RIGID BARRIER IMPACT TEST

U.S. Department of Transportation

National Highway Traffic Safety Administration

Office of Vehicle Safety Research

1200 New Jersey Avenue, SE

Washington, DC 20590

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REVISION CONTROL LOG

FOR OFFICE OF VEHICLE SAFETY RESEARCH TEST PROCEDURE

TEST PROCEDURE OBLIQUE IMPACT DESCRIPTION

REV

NO.

DATE AMENDMENT EFFECTIVE

DATE

01 12/5/2015 Draft 12/5/2015 Draft test procedure 02 06/22/2016 Draft Updates 12/5/2015 version with a more detailed procedure.

03 07/09/2018 Draft 07/09/2018 Removed unnessacary parts of the procedure and adding mounting plates.

OVSR Draft Frontal Test Procedure September 2020 4

SECTION A ‐ PURPOSE AND APPLICATION

This document is a laboratory test procedure provided by the National Highway Traffic Safety

Administration (NHTSA) Office of Vehicle Safety Research (OVSR) for use by contracted testing laboratories.

The OVSR test procedure includes requirements that are general in scope to provide flexibility for contracted laboratories to perform tests. These requirements are not intended to limit or restrain a Contractor from developing or utilizing any testing techniques or equipment which will assist in performing the test and collecting the desired data. This test procedure does not constitute an endorsement or recommendation for use of any particular product or testing method.

NOTE: This OVSR laboratory test procedure is provided for the limited purpose of conveying requirements to independent laboratories under contract to conduct such tests for the OVSR.

This laboratory test procedure is not rules, regulations, or NHTSA interpretations regarding the meaning of an FMVSS. This laboratory test procedure is not intended to limit the requirements of any FMVSS(s).

In addition, this laboratory test procedure may be modified by the OVSR at any time, without notice, and the COR may direct or authorize Contractors to deviate from this procedure, as long as the tests are performed in a manner consistent with this procedure and within the scope of the contract.

Any questions pertaining to the laboratory test procedures or other work requirement must be presented to the Contracting Officer Representative (COR) for discussion and resolution prior to conducting tests.

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SECTION B – DEFINITIONS AND REFERENCE DOCUMENTS

B.1 DEFINITIONS

1) As delivered: Refers to the vehicle in the unloaded vehicle weight (UVW) condition.

2) Designated seating capacity: The number of designated seating positions provided as defined in 49 CFR Part 571.3.

3) Fuel spillage: The fall, flow, or run of fuel from the vehicle but does not include wetness resulting from capillary action.

4) Gross axle weight rating or GAWR: The value specified by the vehicle manufacturer as the load‐carrying capacity of a single axle system as measured at the tire‐ground interfaces.

5) Gross vehicle weight rating or GVWR: The value specified by the manufacturer as the loaded weight of a single vehicle.

6) H‐Point: The pivot center of the torso and thigh on the three‐dimensional device used in defining and measuring vehicle seating accommodation, as defined in Society of

Automotive Engineers (SAE) Recommended Practice J1100, revised November 2009, “Motor

Vehicle Dimensions”

7) Longitudinal or longitudinally: Parallel to the longitudinal centerline of the vehicle.

8) Vehicle width: Maximum dimension measured across the widest part of the vehicle, including bumpers and molding but excluding such components as exterior mirrors, flexible mud flaps, marker lamps, and dual rear wheel configurations.

9) Rated cargo and luggage capacity weight (RCLW): RCLW = vehicle capacity weight – (68 kg x designated seating capacity). Maximum RCLW used in testing a truck, MPV, or bus is 136 kg.

10) Seating reference point (SgRP): The unique design H‐point, as defined in SAE J1100

(November 2009), which:

i) Establishes the rearmost normal design driving or riding position of each designated seating position, which includes consideration of all modes of adjustment, horizontal, vertical, and tilt, in a vehicle;

ii) Has X, Y, and Z coordinates, as defined in SAE J1100 (November 2009), established relative to the designed vehicle structure;

iii) Simulates the position of the pivot center of the human torso and thigh;

iv) Is the reference point employed to position the two‐dimensional drafting template with the 95th percentile leg described in SAE J826 (November 2008), or, if the drafting

OVSR Draft Frontal Test Procedure September 2020 6 template with the 95th percentile leg cannot be positioned in the seating position, is located with the seat in its most rearward adjustment position.

11) Seat cushion reference point (SCRP): A point placed on the outboard side of the seat cushion at a horizontal distance between 150 mm (5.9 in.) and 250 mm (9.8 in.) from the front edge of the seat which is used as a guide in positioning the seat.

12) Seat cushion reference line (SCRL): A line on the side of the seat cushion, passing through the seat cushion reference point, whose projection in the vehicle vertical longitudinal plane is straight and has a known angle with respect to the horizontal.

13) Unloaded vehicle weight (UVW): The weight of a vehicle with maximum capacity of all fluids necessary for operation of the vehicle, but without cargo, occupants, or accessories that are ordinarily removed from the vehicle when they are not in use.

14) Vehicle capacity weight (VCW): The VCW is provided by the vehicle manufacturer and is displayed on the Tire and Loading Information placard as XXX in the statement “The combined weight of occupants and cargo should never exceed XXX kilograms or XXX pounds.”

