Attach 1 - ATD Technical Specification Final .pdf

CUI Technical Specifica�ons Atachment 1

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Anthropomorphic Test Device (ATD) Requirements The biofidelic manikins represent human anthropometry mass properties and are designed to respond to the egress forces and accelerations in a way similar to that of humans. The Lightest Occupant In Service (LOIS) and Large Anthropomorphic Research Dummy (LARD) manikins have physical characteristics of small and large aircrew, respectively. The LOIS and LARD manikins were chosen because the United States Government (USG) aerospace test industry has developed and identified two anthropometric test manikins/types as representing the extremes of the Joint Primary Aircraft Training System (JPATS) population from dimensional and mass properties perspectives (i.e., worst case scenarios).

This document is a list of requirements for the procurement of additional JPATS Case 6 (LARD) and JPATS Case 1 Reduced Weight (LOIS) manikins for use in egress and survival sled testing. Most of the requirement information was extracted from the Crew Systems Bulletin (dated 28 Nov 2016) Appendix D-1 Lightest Occupant in Service (LOIS, Case 1, Reduced Weight) 103 +5 / -0 lbs instrumented and Appendix D-4 Large Anthropomorphic Research Dummy (LARD, Case 6) 245 ± 3 lbs instrumented.

LOIS (JPATS Case 1 Reduced Weight) Mechanical Requirements The manikin will support a 5th percentile hybrid III automotive neck and the JSF-SF81 head form. The non-instrumented manikin weight will be 96 ± 0.5 lbs, where the nude fully-instrumented manikin weight will be 103-108 lbs. The center of gravity (CG) is shown below for the manikin in a seated position, and with respect to the Seat Reference Point (SRP), which is located at the intersection of the seat back and the seat pan, at the mid-line of the seat. The table below gives the required anthropometry measurement requirements. Measurements shall be documented and verified by the vendor. Please see the ATD Instrumentation and Calibration Requirements section for a list of instrumentation, as well as durometer, CG and mass moment of inertia (MMOI) measurement parameters.

Case 1 Reduced Weight (LOIS) Anthropometry Measurement Requirements – in inches Stature 60.7 ± 3.0 Head Length 7.52 ± 0.25 CGx 7.2 ± 0.5 CGz 9.7 ± 0.5 Head Breadth 6.09 ± 0.25 Head Circumference 21.73 ± 0.25 Sitting Height 32.80 ± 0.25 Eye Height Sitting 27.75 ± 0.25 Thumb Tip Reach 27.10 ± 0.25 Shoulder Breadth 16.40 ± 1.70 Chest Depth 9.15 ± 1.75 Chest Breadth 10.10 ± 0.25 Chest Circumference 34.10 ± 0.25 Waist Circumference 31.00 ± 0.25 Hip Breadth 11.60 ± 0.25 Thigh Circumference 21.75 ± 3.25 Buttock-Knee Length 21.15 ± 0.25 Knee-Height Sitting 18.70 ± 0.25 Foot Length 8.80 ± 0.25 Shoulder Height Sitting 21.10 ± 0.50

Note: Multiple sources were used to create the above table and include:

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[1] Zehner, G.F., Meindl, R.S., and Hudson, J.A. (1993). A Multivariate Anthropometric Method for Crew Stations Design: Abridged, AL-TR-1992-0164, Armstrong Laboratory, Air Force Systems Command, Wright Patterson Air Force Base, OH.

[2] Hudson, J.A., Robinette, K.M., and Zehner, G.F. (2003). JSF CAESAR: CONSTRUCTION OF A 3-D ANTHROPOMETRIC SAMPLE FOR DESIGN AND SIZING OF JOINT STRIKE FIGHTER PILOT CLOTHING AND PROTECTIVE EQUIPMENT, AFRL-HE-WP-TR-2003-0142, AFRL, Human Effectiveness Directorate, U.S.

Air Force Research Laboratory, Wright Patterson Air Force Base, OH [3] Crew Systems Bulletin (dated 28 Nov 2016), Appendix D-1 [4] Crew Systems Bulletin (dated 2009)

LOIS Head Requirements:

The JSF SF-81H head is required for LOIS ATDs. The head will meet previously established specifications for skin hardness, physical dimensions and mass properties, including CG/MMOI and weight. The head cranium will have enough internal volume to allow multiple sensor types to be installed simultaneously. See the ATD Instrumentation and Calibration Requirements section for more head details

LOIS Neck Requirements:

The required LOIS neck will be the 5th percentile female Hybrid III automotive crash test dummy neck (PN: 880105-255). The LOIS manikin will have the ability to support the use of two six-axis neck load cells at the same time: an upper neck load cell installed at the C0 location and a lower neck load cell installed at the C7/T5 location. The lower neck load cell can either be an adjustable lower neck load cell or a non-adjustable lower neck load cell. The neck load cell part numbers that the LOIS manikin will support are listed below. Please refer to the ATD Instrumentation and Calibration Requirements section for further information on the load cells.

