Attachment J.1 - Appendix F - Test Deliverables and Report Guidelines.docx

APPENDIX F

F2

F2

TEST DELIVERABLES AND REPORT GUIDELINES

APPENDIX F

TEST DELIVERABLES AND REPORT GUIDELINES

Contents

Status Reporting Requirements Vehicle Condition Report For each test vehicle, the contractor must provide a “Vehicle Condition Report” to the COR, which documents the vehicle condition pre- and post-test. The first page of the report shall be completed when the test vehicle arrives at the testing laboratory and shall be submitted within two (2) working days of the vehicle’s arrival. However, the COR shall be notified immediately if the received vehicle is not in good working order or is damaged. In addition to the first page of the report, the contractor shall include a copy of the “window sticker” (or Monroney label) received with the vehicle. The second page of the report is completed after the test and submitted with the Quality Control Package. The required report format is also provided as Supplemental Report (SR) 2 – Vehicle Condition Report in this appendix.

The filename for the Vehicle Condition Report should be formatted as follows:

<NHTSANO> <ModelYear> <Make> <Model> <Drivetrain> <Body> NCAP PedPro Vehicle Condition Report <Pre-Test or Post-Test, as applicable>.pdf Monthly Status Reports The contractor shall submit Monthly Status Reports to the COR no later than the 5th day of each month following the month being reported on. The formats can be found in Supplemental Report (SR) 4 – Monthly Status Reports, in this appendix. The reports shall be submitted until all vehicles or items of equipment are disposed of.

Vehicle Inventory Report The contractor shall submit a Vehicle Inventory Report to the COR no later than the 5th day of each month following the month being reported on. A detailed description of the required Vehicle Inventory Report is provided later in this appendix in Supplemental Report SR4a: Vehicle Inventory Report. The report shall be submitted until all vehicle or items of equipment are disposed of.

The filename for a Vehicle Inventory Report shall be formatted as follows:

<3-Letter Lab Name> <Year> <Month> SR4a Vehicle Inventory Report.xlsx Invoicing Report The contractor shall submit an Invoicing Report to the COR no later than the 5th day of each month following the month being reported on. A detailed description of the required Invoicing Report is provided later in this appendix in the Supplemental Reports section (Supplemental Report SR4b: Invoicing Report).

The filename for an Invoicing Report should be formatted as follows:

<3-Letter Lab Name> <Year> <Month> SR4b Invoicing Report.xlsx ATD and Sensor Inventory Report The contractor shall submit an ATD and Sensor Inventory Report to the COR no later than the 5th day of each month following the month being reported on. A detailed description of the required report is provided later in this appendix in the Supplemental Reports section (Supplemental Report SR4c: ATD and Sensor Inventory Report).

The filename for an Invoicing Report should be formatted as follows:

<3-Letter Lab Name> <Year> <Month> SR4c ATD and Sensor Report.xlsx Parts Procurement and Inventory Report The contractor shall submit Parts Procurement and Inventory Report to the COR no later than the 5th day of each month following the month being reported on. A detailed description of the required report is provided later in this appendix in the Supplemental Reports section (Supplemental Report SR4d: Parts Procurement and Inventory Report).

Note: The contractor shall be prepared to provide this report to the COR on an ad-hoc basis, if requested.

The filename for an Invoicing Report should be formatted as follows:

<3-Letter Lab Name> <Year> <Month> SR4d Parts Procurement Report.xlsx Invalid Test or Excessive Injury Value Report An invalid test or findings of excessive injury values, such as those that exceed a specified channel amplitude class (CAC) specified in Sections 9, 10, and 11 of the main procedure, shall be communicated by telephone to the COR within 24 hours with written notification emailed within 48 hours (Saturday and Sundays excluded). A Laboratory Notice of Excessive Injury Values (located in Section 5, Supplemental Reports, of this appendix) with a copy of related NCAP test data sheet(s) and preliminary data plot(s) shall be included.

In the event that excessive injury values are collected, a post-test calibration check of some of the critically sensitive test equipment and instrumentation may be required for verification of accuracy. The necessity for the calibration shall be at the COR’s discretion.

NCAP Test Deliverables Required deliverables for each test are discussed in this section. A Schedule of Deliverables is also provided at the end of this section.