15) Vehicle fuel tank capacity: The tank’s unusable capacity (i.e., the volume of fuel left at the bottom of the tank when the vehicle’s fuel pump can no longer draw fuel from the tank plus its usable capacity (i.e., the volume of the fuel that can be pumped into the tank through the filler pipe with the vehicle on a level surface and with the unusable capacity already in the tank). The term does not include the vapor volume of the tank (i.e., the space above the fuel tank filler neck) nor the volume of the fuel tank filler neck

B.2 REFERENCE DOCUMENTS

1) PADI

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SECTION C ‐ GENERAL REQUIREMENTS

C.1 METRIC SYSTEM OF MEASUREMENT

Section 5164 of the Omnibus Trade and Competitiveness Act (Pub. L. 100‐418) established that the metric system of measurement was the preferred system of weights and measures for trade and commerce in the United States. Executive order 12770 directed 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).

Therefore, if a testing laboratory has any test equipment which is required to execute this test that cannot provide 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 test reports and injury data 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 E29‐13, “Standard Practice for Using Significant Digits in Test Data to

Determine Conformance with Specifications.”

C.2 GOVERNMENT FURNISHED PROPERTY (GFP)

The Government will furnish the Contractor with the following:

C.2.1 Acceptance of Test Vehicle

The contractor has the responsibility of accepting each NHTSA (GFP) test vehicle whether delivered by a new vehicle dealership or another vehicle transporter. In both instances, the

Contractor acts on behalf of the OVSR when signing an acceptance of the GFP test vehicle delivery order.

When a test vehicle is delivered, the contractor must verify all items identified in the FORM 2 ‐

“Report of Vehicle Condition” (J.1) Should any vehicle damage or discrepancies be discovered at the time of delivery, the COR or an authorized representative of the OVSR is to be notified immediately. The COR must always be notified within 24 hours after a vehicle (and/or equipment item) has been delivered. The FORM 2 ‐ “Report of Vehicle Condition” (J.1) shall be completed by the Contractor then submitted to the COR within 48 hours after delivery. The

COR will provide the appropriate FORM 1 to the Contractor upon vehicle delivery.

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

C.2.2 Anthropomorphic Test Devices (ATDS)

Two (2) assembled THOR 50th percentile male ATDs and the diagnostic equipment necessary for test set‐up including a tilt sensor readout shall be furnished to the contract laboratory by

OVSR. THOR ATDs shall be stored in an upright sitting position, with their weight supported as described in the User’s Manual.

The ATDs shall be stored in a secured room, which is maintained between 18.9° C and 25.5° C

(66° F and 78° F) and at any relative humidity from 10% to 70%. For eight hours prior to the test the ATDs shall be in an environment that is between 20.6° C and 22.2° C (69° F and 72° F).

Upon receiving, after each test is performed and prior to performing further tests, the contracting laboratory shall complete a thorough inspection of each ATD for physical damage and complete a FORM 3 – “THOR Inspection” (J.3) that shall be submitted to the COR after each test. The contracting laboratory shall also review all sensor data after each test and notify the

COR, of any data anomalies that occurred as a result of that test prior to performing further tests. The contracting laboratory may not proceed with additional subsequent tests unless permission to proceed is provided by the COR or an authorized representative of the OVSR.

The COR shall be kept informed of the ATDs’ condition in case replacement parts need to be provided. The Contractor shall keep a detailed record for each ATD, describing parts replaced and the results of qualification tests.

The COR must be notified within 24 hours after delivery of the THOR ATDs. If any discrepancy or damage is found at the time of delivery, a record of this discrepancy or damage must be sent to the COR in writing (e‐mail) immediately upon discovery.

C.2.3 Six Axis Degree‐of‐Freedom Sensor

The Contractor shall be provided with two (2) 6 degree‐of‐freedom sensors. These sensors measure X, Y, Z accelerations and X, Y, Z angular rate sensors. The six axis angular rate sensors shall have a range of either ± 8000 deg/sec (2000 Hz), 2000g or ± 18000 deg/sec (2000 Hz), 2000g and the accelerometers shall have a range of ± 2000 g.

C.2.4 Belt Movement Sensors

The Contractor shall be provided with a two (2) GFE seat belt movement sensors, which shall be installed to measure the displacement of the shoulder belt during the test for both the driver and right front passenger.

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C.3 ‐ DISPOSITION OF GOVERNMENT PROPERTY

Upon acceptance of the Contractor’s final test reports, the COR will determine if the tested vehicles can be released for disposition from the Contractor’s facility. If so, the NHTSA Property

Management Specialist will take appropriate steps to arrange for disposition of NHTSA property.

C.4 ‐ SECURITY

The Contractor shall provide appropriate security measures to protect test vehicles and

Government Furnished Property (GFP) from unauthorized personnel during the entire 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 COR) within 48 hours.

The Contractor shall protect and segregate data associated with each vehicle test as it evolves from activities that occur before and after each crash test. No information concerning the testing program shall be released to anyone except the COR, unless specifically authorized by the COR or the COR's Division Chief.

C.5 RULES FOR CONTRACTORS

1) No vehicle manufacturer's representative(s) or anyone other than the Contractor's personnel working on contracts associated with this test mode and NHTSA personnel shall be allowed to inspect NHTSA vehicles, ATDs or witness vehicle preparations, ATD qualification and/or crash testing without prior permission of the COR or other authorized representative of OVSR. Such permission can never be assumed.