• Denton Upper Neck Load Cell: 1716A

• Humanetics Upper Neck Load Cell: 1716AJLN2

• Denton Non-Adjustable Lower Neck Load Cell: IF-238-HC

• Humanetics Adjustable Lower Neck Load Cell: 5045JLN2

LOIS Chest Requirements:

The chest shall support an aluminum Universal Chest Box that can accommodate a Data Acquisition System (DAS) with sensor wiring and a battery pack for powering the system. The chest box will also provide a housing for installing a DTS six-degree of Freedom (6 DOF) sensor mounting block. The 6 DOF block will house three linear accelerometers and three angular rate sensors (this 6 DOF block will also be supplied by the vendor). The DAS systems that the LOIS chest box are required to house at one time are discussed in the ATD Instrumentation and Calibration Requirements section.

LOIS Pelvis & Lumbar Requirements:

The LOIS manikin pelvis will be a pedestrian design for both standing and sitting positions (adjustable configuration). It will support a straight spine design that accepts a six-axis lumbar load cell, connecting the spine to the pelvis. The required lumbar load cell part numbers are listed below. Please refer to the ATD Instrumentation and Calibration Requirements section for further information.

• Denton Lumbar Load Cell: 1914A

• Humanetics Lumbar Load Cell: 1914AJN2

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LOIS Leg Requirements:

The leg femur shall support the ability to install a six-degree load cell in the femur. The load cell part numbers are listed below:

• Denton Femur Load Cell: 1914A

• Humanetics Femur Load Cell: 1914AJN2

LARD (Case 6) Mechanical Requirements

The manikin will support a 95th percentile hybrid III automotive neck and the JSF-LM110H head form.

The non-instrumented manikin weight will be 233 ± 1 lbs. The nude fully-instrumented manikin weight will be 245 ± 3 lbs. The CG shown below is for the manikin in a seated position, and with respect to the SRP, which is located at the intersection of the seat back and the seat pan, at the mid-line of the seat. The table below gives the required anthropometry measurements. Please refer to the ATD Instrumentation and Calibration Requirements section for a list of instrumentation as well as information on durometer, CG and MMOI measurement parameters.

LARD Anthropometry Measurements – in inches Stature 75.8 ± 3.0 Head Length 8.20 ± 0.25 CGx 10.1 ± 0.5 CGz 10.5 ± 0.5 Head Breadth 6.50 ± 0.25 Head Circumference 24.00 ± 0.25 Sitting Height 38.55 ± 0.55 Eye Height Sitting 32.90 ± 0.25 Thumb Tip Reach 36.00 ± 0.25 Shoulder Breadth 19.65 ± 2.85 Chest Depth 9.8 ± 2.4 Chest Breadth 13.40 ± 0.25 Chest Circumference 44.70 ± 0.25 Waist Circumference 41.70 ± 0.25 Hip Breadth 17.70 ± 0.25 Thigh Circumference 24.4 ± 5.3 Buttock-Knee Length 27.90 ± 0.25 Knee-Height Sitting 24.50 ± 0.30 Foot Length 10.30 ± 0.25 Shoulder Height Sitting 25.00 ± 0.50

**Same sources as LOIS table.

LARD Neck Requirements:

The LARD manikin will support the use of two six-axis neck load cells: an upper neck load cell installed at the C0 location and a lower neck load cell installed at the C7/T5 location. The neck used today is the same one used on the 95% Hybrid III automotive crash test dummy (PN: 880995-1260). Part numbers 880995-1260 and 190-2001 are to be used with neck bushings. The load cell part numbers required are

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listed below. Please refer to the ATD Instrumentation and Calibration Requirements section for further information on the load cells.

• Denton Upper Neck Load Cell: 1716A

• Humanetics Upper Neck Load Cell: 1716AJLN2

• Denton Non-Adjustable Lower Neck Load Cell: IF-210-HC

• Humanetics Non-Adjustable Lower Neck Load Cell: IF-242-HC

• Humanetics Adjustable Lower Neck Load Cell: 5832JLN2

LARD Chest Requirements:

The chest shall support an aluminum Universal Chest Box that can accommodate a DAS system with sensor wiring and a battery pack for powering the system. The chest box will also provide a housing for the mounting of a DTS six-degree of Freedom (6 DOF) block. The 6 DOF block will house three linear accelerometers and three angular rate sensors. Please refer to the ATD Instrumentation and Calibration Requirements section for further DAS information.