Vehicle Markup Data The Contractor shall measure and mark up vehicle landmarks as specified in the main PedPro test procedure. Markup shall include:

vehicle longitudinal centerline data side reference lines (SRLs) leading edge reference line (LERL) rear reference line (RRL) Hood/windshield WAD lines to include WAD1000 mm, WAD1500 mm, WAD1700 mm, and WAD2100 mm lines Front and rear corner reference points (CRPs) the 100 mm x 100 mm test point “grid” Leading edge WAD lines for WAD775 mm and WAD930 mm 520 mm height from ground line upper bumper reference line (UBRL) lower bumper reference line (LBRL) bumper corners internal bumper reference line (IBRL) lower leg to bumper 100 mm test “grid” upper leg to leading edge 100 mm test “grid” Markup data shall be digitized, entered into the CMM template (Section 6), and saved as an Excel file. Photographs of markup landmarks shall be provided. All items shall be combined into one .zip file.

The filename for the markup data should be formatted as follows:

<NHTSANO> <ModelYear> <Make> <Model> <Body> NCAP PedPro Markup.zip Quicklook Report The Quicklook Report is a preliminary summary of the impact test that should be e-mailed to NHTSA within 24 hours of each impact event. The Quicklook Report should detail all relevant injury criteria and vehicle information and should include relevant data traces. Also, anything interesting or out of the ordinary should be included in the Quicklook Report comments section. A sample Quicklook Report is included as Supplemental Report (SR) 5 - Quicklook Report of this appendix.

The filename for the Quicklook Report should be formatted as follows:

<NHTSANO> <ModelYear> <Make> <Model> <Body> NCAP PedPro <TestDevice> <ImpactNo> Quicklook.pdf Data Tape Within one (1) week of completion of each test series of each device, the Contractor shall provide the test data formatted using NHTSA’s test data formatting guidelines as part of the Quality Control Package (see Section 2.4). The COR will direct the Contractor to the latest version of the test reference guide for data formatting and will provide instructions regarding data submission through NHTSA’s online crash test portal.

The filename for the electronic data tape file shall be formatted as follows:

<NHTSANO> <ModelYear> <Make> <Model> <Body> NCAP PedPro <TestDevice> Datatape.zip Quality Control Package The Quality Control Package is a .zip file that includes all the information necessary for NHTSA’s quality control review. It serves as a summary of the test series and includes, organized by folders labeled appropriately:

· Electronic test data tape

· per Section 2.3 of this appendix

· Complete vehicle markup data

· Photographs of vehicle markup landmarks

· CMM file per Section 6 of this appendix.

· Photographs

· Labeled in order per Section 5.7 of the main NCAP PedPro test procedure.

· Videos

· High-speed videos per Sections 5.1 and 5.3 of the main PedPro test procedure.

· Real-time videos per Section 5.2 of the main PedPro test procedure.

· Compiled impact event video per Section 5.6 of the main PedPro test procedure.

· Pre-test device qualification data

· Per guidelines in appropriate appendices.

· Post-test device qualification data, if applicable

· Per guidelines in appropriate appendices.

· Vehicle Condition Report – Post-Test

· Supplemental Report (SR) 2 – Vehicle Condition Report of this appendix.

· Quicklook Report previously e-mailed to NHTSA

· A copy of the Quicklook Report previously e-mailed to NHTSA (updated to reflect any corrections, if applicable) per Supplemental Report (SR) 5 - Quicklook Report of this appendix The Quality Control Package should be uploaded to the FTP site within one (1) week of completion of each test series of each device. Providing this data in a timely manner will ensure that the Contractor and the COR will be able to discuss the details of both test conduct and report content soon after the tests are conducted. The filename for the Quality Control Package should be formatted as follows:

<NHTSANO> <ModelYear> <Make> <Model> <Body> NCAP PedPro <TestDevice> QC.zip The Contractor will also provide any relevant website-related material in a folder within this file, if requested.

Draft Test Report Contractors are required to submit an electronic copy (.pdf or .docx) of the Draft Test Report within one (1) week after completion of all impact tests with all test devices requested for each vehicle model. Required format in Section 3. If the electronic file is larger than 20 MB, the Contractor should upload the file to the FTP site instead. The NHTSA COR and Contractor may use an alternative method of transfer if agreed upon by both parties.

<NHTSANO> <ModelYear> <Make> <Model> <Body> NCAP PedPro Draft Report The Contractor should use detailed descriptions of all test events. Any events that are of technical interest should also be included.

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

Final Test Reports and Deliverables The Final Test Report and associated documentation, including test data, properly labeled and numbered photographs and videos (including documentation, high-speed, and real-time), are relied upon as the chronicle of the NCAP test. Each Final Test Report should also be a complete document capable of standing by itself.

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

Note: Only those photos required in the Final Test Report, as set forth in this procedure, shall be included unless NHTSA requests the inclusion of additional photos to document specific test events or anomalies.