2) All communications with vehicle manufacturers shall be referred to the COR or other authorized representative of OVSR, and at no time shall the Contractor respond to any questions, release crash test data, videos, or photos without the permission of the COR or other authorized representative of OVSR.

3) The vehicle manufacturer's representatives shall only be authorized to visit the Contractor's test facility on the day that the test is scheduled except when their expertise is required for the preparation of the test vehicle (e.g. overriding a restraint suppression system that is unable to recognize an ATD). This work with the vehicle manufacturer must be approved in advance by the COR or other authorized OVSR representative. The representatives must be escorted by NHTSA and/or Contractor personnel.

4) Test vehicle inspection by the vehicle manufacturer's representative(s) shall be limited to 30 minutes prior to the start of vehicle impact test. Post‐test inspection shall be limited to 1 hour after Contractor personnel have completed their test tasks.

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5) Individual data plots and video cannot be viewed by manufacturer representatives until they are reviewed by NHTSA personnel and/or granted express permission by the COR.

6) Manufacturer representatives shall not be permitted to tamper with or remove any parts from the vehicle without the consent of the COR.

C.6 EVENT DATA RECORDER (EDR)

The Contractor shall download the data from the Event Data Recorder from each test using the latest publically available software. The Contractor shall purchase and maintain the hardware and most‐current software. The Contract shall submit the pdf report and binary file.

Note: If the Contractor is not able to download EDR, the Contractor shall notify COR via e‐ mail why the EDR cannot be downloaded.

C.7 CAMERA REQUIREMENTS

A digital file for each high‐speed and real‐time camera specified in this section shall be delivered in one of the following formats (.avi, .wmv, or .mpeg) using a standard or generally available “codec.” Other types of files can be used only if prior approval is granted by the COR.

Also, no fisheye lenses shall be used without prior approval by the COR. NHTSA reserves the right to modify the placement of all cameras.

C.8 HIGH SPEED DIGITAL COLOR CAMERAS

The Contractor shall have a minimum of nine high speed digital color cameras able to record

1000 fps and have a minimum resolution of 1024 by 1024 pixels. Two of the high speed digital color cameras must be high “g” rated

The Contractor shall have 12 high speed digital color cameras able to record at 500 fps and have a minimum resolution of 512 by 512 pixels. Four of these cameras must be high “g” rated

Cameras must operate for at least 50 ms before time zero and for at least 300 ms after time zero, t0, where t0 is defined as the instant when the oblique moving deformable barrier (OMDB) contacts the test vehicle.

All videos shall have a time zero light in the registered frame to indicate when contact with the test vehicle and OMDB occurs. This may be accomplished by placing strobe lights or flash bulbs that illuminate at time zero in each field‐of‐view. The strobes can be wired to contact tape switches placed at the point of contact between the target test vehicle and the bullet OMDB.

Each video 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.

Each on‐board video shall contain the NHTSA Number in the field of view at time zero.

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The impact area must be equipped with sufficient lighting to provide the proper exposure without producing excess glare or shadows. The vehicle interior may require auxiliary onboard lighting to facilitate video analysis.

The contractor shall meet all the field of views specified in the test procedure.

C.9 REAL TIME COLOR CAMERA

The Contractor shall have two (2) real time HD digital color cameras able to record a minimum of 24 frames per second (fps) and have a minimum resolution of 1920 pixels wide and 1080 pixels high.

C.10 DIGITAL STILL PHOTOGRAPHS

Clear and properly focused digital, color still photographs in .jpg format shall be taken to document the test. The minimum resolution for digital photographs 1,600 by 1,200 pixels.

Information placards which identify the test vehicle, NHTSA number, and test date, along with an indication of whether the photograph was taken pre‐test or post‐test, shall appear in each photograph and be legible. All pre‐test photographs should be taken prior to impact, and all post‐test photographs should be taken following impact. Glare or light from any illuminated or reflective surface should be minimized while taking photographs. Also, the contractor shall meet all the field of views specified in the test procedure.

Two photographs shall be provided to fill each page of Appendix A of the Final Test Report, and each photograph in this test procedure shall be labeled as to subject matter in accordance to the specified picture to be taken.

C.11 CALIBRATION AND TEST INSTRUMENTATION

Before the Contractor initiates the OVSR test program, a test instrumentation calibration system must be implemented and maintained in accordance with established calibration best practices. At a minimum, the calibration system shall include the criteria listed below.

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

2) All measuring instruments and standards shall be calibrated by the Contractor, or a commercial facility, against a higher order standard at periodic intervals. For accelerometers, the interval shall not exceed 6 months, after a test failure, or after any indication from calibration checks that there may be a problem with the accelerometer, whichever occurs sooner. For load cells, instruments, and calibration standards (except for static types of measuring devices such as rulers, weights, etc.), the interval shall be 12 months.

3) All measuring and test equipment and measuring standards shall be labeled with the following information:

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i) Date of calibration

ii) Date of next scheduled calibration

iii) Name of the technician who calibrated the equipment

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

i) Type of equipment, manufacturer, model number, etc.

ii) Measurement range

iii) Accuracy

iv) Calibration interval

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

vi) The actual procedures and forms used to perform the calibrations

vii) Records, showing the calibration traceability to the applicable National Institute of

Standards and Technology (NIST) standard, shall be maintained for all measurement and test equipment for a period of at least 5 years. All such records shall be readily available for inspection when requested by the COR. The calibration system shall need the acceptance of the COR before testing commences.