LARD Pelvis & Lumbar Requirements:

The LARD manikin pelvis will be a pedestrian design for both standing and sitting (adjustable configuration). The LARD pelvis will have the mass properties of the modified JPATS Large manikin (not the original JPATS Large manikin) since shortly after the original JPATS Large manikin was developed, it was discovered that the manikin assembly CG was not representative. Therefore, the original mass properties were adjusted by moving mass from the knees to the manikin pelvis. Please refer to reference 6 for further information on this. The LARD pelvis will have provisions for three orthogonally mounted, linear accelerometers. Additionally, it will support a straight spine design that accepts a six-axis lumbar load cell and attaches to the pelvis. The load cell part numbers are listed below:

• Denton Load Cell: 1914A

• Humanetics Load Cell: 1914AJN2

LARD Leg Requirements:

The leg femur shall support the ability to install a six-axis load cell in the femur. The femur flanges should have part numbers: 880995-425-1 and 880995-425-2. The load cell part numbers are listed below:

• Denton Femur Load Cell: 1914A

• Humanetics Femur Load Cell:1914AJN2

ATD Instrumentation and Calibration Requirements Head:

Manikin head center of gravity (CG) and Mass Moment of Inertia (MMOI) measurements shall be performed with instrumentation installed. The installed instrumentation shall include upper neck load cells and mounting bolts, triaxial head linear accelerometers and mounts, triaxial head angular rates and mounts, and all cabling. Measurement parameters are specified in the Crew Systems Engineering Bulletin EZFC-CSB-16-001, USAF Revision of MIL-HDBK-516C, 28 November 2016. The CG

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requirements are listed in table 1 below and the MMOI requirements are listed in table 2 below. In addition to CG and MMOI measurements, head drop tests shall also be performed in accordance with SAE J2860 specifications. Head weight for the JSF-SF81H shall be 8.1 ± 0.2 lb and head weight for the JSF-LM110H shall be 11.0 ± 0.2 lbs, where both head weights include the instrumentation specified above. Head measurements shall also include durometer Shore A readings. Durometer measurement locations are indicated in figure 1 below and shall have an average durometer shore A reading of 57 ± 1.

Calibration certificates stating all measurement results discussed herein must be provided with each manikin delivery.

Table 1: Manikin Head CG Requirements

JSF-LM110H JSF-SF81H

Landmark CGX CGY CGZ CGX CGY CGZ CG Anatomical Location -0.13 0.15 0.53 0.10 0.03 0.71 CG Head/Neck Joint Location 0.70 -0.08 1.97 0.62 -0.02 1.87 CG Manufacturer Location 2.50 -0.07 1.47 2.13 0.01 1.39 CG Head/Neck Joint Subtracting ½ Load Cell and OC Pin

0.74 -0.04 2.08 0.66 -0.02 2.01

Note: Measurements are all in inches. Tolerances on all values shall be ± 0.15 inches.

Table 2: Manikin Head MMOI Requirements

Item IYY IXX IZZ

JSF-SF81H 59 52 38

JSF-LM110H 99 79 70

Note: Measurements are all in lb-in2. Tolerances on all values shall be ± 1 lb-in2.

Neck

Manikin neck flexion and extension must be calibrated and certified per Hybrid III certification procedures detailed in 49 CFR Part 572. Calibration measurements should include Head Pot, Pendulum Pot, D-Plane Angle, Force X, Moment Y, Resultant Moment, Pendulum Acceleration, and Pendulum Velocity. Additionally, calibration documentation should include which nodding blocks (serial numbers) were used, as well as nodding block locations. Calibration certificates must be provided with each manikin delivery.

Figure 1: Durometer Measurement Points on the Manikin Head

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Upper Neck Load Cells

It is required to use a Denton 1716 upper neck load cell in both the LOIS and LARD manikins. Upper neck load cells must be calibrated and certified. Upper neck force measurements must meet SAE J211 CFC 1,000 standards with a Corner Frequency (-3 dB) of 1,650 Hz or greater. Upper neck moment measurements must meet SAE J211 CFC 600 standards with a Corner Frequency of 1,000 Hz or greater.