The Contractor shall upload the Final Test Report and final versions of the associated test data, photos, and videos as a .zip file to the FTP site within one (1) week of receiving data tape and Draft Test Report comments from the COR. The format for its filename should be as follows:

<NHTSANO> <ModelYear> <Make> <Model> <Body> NCAP PedPro Final Deliverables.zip Test Deliverable Schedule The following is a summary of all NCAP test deliverable requirements:

One (1) week of COR approval to begin markup FTP or other pre-approved method

<3-Letter Lab Name> <Year> <Month> SR4a Vehicle Inventory Report.xlsx

<3-Letter Lab Name> <Year> <Month> SR4b Invoicing Report.xlsx

<3-Letter Lab Name> <Year> <Month> SR4c ATD and Sensor Report.xlsx

<3-Letter Lab Name> <Year> <Month> SR4d Parts Procurement Report.xlsx

Test Report Requirements The Final Test Report and associated documentation (including photographs and videos) is relied upon as the chronicle of the NCAP test. The final documentation and data will be released to the public domain after review and acceptance by the COR. For these reasons, each Final Test Report must be a complete document capable of standing by itself.

Instructions for the preparation of the first three pages of the final test report are provided below for standardization purposes.

Sample Test Report Layout - First Three Pages

where ‑ ‑

NEW CAR ASSESSMENT PROGRAM (NCAP)

Crashworthiness Pedestrian Protection Test Series World Motors Corporation 200X XYZ 4‑door sedan NHTSA No. CX0401

c. Contractor's Name and Address, such as

XYZ TESTING LABORATORIES, INC.

4335 West Dearborn Street Detroit, Michigan 48090 Note: DOT symbol should be placed between items (c) and (d).

d. Date of Final Report completion

e. The words “FINAL REPORT”

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

U. S. DEPARTMENT OF TRANSPORTATION

National Highway Traffic Safety Administration Office of Crashworthiness Standards 1200 New Jersey Ave, SE West Building, 4th Floor (NRM-110) Washington, DC 20590

2. First Page After Front Cover ‑ A disclaimer statement and an acceptance signature block for the COR shall be provided as follows:

Prepared for the Department of Transportation, National Highway Traffic Safety Administration, under Contract No. 693JJ92XD000XXX.

This publication is distributed by the U.S. Department of Transportation, National Highway Traffic Safety Administration, in the interest of information exchange. The opinions, findings and conclusions expressed in this publication are those of the author(s) and not necessarily those of the Department of Transportation or the National Highway Traffic Safety Administration. The United States Government assumes no liability for its contents or use thereof. If trade or manufacturers' names or products are mentioned, it is only because they are considered essential to the object of the publication and should not be construed as an endorsement. The United States Government does not endorse products or manufacturers.

Prepared by: _____________________________________ Title: ___________________________________________

Approved by: ____________________________________ Title: ___________________________________________

3. Second Page After Front Cover ‑ A completed Technical Report Documentation Page (Form DOT F1700.7) shall be completed for those items that are applicable with the other spaces left blank. Sample data for the applicable block numbers of the title page follows.

Block No. 1 ‑ REPORT NO.

NCAP‑ABC‑PED-XX‑001

Block No. 2 ‑ GOVERNMENT ACCESSION NUMBER Leave blank Block No. 3 ‑ RECIPIENT'S CATALOG NUMBER Leave blank Block No. 4 ‑ TITLE AND SUBTITLE Final Report of NEW CAR ASSESSMENT PROGRAM PedPro Testing of a 20XX World XYZ Deluxe 4‑door sedan NHTSA No. MX20XXXXXX Block No. 5 ‑ REPORT DATE March 1, 20XX Block No. 6 ‑ PERFORMING ORGANIZATION CODE

ABC

Block No. 7 ‑ AUTHOR(S) John Smith, Project Manager Bill Doe, Project Engineer Block No. 8 ‑ PERFORMING ORGANIZATION REPORT NUMBER

ABC‑DOT‑XXX‑001

Block No. 9 ‑ PERFORMING ORGANIZATION NAME AND ADDRESS ABC Laboratories 405 Main Street Detroit, Ml 48070 Block No. 10 ‑ WORK UNIT NUMBER Leave blank Block No. 11 ‑ CONTRACTOR GRANT NUMBER

693JJ92XD000XXX

Block No. 12 ‑ SPONSORING AGENCY NAME AND ADDRESS US Department of Transportation National Highway Traffic Safety Administration Office of Crashworthiness Standards 1200 New Jersey Ave, SE West Building, 4th Floor (NRM-110) Washington, DC 20590 Block No. 13 ‑ TYPE OF REPORT AND PERIOD COVERED Final Test Report Feb. 15 to Mar. 15, 20XX Block No. 14 ‑ SPONSORING AGENCY CODE

NRM-110

Block No. 15 ‑ SUPPLEMENTARY NOTES Leave blank Block No. 16 ‑ ABSTRACT This report contains results from New Car Assessment Program (NCAP) Crashworthiness Pedestrian Protection impact testing on a 20XX XYZ Deluxe 4-door sedan between February 15, 20XX and March 15, 20XX. Pedestrian impact testing is performed to determine a vehicle model’s ability to mitigate pedestrian injury in the event of a crash. This testing was conducted in accordance with the specifications of the National Highway Traffic Safety Administration’s Laboratory Test Procedure for Crashworthiness Pedestrian Protection.