5) The Contractor shall perform a polarity check for all ATD and vehicle sensors to ensure that all data is accurately recorded and reported. Also, the contractor shall not zero out the appropriate channels. All checks shall be recorded by the test technician(s).

6) Test equipment shall receive a system functional check using a known test input immediately before and after the test. This check shall be recorded by the test technician(s).

Further guidance is provided in the International Standard ISO 10012:2003, “Measurement management systems — Requirements for measurement processes and measuring equipment” and American National Standard ANSI/NCSL Z540.3‐2006, “Calibration Laboratories and

Measuring and Test Equipment General Requirements

C.12 ATD QUALIFICATION

ATDs shall be qualified as defined by the contract. If qualification before and after each test is required, the post‐test qualification data obtained after a crash test can be used as the pre‐test calibration qualification data for a subsequent crash test as long as the dummy is used within eight (8) weeks of the post‐test calibration qualification, and the dummy is not used for any other static or dynamic tests during that time period.

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The qualification data for the test device shall be submitted as part of the Quality Control

Package, the Draft Test Report, and Final Test Report (see Deliverables). Qualification data must also be available electronically (in UDS format with an .ev5 header) if requested by the

COR. Electronic data collected for all ATD qualifications must be retained by the Contractor for at least five years from the test date.

In the event of a test failure (i.e. failure to meet performance requirements) or data anomaly, the ATD must be inspected to identify any type of contributing electrical or mechanical issue.

Furthermore, the COR may request that the region be re‐qualified before testing can resume.

Additional checks of test equipment and instrumentation may be required for verification of accuracy. The necessity for investigations and the qualification will be at the COR’s discretion and will be performed without additional cost.

C.13 TOW ROAD

There are two options for the tow road:

C.13.1 Option1

The tow road should be at least 152 m (500 feet) in length and terminate at the face of the non‐energy‐absorbing barrier as shown in Figure 1. The first 61 m (200 feet) (approximate) from the head of the tow road will be used to accelerate the test vehicle up to the specified velocity without exceeding 0.30g, which could affect the positioning of the P572 test dummies in the test vehicle. The next 30 m (100 feet, approximate) of tow road shall be used for dummy stabilization. At this juncture, the test vehicle should have reached the desired impact velocity and should be experiencing zero acceleration. The remaining 61 m

(200 feet, approximate) of tow road will be used for test vehicle speed stabilization. The width of the tow road should be approximately 2.4 to 4.3 m (8 to 14 feet) and should be straight and level so that the test vehicle does not oscillate vertically in excess of 0.29g (SAE

J211/Mar 95 filter class 60).

C.13.2 Option 2

A tow road that is shorter than the length described in Option 1 may be approved for use in frontal NCAP testing if the Contractor demonstrates that test vehicles can be smoothly and reliably accelerated to target speed without exceeding 0.30g and without affecting the position of the P572 test dummies in the test vehicle. Because a shorter tow road may have less distance available for vehicle stabilization at constant velocity, the contractor is expected to use an electronic feedback control system to accelerate the vehicle according to a preprogrammed velocity profile. The system shall automatically abort the test (without operator intervention) if, at any time, the speed deviates from the velocity profile to any degree that will threaten achieving target speed given there is adequate distance to stop the test without damage to the vehicle. The width of the tow road should be approximately

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2.4 to 4.3 m (8 to 14 feet) and should be straight and level so that the test vehicle does not oscillate vertically in excess of 0.29g (SAE J211/Mar 95 filter class 60). If a tow road that is shorter than the length described in Option 1 is proposed, the Contractor shall submit a minimum of the following information to the COR for approval:

1. At least two representative acceleration plots of sample vehicle tests with a target test speed equal to the frontal NCAP test. The plots should reflect the entire duration of the tow event, from the beginning of vehicle movement to barrier impact for:

a. One “average” NCAP test weight vehicle (example: 4 door sedan or small

SUV/crossover)

b. One “maximum” NCAP test weight vehicle (example: large full size pickup)

2. A complete description of the feedback control system including data and/or plots that demonstrate:

a. The system can reliably accelerate a vehicle following a preprogrammed velocity profile.

b. The vehicle speed is monitored continuously and maintained within a corridor throughout entire tow event.

c. The vehicle will be traveling at or near constant velocity and within ± 0.80 km/h of the target velocity prior to and at impact.

3. A complete description of the system’s abort approach and capability, which should include the ability to abort automatically in the case of nonconformance with item 2 of this list.

COR approval of the tow system does not absolve the contractor from the retest requirements described in Section 13.1 of Reference 3 in the case of an invalid test.

C.14 PHOTOGRAPHIC PIT

A photographic pit will be located under the tow road at the stationary barrier face so that structural crush and possible fluid leakage of Stoddard solvent can be photographed during the impact event. The pit shall be covered using the following guidelines:

1. Use a transparent material that allows for use of pit cameras.

2. The covering and its supports shall be of sufficient strength in case the vehicle structure comes in contact with it during the NCAP test.

3. The entire pit should be covered except for the area needed for the tow system to operate.

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4. Precautions must be taken to ensure there is no electromagnetic interference generated by the pit cover material.