Measurement amplitude ranges are included below:

• Upper Neck Force X: ± 2,000 lbf

• Upper Neck Force Y: ± 2,000 lbf

• Upper Neck Force Z: ± 3,000 lbf

• Upper Neck Moment X: ± 2,500 in-lbf

• Upper Neck Moment Y: ± 2,500 in-lbf

• Upper Neck Moment Z: ± 2,500 in-lbf

Calibration measurements should include Crosstalk % (a maximum of 1% cross-axis sensitivity is preferred), nonlinearity, hysteresis, output capacity, and sensitivity. Calibration certificates must be provided with each manikin delivery.

Adjustable/Fixed Lower Neck Load Cells

Both the LARD and LOIS manikins must be equipped to accept either an adjustable or non-adjustable lower neck load cell. Required fixed lower neck load cells include First Technology IF-238 (LOIS) and First Technology IF-242-HC (LARD). Required adjustable lower neck load cells include Denton 5045JLN2 (LOIS) and Humanetics 5832JLN2 (LARD). Lower neck load cells must be calibrated and certified. Lower neck force measurements must meet SAE J211 CFC 1,000 standards with a Corner Frequency (-3 dB) of 1,650 Hz or greater. Lower neck moment measurements must meet SAE J211 CFC 600 standards with a Corner Frequency of 1,000 Hz or greater. Measurement amplitude ranges are included below:

• Lower Neck Force X: ± 3,000 lbf

• Lower Neck Force Y: ± 3,000 lbf

• Lower Neck Force Z: ± 3,000 lbf

• Lower Neck Moment X: ± 6,000 in-lbf (LARD), or ± 4,000 in-lbf (LOIS)

• Lower Neck Moment Y: ± 6,000 in-lbf (LARD), or ± 4,000 in-lbf (LOIS)

• Lower Neck Moment Z: ± 4,000 in-lbf (LARD), or ± 3,000 in-lbf (LOIS)

Calibration measurements should include Crosstalk % (a maximum of 1% cross-axis sensitivity is preferred), nonlinearity, hysteresis, output capacity, and sensitivity. Calibration certificates must be provided with each manikin delivery.

Head and Chest Angular Rate

It is recommended to use DTS ARS PRO-8K (2kHz) angular rate sensors. Three angular rate sensors will be installed into each manikin head to measure X, Y and Z rotational data. Additionally, three angular rate sensors will be installed into each manikin chest to measure X, Y and Z rotational data. Angular rate sensors must be calibrated and certified. Head sensor measurements must meet SAE J211 CFC 1,000 standards with a Corner Frequency (-3 dB) of 1,650 Hz or greater. Head and chest measurement ranges should be ± 140 rad/s (or ± 8,000 deg/s). A maximum of 1% cross-axis sensitivity is preferred.

Calibration measurements should include nonlinearity for full range of sensor, bridge resistance, CUI frequency response (10 – 2,000 Hz), and sensitivity. Calibration certificates must be provided with each manikin delivery.

Head, Chest and Lumbar Linear Acceleration

It is recommended to use Measurement Specialties EGCS-S425-250 accelerometers. Three linear accelerometers will be installed into each manikin head, chest and lumbar regions to measure X, Y and Z linear acceleration data. Accelerometers must be calibrated and certified. Head and chest sensor measurements must meet SAE J211 CFC 1,000 standards with a Corner Frequency (-3 dB) of 1,650 Hz or greater. Head, chest and lumbar measurement ranges should be ± 250 g. A maximum of 1% cross-axis sensitivity is preferred. Damping ratios shall be no less than 0.3, with a preferred damping ratio of 0.7.

Calibration measurements should include nonlinearity to be < 1% for full range of sensor, frequency response (10 – 2,000 Hz), and sensitivity. Calibration certificates must be provided with each manikin delivery.

Lumbar Load Cells

It is required to use Denton 1914A lumbar load cells. Lumbar load cells must be calibrated and certified.

Lumbar force and moment measurements must meet SAE J211 CFC 600 standards with a Corner Frequency (-3 dB) of 1,000 Hz or greater. Measurement ranges are included below:

• Lumbar Force X: ± 3,000 lbf

• Lumbar Force Y: ± 3,000 lbf

• Lumbar Force Z: ± 5,000 lbf

• Lumbar Moment X: ± 3,000 in-lbf

• Lumbar Moment Y: ± 3,000 in-lbf

• Lumbar Moment Z: ± 3,000 in-lbf

Calibration measurements should include Crosstalk % (a maximum of 1% cross-axis sensitivity is preferred), nonlinearity, hysteresis, output capacity, and sensitivity. Calibration certificates must be provided with each manikin delivery.