Block No. 17 ‑ KEY WORDS PedPro Crashworthiness Pedestrian Protection New Car Assessment Program

NCAP

Block No. 18 ‑ DISTRIBUTION STATEMENT Copies of this report are available from the following:

National Highway Traffic Safety Administration Technical Information Services Division 1200 New Jersey Ave, SE Washington, DC 20590 Block No. 19 ‑ SECURITY CLASSIFICATION OF REPORT Unclassified Block No. 20 ‑ SECURITY CLASSIFICATION OF PAGE Unclassified Block No. 21 ‑ NO. OF PAGES Add appropriate number Block No. 22 ‑ PRICE Leave blank Test Report Layout – Remainder of Report Draft and final NCAP test reports shall have the following layout for standardization purposes:

Section

Page No.

Appendix

Page No.

Report Section 1: Purpose and Summary of Tests Section 1 of the test report contains two sub-sections: PURPOSE and SUMMARY. For the PURPOSE sub-section, the contractor shall outline the purpose for conducting the crashworthiness pedestrian protection impact tests and state the test procedure followed. For the SUMMARY sub-section, the contractor shall briefly outline a summary of the test(s) conducted. The following language is provided as an example:

PURPOSE

The purpose of this test was to obtain vehicle crashworthiness pedestrian protection performance data for consumer information purposes.

SUMMARY

A 20XX XYZ Deluxe 4-Door Sedan underwent headform, upper legform, and lower legform pedestrian protection impact testing according to the Laboratory Test Procedure for NCAP Pedestrian Impact Testing, November 20XX between February 15, 20XX and March 15, 20XX at ABC Laboratories in Detroit, MI. Ten head impacts, five upper legform impacts, and five lower legform impacts were conducted.

One real-time camera and one high-speed camera was used to document each impact event. Camera locations and other pertinent camera information can be found in this report.

The headforms, upper legform (TRL), and lower legform (FlexPLI) used are specified in the aforementioned test procedure.

Both child and adult-size headforms were instrumented with tri-axial accelerometers. The TRL upper legform was instrumented with upper and lower force transducers and moment transducers to measure loading and bending moments. The FlexPLI lower legform was instrumented with knee potentiometers to measure knee bending, tibia load cells to measure tibia forces and bending moments, and a knee accelerometer to measure acceleration of the impactor.

All four impactors (adult headform <SerialNo1>, child headform <SerialNo2>, upper legform <SerialNo3>, and FlexPLI <SerialNo4>) were qualified prior to this test. Certification details, along with instrumentation calibration data, are found in Appendix A of this report.

Report sections 3, 4, and 5 contain the impactor response data traces.

The impactor data is summarized below:

INSERT SUMMARY TABLE OF IMPACTOR DATA

Report Section 2: General Vehicle Information Report Section 2 shall contain information describing the tested vehicle, including specifications and vehicle markup data. Data sheets pertaining to Report Section 2 can be found in Section 4 of this appendix. For purposes of consistency, it is highly suggested that exact replicas of these sheets (where applicable) are inserted into the Final Test Report. The Contractor may expand upon the data sheets if desired; however, the data must be presented in the order listed under the above “SAMPLE TEST REPORT LAYOUT.” Any additional inclusions MUST be placed after the required sheets.

Report Section 3: Headform Testing Report Section 3 shall contain all data relevant to headform testing completed on the subject vehicle model. Data sheets pertaining to Report Section 3 can be found in Section 4 of this appendix. Data Sheet No. 3, Headform Test Result Summary, shall be included in this section, along with one Data Sheet No. 4, Headform Test Result Details for each headform impact performed. Additionally, data plots for each data channel collected shall be inserted two per page.

Pre- and post-test photographs of the vehicle impact point shall be included after the data plot pages. A vehicle information placard, identifying the test vehicle, NHTSA number, test date, test type, and impact location, along with an indication of whether the photo was taken pre-test or post-test, shall clearly appear in each photograph. A time/date stamp on each photo is also highly recommended.