C.15 TEST VEHICLE PREPARATION BUILDING / STRUCTURE

The test vehicle preparation building/structure encloses the area where the test vehicle is prepped during pre‐test set‐up that occurs just prior to the impact test. This building or structure shall be temperature‐controlled, sealed to keep fine debris out, and large enough to house the test vehicle, test equipment and instrumentation, while allowing room for personnel to move freely about the test vehicle. The temperature inside the test vehicle must be maintained between 20.6° C and 22.2° C (69° F and 72° F) for a minimum of four 4 hours prior to the impact event. For facilities that require testing outdoors, the preparation structure must be capable of being removed quickly prior to conducting the test and the vehicle interior temperature must be maintained within the specified range until just before the OMDB is towed into the test vehicle.

C.16 DATA ACQUISITION SYSTEM

The Contractor‐furnished data acquisition system shall have the ability to capture a minimum of

288 channels available for recording and processing signals from the ATDs and vehicle sensors starting 50 ms prior to impact and continuing through 300 ms after impact. The system must record time histories of the instrumentation specified for each ATD used in the test. Each data channel shall be comprised of a sensor, signal conditioner, data acquisition device, and all interconnecting cables, and it must conform to the appropriate section of SAE Recommended

Practice SAE J211/2 June 2014. NHTSA reserves the right to add an additional 20 channels.

C.17 CMM MACHINE

The contractor shall have a coordinate measuring machine (CMM) with accuracy of 1 mm.

NHTSA reserves the right to add an additional 30 measurement points beyond those identified in this test procedure.

C.18 TARGET VEHICLE INFORMATION PLACARDS

Test vehicle identification placards shall be positioned so that at least one placard will be visible and legible in each of the off board high speed cameras’ field of view. The test laboratory’s name or logo shall not appear on vehicle information placards.

The COR(TO) will specify information to be placed on the placards in writing (e‐mail) before testing begins.

C.19 PRE‐TEST REQUIREMENT

Prior to conducting a test, the contractor shall:

1) Verify COR approval of Contractor’s in‐house test procedure

2) Verify the training of technicians for performance of this test

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3) Verify the calibration and qualification status of test equipment

4) Review vehicle Owner’s Manual and FORM1

5) Set cold tire pressures according to the vehicle manufacturer’s recommendations (where applicable).

C.20 DETAILED TEST AND QUALITY CONTROL PROCEDURES REQUIRED

The Contractor shall submit a detailed test procedure to the COR before initiating the test program. The procedure must include:

1) A step‐by‐step description of the methodology to be used

2) A complete listing of test equipment to be used including instrument accuracy and calibration dates

3) Detailed checklists that sequentially cover all steps of the test including data review

Each separate checklist shall identify the lab, test date, vehicle and test technicians. These check sheets shall be used to document that all requirements and procedures have been completed.

There shall be no contradiction between this laboratory test procedure and the Contractor’s in‐ house test procedure. If the Contractor observes deficiencies in this laboratory test procedure, the Contractor is required to advise the COR to resolve the discrepancy as soon as practicable, prior to the start of testing.

The Contractor shall also submit a written Quality Control (QC) Procedure which must include:

the instrumentation and test equipment calibration process, data review process, report review process, and shall identify the people assigned to perform QC on each task.

Written approval of any and all in‐house test procedures and QC procedures shall be obtained from the COR before initiating a test program.

C.21 EV5 SUBMISSION

The contractor shall submit the test videos, pictures, and data according to NHTSA’s EV5 and intrusion data format as specified in Version 5 Test Reference Guide, Volume 1: Vehicle Tests

(VRTG).

The Contractor shall add a statement after the text in INSCOM if the data is questionable. For example: V2P1 LR CHEST IR‐TRACC DX ‐>QD ‐ NOISE ON DATA

C.22 TEST REPORTS

The contractor shall submit the test report using the attached example test report. The contractor shall not deviate from this example test report without permission from the COR.

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C.22.1 Filtering Requirements

The contractor shall use the following filtering class in Table C‐1 for the curves plotted in the test report

Table C-1: Filtering Class of Data Channels in Test Report

FILTER CLASS

Head Accelerations 1000

Head Angular Rate 60

Neck Forces 1000

Neck Moments 600

Neck Spring Force 1000

Occipital Condyle Rotation 180

Spine Acceleration 180

Thorax/Chest Acceleration 180

CRUX 180

DGSP 180

Acetabulum Force 600

Femur Force 600

Femur Moment 600

Knee Displacement 180

Tibia Force 600

Tibia Moment 600

Tibia Acceleration 1000

Ankle Rotations 180

Foot Acceleration 1000

C.22.2 Data Plots

The Contractor shall include the information shown in Figure C‐1 on each data plot. Below provides the details of what to include on the plot.

1) Chart title shall be project title

2) Chart subtitle shall include the following information.

i) Vehno=Target or OMDB

ii) Senloc=Driver, Right Front Pass, Left Rear Seat, etc.

iii) Senatt= Head, Chest, Neck, etc.

iv) Axis=X‐Axis, Y‐Axis, or Z‐Axis

v) Unit Description=Acceleration, Force, moment, etc.

vi) Yunits=g,N, NM, etc.