DAS Units

The manikin shall be instrumented with a Diversified Technical Systems (DTS) SLICE6 HB Data Acquisition System (DAS) that has the ability to record data from no less than 60 sensors. DAS units must be calibrated, certified and SAE J211 CFC 1,000 compliant. Calibration certificates must be provided with each manikin delivery.

Additionally, the manikin chest cavity shall have space and be plumbed for an Electro Mechanical Engineering Corporation (EME) Pico16 DAS system. This particular DAS unit will be installed by government personnel upon manikin delivery. However, overall manikin CG/MOI measurements must be conducted with both the DTS and EME DAS systems installed. EME DAS units, batteries, and cabling will be supplied to the vendor for these measurements.

Instrumentation Summary Table

Below is a list of all instrumentation that shall be installed in the ATDs upon delivery. It is a summary of the instrumentation discussed within this document.

Sensor Description Sensor Part Number Upper Neck Force X Denton 1716

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Upper Neck Force Y Denton 1716 Upper Neck Force Z Denton 1716 Upper Neck Moment X Denton 1716 Upper Neck Moment Y Denton 1716 Upper Neck Moment Z Denton 1716 Head Linear Acceleration X EGCS-S425-250 Head Linear Acceleration Y EGCS-S425-250 Head Linear Acceleration Z EGCS-S425-250 Head Angular Rate X DTS ARS PRO-8K (2kHz) Head Angular Rate Y DTS ARS PRO-8K (2kHz) Head Angular Rate Z DTS ARS PRO-8K (2kHz) Lower Neck Force X First Technology IF-238 (LOIS, fixed)

First Technology IF-242-HC (LARD, fixed) Denton 5045JLN2 (LOIS, adjustable) Humanetics 5832JLN2 (LARD, adjustable)

Lower Neck Force Y First Technology IF-238 (LOIS, fixed) First Technology IF-242-HC (LARD, fixed) Denton 5045JLN2 (LOIS, adjustable) Humanetics 5832JLN2 (LARD, adjustable)

Lower Neck Force Z First Technology IF-238 (LOIS, fixed) First Technology IF-242-HC (LARD, fixed) Denton 5045JLN2 (LOIS, adjustable) Humanetics 5832JLN2 (LARD, adjustable)

Lower Neck Moment X First Technology IF-238 (LOIS, fixed) First Technology IF-242-HC (LARD, fixed) Denton 5045JLN2 (LOIS, adjustable) Humanetics 5832JLN2 (LARD, adjustable)

Lower Neck Moment Y First Technology IF-238 (LOIS, fixed) First Technology IF-242-HC (LARD, fixed) Denton 5045JLN2 (LOIS, adjustable) Humanetics 5832JLN2 (LARD, adjustable)

Lower Neck Moment Z First Technology IF-238 (LOIS, fixed) First Technology IF-242-HC (LARD, fixed) Denton 5045JLN2 (LOIS, adjustable) Humanetics 5832JLN2 (LARD, adjustable)

Chest Linear Acceleration X EGCS-S425-250 Chest Linear Acceleration Y EGCS-S425-250 Chest Linear Acceleration Z EGCS-S425-250 Chest Angular Rate X DTS ARS-8K (2kHz) Chest Angular Rate Y DTS ARS PRO-8K (2kHz) Chest Angular Rate Z DTS ARS PRO-8K (2kHz) Lumbar Linear Acceleration X EGCS-S425-250 Lumbar Linear Acceleration Y EGCS-S425-250 Lumbar Linear Acceleration Z EGCS-S425-250 Lumbar Force X Denton 1914A Lumbar Force Y Denton 1914A Lumbar Force Z Denton 1914A Lumbar Moment X Denton 1914A Lumbar Moment Y Denton 1914A

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Lumbar Moment Z Denton 1914A

References

[1] AFLCMC/Crew Systems Engineering (EZFC). Crew Systems Engineering Bulletin EZFC-CSB-16- 001, USAF Revision of MIL-HDBK-516C. 28 November 2016.

[2] SAE J211-1. SAE International, Surface Vehicle Recommended Practice. July 2007.

[3] SAEJ2570. SAE International, Surface Vehicle Recommended Practice. November 2019.

[4] AFRL-HE-WP-TR-2005-0044. AFRL Design and Development for Anthropometrically Correct Head Forms for Joint Strike Fighter Ejection Seat Testing. February 2005.

[5] SAEJ2860. SAE International, Surface Vehicle Recommended Practice. September 2012.

[6] A Comparison of Human and Ejection Seat Test Manikin Static Centers of Gravity and Moments of Inertia. Christopher Albery. Unknown date.