Report Section 4: Lower Legform Testing Report Section 4 shall contain all data relevant to lower legform testing completed on the subject vehicle model. Data sheets pertaining to Report Section 4 can be found in Section 4 of this appendix. Data Sheet No. 5, Lower Legform Test Result Summary, shall be included in this section, along with one Data Sheet No. 6, Lower Legform Test Result Details for each lower legform impact performed. Additionally, data plots for each data channel collected shall be inserted two per page.

Pre- and post-test photographs of the vehicle impact point shall be included after the data plot pages. A vehicle information placard, identifying the test vehicle, NHTSA number, test date, test type, and impact location, along with an indication of whether the photo was taken pre-test or post-test, shall clearly appear in each photograph. A time/date stamp on each photo is also highly recommended.

Report Section 5: Upper Legform Testing Report Section 5 shall contain all data relevant to upper legform testing completed on the subject vehicle model. Data sheets pertaining to Report Section 5 can be found in Section 4 of this appendix. Data Sheet No. 7, Upper Legform Test Result Summary, shall be included in this section, along with one Data Sheet No. 8, Upper Legform Test Result Details for each lower legform impact performed. Additionally, data plots for each data channel collected shall be inserted two per page.

Pre- and post-test photographs of the vehicle impact point shall be included after the data plot pages. A vehicle information placard, identifying the test vehicle, NHTSA number, test date, test type, and impact location, along with an indication of whether the photo was taken pre-test or post-test, shall clearly appear in each photograph. A time/date stamp on each photo is also highly recommended.

Appendix A: Impactor Qualification and Performance Verification Data gathered during testing described in Appendix E of the main procedure shall be included to document impactor qualification as Appendix A of the Final Test Report. A copy of Appendix A should also be provided to NHTSA as part of the Quality Control Package.

Appendix B: Test Equipment and Instrumentation Calibration A list of test equipment and instrumentation used during the test series, along with serial numbers and manufacturer information, should be provided as Appendix B of each vehicle Final Test Report. Appendix B should identify all test equipment, impactor sensors, potentiometers, and load cells used to collect data during the test. Comments should also be included, if appropriate.

Data Sheets Data sheets are provided as tools to document test data in the final test report format as outlined in Section 3 of this appendix. The Contractor is not restricted from using other tools or expanding the data sheets provided in this section. Nevertheless, for consistency and uniformity in reporting data, the Contractor should present the data in the order outlined in this section.

DATA SHEET NO. 1 - GENERAL VEHICLE PARAMETER DATA

TEST VEHICLE INFORMATION

NHTSA No./ID No.

Engine Displacement (L)

Model Year

Type/No. Cylinders

Make

Engine Placement

Model

Height-Adjustable Suspension?

Body Style

Fuel Tank Capacity (L)

Trimline

Transmission Type

VIN

Transmission Speeds

Body Color

Final Drive

Odometer Reading (km/mi)

Bumper Options (e.g. tow hooks)

Does vehicle have DPPS?

If yes, type of DPPS:

DATA FROM CERTIFICATION LABEL

Manufactured By

GVWR (kg)

Date of Manufacture

GAWR Front (kg)

Vehicle Type

GAWR Rear (kg)

VEHICLE SEATING AND WEIGHT CAPACITY

Designated Seating Capacity (DSC)

Capacity Wt. (VCW) (kg)

Cargo Wt. (RCLW) (kg)

DATA SHEET NO. 1 - GENERAL VEHICLE PARAMETER DATA (CONT’D)

Collect items circled in red, tire manufacturer, tire name, and tire condition.

Maximum Tire Pressure (kPa)

Cold Pressure (kPa)

Recommended Tire Size

Tire Size on Vehicle

Tire Manufacturer

Tire Model

Treadwear

Traction

Temperature Grades

Tire Plies Sidewall

Tire Plies Body

Load Index/Speed Symbol

Tire Material

DOT Safety Code Left

DOT Safety Code Right

Tire Condition

DATA SHEET NO. 1 - GENERAL VEHICLE PARAMETER DATA (CONT’D)

FUEL TANK CAPACITY

Liters

Usable Capacity of “Standard Tank”

Usable Capacity of “Optional Tank”

MARKUP TIRE PRESSURE

VEHICLE WEIGHT

TEST VEHICLE ATTITUDES

Is lab Normal Ride Attitude within 25 mm of Manufacturer’s Ride Height?