3) The plot shall also include the following information below the plot:

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i) NHTSA number

ii) SAE filter class

iii) Min value

iv) Min value time

v) Max value

vi) Max value time

If the channel failed or contains questionable data, the description of the failure shall be placed in the plot area.

Figure C-1: Example data plot with questionable data

C.23 GOOD HOUSEKEEPING

Contractors shall keep the vehicle preparation area, test area and ATD qualification laboratory neat, orderly, clean and presentable, which is consistent with good test laboratory practices.

Furthermore, all test fixtures, equipment, instrumentation, cabling, and GFP shall also be well maintained, stored appropriately, in a neat orderly manner and in good condition which is also consistent with good test laboratory practices.

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C.24 TEST SCHEDULING AND MONITORING

Tests shall be completed as required in the contract. The Contractor shall submit to the COR a test date for each vehicle to be tested prior to conducting any test. If not specified in the contract, tests shall be conducted within 2 weeks after receiving the test vehicle and related setup information (Form 1) unless otherwise specified by the COR.

Scheduling and order of tests shall be adjusted based on vehicle and equipment availability or program requirements as required by the COR. All testing shall be coordinated with the COR in order to allow monitoring by the COR and/or other NHTSA personnel, if desired. The

Contractor shall submit a monthly test status report and a vehicle status report (if applicable) to the COR. These reports must be submitted to the COR by the 15th day of each month. The vehicle status report shall be submitted until all vehicles are disposed of.

C.25 INVALID TEST DESCRIPTION

An invalid test is one which does not conform precisely to all critical Deliverables in Section C.26 and C.27

C.25.1 Invalid Test Notification

The Contractor shall notify NHTSA of any test not meeting all requirements of the OVSR

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 COR within 48 hours of the test completion.

C.25.2 Retest Notification

The CO is the only NHTSA official authorized to notify the Contractor that a retest is required.

C.25.3 Waver 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 NHTSA's waiving or not waiving any requirement.

C.25.4 Test Vehicle

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

COR that the test report has been accepted.

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C.25.5 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 COR.

C.26 CRITICAL DELIVERABLES

C.26.1 Anthropomorphic Test Device (ATD)

Table C‐2 defines the critical channels that must be collected for each THOR in order to have a valid test. If data associated with these channels is not collected, the test laboratory is required to contact the COR within 24 hours of the test. A re‐test may be required.

Table C-2: Anthropomorphic Test Device critical deliverables

CHANNEL NAME DESCRIPTION

V2P1 HDCG AX V2P1 HEAD CG X

V2P1 HDCG AY V2P1 HEAD CG Y

V2P1 HDCG AZ V2P1 HEAD CG Z

V2P1 SPNU AX V2P1 T1 ACCEL AX

V2P1 SPNU AY V2P1 T1 ACCEL AY

V2P1 SPNU AZ V2P1 T1 ACCEL AZ

V2P1 HDCG RX V2P1 HEAD ANGULAR RATE RX

V2P1 HDCG RY V2P1 HEAD ANGULAR RATE RY

V2P1 HDCG RY V2P1 HEAD ANGULAR RATE RZ

V2P1 CHLU DX V2P1 UL CHEST IR‐TRACC DX

V2P1 CHLU RY V2P1 UL CHEST RY

V2P1 CHLU RZ V2P1 UL CHEST RZ

V2P1 CHRU DX V2P1 UR CHEST IR‐TRACC DX

V2P1 CHRU RY V2P1 UR CHEST RY

V2P1 CHRU RZ V2P1 UR CHEST RZ

V2P1 CHLL DX V2P1 LL CHEST IR‐TRACC DX

V2P1 CHLL RY V2P1 LL CHEST RY

V2P1 CHLL RZ V2P1 LL CHEST RZ

V2P1 CHRL DX V2P1 LR CHEST IR‐TRACC DX

V2P1 CHRL RY V2P1 LR CHEST RY

V2P1 CHRL RZ V2P1 LR CHEST RZ

V2P1 FMRL FZ V2P1 LEFT FEMUR FZ

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V2P1 FMRR FZ V2P1 RIGHT FEMUR FZ

C.26.2 Test Vehicle

Table C‐3 defines the critical channels that must be collected in order to have a valid test. If data associated with these channels is not collected, the test laboratory is required to contact the COR within 24 hours of the test. A re‐test may be required.

Table C-3: Test vehicle critical deliverables

CHANNEL NAME DESCRIPTION

V2 DSLR AX V2 LEFT REAR SILL X

V2 DSLR AY V2 LEFT REAR SILL Y

V2 DSRR AX V2 RIGHT REAR SILL X

V2 DSRR AY V2 RIGHT REAR SILL Y

V2 VHCG AX V2 VEHICLE CG ACCELERATION AX

V2 VHCG AY V2 VEHICLE CG ACCELERATION AY

C.26.3 Videos

Table C‐4 defines the critical videos that must be collected in order to have a valid test. If data associated with these channels is not collected, the test laboratory is required to contact the COR within 24 hours of the test. A re‐test may be required.

Table C-4: High speed camera critical deliverables

CAMERA

NUMBER

CAMERA NAME

Onboard Driver Over Shoulder

Onboard Center Driver Passenger

Onboard Driver Over Shoulder

C.27 TESTING REQUIREMENTS

C.27.1 Tow and Guidance System

The tow system shall be capable of ensuring that the vehicle impacts the test vehicle at a speed of 56 ± 0.80 km/h. The vehicle shall be continuously towed until 305 mm from the impact point, with a tolerance window of 610 mm to 150 mm. The tow cable attachment device must release from the tow cable within the tolerance window. The OMDB velocity measurement shall be taken after cable release.

C.27.2 Impact Speed Measurement

Impact speed shall be measured by no less than two sets of independent timing devices, accurate to within ± 0.08 km/h and calibrated by an instrument traceable to the National

Institute of Standards and Technology (NIST). The impact speed measurement recorded closest to the point of impact should be regarded as the primary measurement.

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The physical locations of the recorded primary and redundant impact speed readouts should remain the same from test to test. For example, the laboratory may always choose to display the primary speed on the left‐hand side, etc. These displayed values shall be labeled to indicate which display is the primary and which display is the redundant. The displayed values shall be to the hundredths and shall be in the units of kilometers per hour.

The impact speed shall be documented by both digital real time video and digital photography.

A computer screen read‐out may be utilized as a secondary display, should the primary display not function as intended.

C.27.3 TEST TEMPERATURE CONDITIONS

The Contractor must verify that the dummy temperature is in the specified temperature range of 20.6° C and 22.2° C (69° F and 72° F). The temperature sensors for both methods shall be accurate at least to within ± 0.3° C (0.54° F).

The dummy must be soaked in an ambient air environment in the specified range as shown above for 8 hours prior to the test and any time after that until just before the movement of the vehicle towards the impact barrier. The ambient air temperature must be monitored and continuously recorded within 36 inches of the dummies.

For facilities that require testing outdoors, the vehicle’s interior temperature shall be monitored, continuously recorded, and confirmed to have remained within the specified range following removal of the preparation structure until just before the OMDB is towed into the test vehicle.

The Contractor shall mark the ambient air temperature recording with the date, time and technician name at the beginning of the 8 hour soak and when the OMDB begins to move towards the test vehicle. Temperature recordings shall be supplied to the COR with final test reports.

C.28 QUICK LOOK DATA

The Contractor shall conduct a "quick‐look" analysis of test data and cameras to determine if there any anomalies in the recorded data or any indications of that all the critical delevables are not meet. Any anomalies or indication of a test failure shall be discussed with the COR within

24 hours of performing the test.

C.29 QUICKLOOK REPORT

The Contractor shall provide a Quicklook Report within 24 hours of the impact event. The COR will provide an example of the Quicklook Report before testing begins.

C.30 INDICANT TESTING

The contractor shall perform the following indicant testing:

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C.30.1 FMVSS No. 212, Windshield Mounting and FMVSS No. 209 Windshield Zone Intrusion –

Partial (Indicant Test)

Note: In the case of a result that does not meet the requirements set forth in FMVSS No.

212 or FMVSS No. 219, the test laboratory is required to contact the COR within 24 hours of the test.

C.30.2 FMVSS No. 301, Fuel System Integrity (Indicant Test)

The contracting laboratory shall prepare the vehicle fuel system and measure post impact fuel system fluid spillage following the NHTSA test procedure for the FMVSS No. 301 frontal test.

Note: In the case of a result that does not meet the requirements set forth in FMVSS No.

301 and the associated compliance test procedure, the test laboratory is required to contact the COR within 24 hours of the test.

C.30.3 FMVSS No. 305, Electric Powered Vehicles, Electrolyte Spillage, and Electrical Shock

Protection (Indicant Test)

Any test vehicle with full or partial electric motive power must be tested to the requirements outlined in 49 CFR §571.305 Sections 5.1, 5.2, and 5.3.

In the case of a result that does not meet these requirements, the test laboratory is required to contact the COR within 24 hours of the test.

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SECTION D – RECEIPT OF GOVERNMENT FURNISHED EQUIPMENT

The flow chart below shows the summary of steps for receiving Government Furnished

Equipment (GFE).

DummiesTest Vehicle

Verify dummy instrumentation to

TP

Verify all instrumentation is in

Calibration

Obtain IR-TRACC Calibration

Obtain Certification Sheets

Inspect Dummies

Receipt of Vehicle

Get NHTSA Number

Gather and Collect Information for Form 2

Obtain Form 1

Certification Label Information

Seat and Cargo Information

Tire Information

Obtain Instrumentation

Sensitivity

Extra Instrumentation

Verify Extra Instrumentation to

TP

Verify all instrumentation is in

Calibration

Obtain Instrumentation

Sensitivity

OVSR Draft Frontal Test Procedure September 2020 25

D.1 – RECEIPT OF TEST VEHICLE

D.1.1 Test Vehicle and Inspection

STEP D.1.1.1 All options listed on the "window sticker" are present on the test vehicle.

STEP D.1.1.2 Tires and wheel rims are new and the same as listed.

STEP D.1.1.3 There are no dents or other interior or exterior flaws in the vehicle body.

STEP D.1.1.4 The vehicle has been properly prepared and is in running condition.

STEP D.1.1.5 The glove box contains an owner's manual, warranty document, consumer information, and extra set of keys.

STEP D.1.1.6 The proper fuel filler cap is supplied on the test vehicle.

STEP D.1.1.7 The spare tire, jack, lug wrench and tool kit (if applicable) are located in the vehicle cargo area.