[INSERT OVERALL VEHICLE AS DELIVERED PHOTOS HERE]

DATA SHEET NO. 2 – VEHICLE MARKUP DATA

GENERAL MARKUP INFORMATION

Origin Description

Internal Bumper Reference Line Height @ Centerline (mm)

Hood Leading Edge Height @ Centerline (mm)

Origin Height Above Ground (mm)

Markup Ride Heights (measured vertically up from each wheel arch)

VEHICLE MARKUP DATA

The CMM coordinate system is aligned such that:

Hood Edges at Centerline for Comparison

Centerline Wrap Around Distances (WADs)

Leading Edge Reference Line (LERL)

Front Corner Reference Point (CRP)

Side Reference Line (SRL)

Rear Corner

Rear Reference Line (RRL)

WAD 1000 mm Line

WAD 1500 mm Line

WAD 1700 mm Line

WAD 2100 mm Line

Head Impact Grid Points

Upper Bumper Reference Line

Lower Bumper Reference Line

Bumper Corners

WAD 930

WAD 775

Internal Bumper Reference Line (IBRL)

IBRL Translated to External Fascia

Upper Leg Impact Grid Points

Lower Leg Impact Grid Points

[The Contractor shall insert a copy of the full NHTSA CMM markup template in this space. See attachment.]

[INSERT OVERALL VEHICLE MARKUP PHOTOS HERE]

DATA SHEET NO. 3 – HEADFORM TEST RESULT SUMMARY

SUMMARY

CAMERA LOCATIONS - HEADFORM

* COORDINATES:

DATA SHEET NO. 4 – HEADFORM TEST RESULT DETAILS

TEST PARAMETERS

Targeting Details

Laboratory Details

Target Impact Point:

Temperature (C):

Target Impact Angle (deg):

Humidity (%):

Target Impact Velocity (km/h):

Deployable Pedestrian Protection System(s):

Targeting Method:

Type:

Local Hood Angle XZ (deg):

State:

Local Hood Angle YZ (deg):

Timing:

TEST RESULTS

Test No.:

Test Date:

Primary Structure Impacted:

Post-Test Inspection

Target to Impact Distance, x (mm):

Damage Summary:

Target to Impact Distance, y (mm):

Speed Trap Velocity (km/h):

Damage outside/underneath impact area:

Contact Time (ms):

HIC15:

Notes:

Components to be replaced prior to next test:

DATA SHEET NO. 4 – HEADFORM TEST RESULT DETAILS (CONT’D)

CRITICAL INJURY VALUES

HIC15

Impact Velocity from Integration (km/h)

Impact Velocity from Speed Trap (km/h)

MAXIMUM/MINIMUM VALUES

CFC1000

CFC1000

CFC1000

CFC1000

[Insert Data Plots in this location.]

[Insert Pre- and Post-Test Photos in this location.]

DATA SHEET NO. 5 – LOWER LEGFORM TEST RESULT SUMMARY

SUMMARY

CAMERA LOCATIONS – LOWER LEGFORM

+X points from the vehicle’s rear to front; +Y points from the vehicle’s driver side to passenger side; +Z points towards ground.

DATA SHEET NO. 6 – LOWER LEGFORM TEST RESULT DETAILS

Targeting Details

Laboratory Details

Target Impact Point:

Temperature (C):

Target Impact Angle (deg):

Humidity (%):

Target Impact Velocity (km/h):

Deployable Pedestrian Protection System(s):

Target Location Description:

Type:

State:

Timing:

Test No.:

Test Date:

Primary Structure Impacted:

Impact Location from Target - Lateral (mm):

Post-Test Inspection

Speed Trap Velocity (km/h):

Damage Summary:

Tibia Max Bending Moment (Nm):

Tibia Max Bending Channel:

Damage outside/underneath impact area:

MCL Max Elongation (mm):

ACL Max Elongation (mm):

PCL Max Elongation (mm):

Notes:

Components to be replaced prior to next test:

DATA SHEET NO. 6 – LOWER LEGFORM TEST RESULT DETAILS (CONT’D)

Max Tibia Bending Moment (Nm)

MCL Elongation (mm)

ACL Threshold (Pass/Fail)

PCL Threshold (Pass/Fail)

CFC 180

CFC 180

CFC 180

CFC 180

CFC 180

CFC 180

CFC 180

CFC 180

CFC 180

CFC 180

CFC 180

CFC 180

DATA SHEET NO. 7 – UPPER LEGFORM TEST RESULT SUMMARY

SUMMARY

CAMERA LOCATIONS – UPPER LEGFORM

+X points from the vehicle’s rear to front; +Y points from the vehicle’s driver side to passenger side; +Z points towards ground.

DATA SHEET NO. 8 – UPPER LEGFORM TEST RESULT DETAILS

Targeting Details

Laboratory Details

Target Impact Point:

Temperature (C):

Target Impact Angle (deg):

Humidity (%):

Target Impact Velocity (km/h):

Deployable Pedestrian Protection System(s):

Target Location Description:

Type:

Nominal Impact Energy (J):

State:

Foam ID:

Timing:

Test No.:

Test Date:

Primary Structure Impacted:

Impact Location from Target - Lateral (mm):

Post-Test Inspection

Speed Trap Velocity (km/h):

Damage Summary:

Sum of Femur Forces (N):

Upper Bending Moment (Nm):

Middle Bending Moment (Nm):

Damage outside/underneath impact area:

Lower Bending Moment (Nm):

Upper Femur Force (N):

Lower Femur Force (N):

Components to be replaced prior to next test:

Torque limiting joint slip?