STEP D.1.1.8 The odometer reflects that the vehicle has been driven less than or equal to

200 miles.

STEP D.1.1.9 The VIN (vehicle identification number) matches the VIN supplied by

NHTSA.

STEP D.1.1.10 The vehicle is equipped / matches description provided by NHTSA.

STEP D.1.1.11 Vehicle warning lights (i.e. check engine, SRS, etc.) are not illuminated.

If the vehicle has any damage or discrepancies at the time of delivery, the

COR is to be notified immediately.

D.1.2 General Test Vehicle Data and Condition Report (FORM 2)

STEP D.1.2.1 Obtain a FORM 1 “Test Vehicle Information” from the COR before testing preparation and insert it in J.1. Information on this form is supplied by the automobile manufacturer to aid in the initial test setup and shall be considered as reference material. After vehicle preparation is complete, the Test Vehicle Information form shall be discarded. Note: The contractor shall notify the COR if any information on Form No. 1 is in conflict with any requirement in this test procedure.

STEP D.1.2.2 Using the owner’s manual, certification labels, information provided by the

COR and/or vehicle manufacturer, and any other data available, complete the table in FORM2 “Vehicle Condition Report.” (see J.2)

D.1.3 Photographic Documentation

STEP D.1.3.1 Place camera on a walking stick or tripod

STEP D.1.3.2 Position the height of the camera at the height of the door handle on the opposite side of the impact (CH)

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STEP D.1.3.3 Take the following photographs from the positions shown in Figure D‐1and field of view in Table D‐1

STEP D.1.3.4 Send FORM2 to the COR within 48 hours after vehicle delivery.

Figure D-1: Camera positioning

Table D-1: Field of view for each camera postion

DESCRIPTION (FIELD OF VIEW) EXAMPLE PICTURE

Picture D-1: “As Delivered”-Front Left Side Oblique

1) The vertical height is at camera height (CH)

2) Move back from the front left corner at 45 degrees to meet the field of view requirement

3) The left side field of view is the right front corner of the vehicle

4) The right side field of view is the left rear corner of the vehicle

5) The vertical field of view is centered on the vehicle

Camera Position

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Picture D-2: “As Delivered”-Front View of Vehicle

1) The vertical height shall be at CH

2) Move back perpendicular from the front of the vehicle at the centerline of the vehicle to meet the field of view

3) The left side field of view shall be the right outer edge of the vehicle

4) The right side field of view shall be the left outer edge of the vehicle

5) The vertical field of view shall be centered

Picture D-3: “As Delivered”-Front Right Side Obliqu

1) The vertical height is at CH

2) Move back from the right front corner at 45 degrees to meet the field of view requirement

3) The left side field of view is the right rear corner of the vehicle

4) The right side field of view is the left front corner of the vehicle

Picture D-4: “As Delivered”-Right Side right side of the vehicle at the center of the vehicle until the following field of view are met

3) The left side field of view is the outer edge of the rear bumper

4) The right side field of view is the outer edge of the front bumper

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Picture D-5: “As Delivered”-Rear Right

Side Oblique

2) Move back from the right rear corner at 45 degrees until the following field of view are met

3) The left side field of view is the left rear corner of the vehicle

4) The right side field of view is the right front corner of the vehicle

Picture D-6: “As Delivered”-Rear of Vehicle rear of the vehicle at the longitudinal centerline of the vehicle until the following field of view are met

3) The left side field of view is the outer left edge of the vehicle

4) The right side field of view is the outer right edge of the vehicle

Picture D-7: “As Delivered”-Rear Left Side Oblique

2) Move back from the left rear corner at 45 degrees until the following field of view are met

3) The left side field of view is the left front corner of the vehicle

4) The right side field of view is the right rear corner of the vehicle

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Picture D-8: “As Delivered”-: Left Side left side of the vehicle at the center of the vehicle until the following field of view are met

3) The left side field of view is the outer edge of the front bumper

4) The right side field of view is the outer edge of the rear bumper

Picture D-9: Monroney Label Photograph

1) Scan the Monroney Label or window sticker

D.1.4 Certification Label Data for Test Vehicle

STEP D.1.4.1 Take picture of the vehicle’s certification label. Make sure the NHTSA

Number and label is readable in the picture (Picture D‐10)

Picture D-10: Test Vehicle Certification Label

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STEP D.1.4.2 Record data from the vehicle’s certification label in Table D‐2

Table D-2: Certification Label Data Manufacturer Build date (or month and year of manufacture) Vehicle Type Gross Vehicle Weight Rating (GVWR) kg Gross Axle Weight Rating (GAWR) for the front kg Gross Axle Weight Rating (GAWR) for the rear kg

D.1.5 Seat Type

STEP D.1.5.1 Visually inspect the seat to verify seat type and record the following information from the vehicle’s certification label (Table D‐3):

STEP D.1.5.2 Type of front seat – bucket, bench, or split bench

STEP D.1.5.3 Type of front seat back – fixed or adjustable with lever or knob

STEP D.1.5.4 Type of rear seat – bucket, bench or split bench

STEP D.1.5.5 Type of rear seat back – fixed or adjustable with lever or knob

STEP D.1.5.6 Designated Seating Capacity (DSC)

STEP D.1.5.7 Vehicle Capacity Weight (VCW)

STEP D.1.5.8 Rated Cargo and…