Notes:

DATA SHEET NO. 8 – UPPER LEGFORM TEST RESULT DETAILS (CONT’D)

Sum of Femur Force (N)

Maximum Bending Moment (Nm)

CFC 180

CFC 180

CFC 180

CFC 180

CFC 180

Supplemental Reports Supplemental Reports, like Data Sheets, are provided as tools to use in the exchange of vehicle and test information between the COR and the Contractor. Unlike Data Sheets, these are not part of the Final Test Report. The Contractor is not restricted from using other tools or expanding the information outlined in this section.

Supplemental Report (SR) 1 – Test Vehicle Setup Information “Test Vehicle Setup Information” will be supplied, either by the purchasing Contractor or the COR, to the Contractor before testing preparation. This information is supplied by the vehicle manufacturer to aid in the initial test setup and shall be considered as reference material.

Supplemental Report (SR) 2 – Vehicle Condition Report A “Report of Vehicle Condition” must be submitted to the COR. The first page shall be completed when the test vehicle arrives at the testing laboratory. The second page is completed after the test and submitted with the Quality Control Package. The third page of the report should be completed and submitted to the COR within 14 days of receiving authorization to complete restraint deactivation activities. The report shall be legible (handwritten versions are unacceptable) and complete (all information requested is included).

Supplemental Report (SR) 3 – Laboratory Notice of Invalid Test or Excessive Injury Value A “Laboratory Notice of Invalid Test or Excessive Injury Value” will be submitted to the NHTSA COR to report a test that was conducted that did not meet the required specifications or an excessive injury value obtained during the impact test.

Supplemental Report (SR) 4 – Monthly Status Reports SR4a: Vehicle Inventory Report The purpose of a “Vehicle Inventory Report” is to track all vehicles tested under NCAP and in the Contractor’s possession. It should contain all NCAP-owned, optional, and lab-owned retest vehicles. The information should be organized in an Excel file format according to the structure described by SR4a and submitted to the COR each month (no later than the 5th of the month following the reporting month) until all vehicles have been discarded. An alternative schedule may be used if approved by the COR. A sample template will be provided by the COR.

SR4b: Invoicing Report The “Invoicing Report” allows NHTSA to identify and reconcile its internal invoicing records against the Contractor’s. The invoicing report also may include forecast work expected during the next reporting period, if applicable. The information should be organized in an Excel file format according to the structure outlined under SR4b and submitted to the COR each month (no later than the 5th of the month following the reporting month). A sample template will be provided by the COR.

SR4c: ATD and Sensor Inventory Report An “ATD and Sensor Inventory Report,” in Excel file format and according to the structure outlined under SR4c, shall be submitted to the COR either monthly (no later than the 5th of the month following the reporting month) or upon request, depending on the section of the “ATD and Sensor Inventory Report” in question. An alternative schedule may be used if approved by the COR. A sample template will be provided by the COR.

SR4d: Parts Procurement and Inventory Report A “Parts Procurement and Inventory Report,” in Excel file format and according to the structure outlined under SR4d, shall be submitted to the COR either monthly (no later than the 5th of the month following the reporting month) or upon request, depending on the section of the “Parts Procurement and Inventory Report” in question. An alternative schedule may be used if approved by the COR. A sample template will be provided by the COR.

Supplemental Report (SR) 5 - Quicklook Report A “Quicklook Report” of pertinent test data, as described in Section 2.2 of this appendix, should be prepared and sent via e-mail to pertinent NHTSA personnel within twenty-four (24) hours of test completion.

SUPPLEMENTAL REPORT 1

Test Vehicle Setup Information NCAP Crashworthiness Pedestrian Protection Tests

Vehicle Model Year and Make: __________________________________________________ Vehicle Model and Body Style: __________________________________________________

[Sample report content to be provided prior to start of testing program.] Comment by Smith, Patrick (NHTSA): To do

SUPPLEMENTAL REPORT 2

Pre-Test

This vehicle was inspected upon delivery at the laboratory and was found to contain all the required equipment. Any and all variances should be noted. NCAP should be notified immediately if the received vehicle is not in good working order or is damaged. Submission of this report acknowledges that the vehicle was received in good working order and was undamaged.

Model Year

GVWR

Make

Transmission

Model

VIN

Body Style

Body Color

Engine Type

Delivery Date

Final Drive

Odometer Reading

# Seating Positions

Dealer

Please list any other pertinent information below:

Please also provide/attach a copy of the window sticker (Monroney label).

SUPPLEMENTAL REPORT 2

Post-Test

Remarks:

Equipment that is no longer on the test vehicle or functioning on the test vehicle:

Explanation for equipment removal or loss of function:

Describe the nature of any vehicle/technology system damage and note if the damage is repairable/replaceable, or has been repaired/replaced:

Attach photos of any damage.

SUPPLEMENTAL REPORT 3

Laboratory Notice of Invalid Test or Excessive Injury Value

Test Vehicle:

Test Type:

NHTSA Number:

VIN:

Test Lab:

Test Date:

Contract Number:

☐ Invalid Test Describe the nature of the nonconformance in the space below. Briefly describe the reason(s) for the nonconformance, if known. Provide related supplemental information as a separate attachment.

☐ Excessive Injury Value Fill the table below with information relevant to the excessive injury value. Provide related supplemental information, such as pre- and post-test qualification data, photographs, etc., as a separate attachment.

Impactor Type

Impact Location

Impactor Serial No.

Relevant Injury Value(s)

NHTSA COR Acknowledgement: _______________________________ Date:____________

SUPPLEMENTAL REPORT 4a Vehicle Inventory Report Each month, the Contractor should provide the COR with a report of the NCAP-related vehicles they have in inventory. This should include NCAP-owned, optional (if applicable), and lab-owned retest vehicles. If the Contractor is in possession of vehicles that are associated with more than one NCAP contract, each tab in the file should only include details related to one contract number. Each tab should be named using the contract number along with an indication of the test type(s). The chart below should be recreated in an Excel file with data added according to the chart key below.

The Excel file name should be structured as follows:

< 3 Letter Lab Name/TSTPRF><Year><Month>SR4a Vehicle Inventory Report.xlsx All columns shown below must be included, in the same order shown. Additional columns of pertinent information may be added to (but not inserted in between) these columns.

Chart Key:

· No.: Sequential number identifying each vehicle purchased under the contract.

· Test Type(s): Indicate the type(s) of test(s) performed on the vehicle.

· Year/Make/Model: Indicate the year, make, and model of the vehicle.

· NHTSA No.: Indicate the vehicle’s NHTSA number.

· Owner: Indicate the owner (i.e., COR or test lab) of the NCAP vehicle.

· VIN: Indicate the vehicle’s 17-digit identification number (VIN).

· Delivery Date: Indicate the date the vehicle was received at your laboratory.

· Initial Test Date: Indicate the first date the vehicle was subject to testing.

· Final Test Date: Indicate the last date the vehicle was subject to testing.

· Final Odometer Reading: Indicate the final odometer reading just prior to releasing or transferring the vehicle out of your possession.

· Vehicle Disposal Date: Indicate the date the vehicle is transferred out of your possession.

· Transferred to?: Indicate the recipient of the vehicle once is it transferred out of your possession.

SUPPLEMENTAL REPORT 4b Invoicing Report Each month, the Contractor should supply the COR with a report of current and forecast invoicing activities.

The Excel file name should be structured as follows:

< 3 Letter Lab Name/TSTPRF><Year><Month>SR4b Invoicing Report.xlsx If the Contractor is invoicing items on multiple NCAP contracts, each tab in the Excel file should only include details related to delivery orders associated with that one contract number. Each tab should be named using the contract number.

The header and chart information detailed below should be replicated for each separate delivery order issued under the contract, so that all delivery orders issued under a contract are contained on one tab in the Excel file. The lab should construct a completely new chart for each delivery order issued under a contract based on the items included in each subsequent delivery order.

All header items and chart columns shown below must be included in the same order shown. Additional chart columns of pertinent information may be added to (but not inserted in between) these chart columns. For ease of discussion, the “left side” and “right side” of the chart are discussed separately. Spreadsheets should be designed according to the header, “left side,” and “right side” chart keys below.

In addition to building in the calculations and functionality described throughout the following sections, the Contractor should use conditional formatting or other functions in Excel to flag or highlight information that could lead to problems such as invoicing more contract line item numbers (CLINs) than were ordered or charging the incorrect price.

Header Key:

Contract No: 693JJ92XD000XXX

· Contract No: Place the contract number in a larger font at the top left corner of the sheet. This should be duplicated towards the top left corner of each delivery order chart generated on the tab.

· Delivery Order: Delivery order number.

· Requisition No: Requisition number.

· DO PoP Start Date: The start date for the delivery order’s period of performance (PoP).

· DO PoP End Date: The end date for the delivery order’s period of performance (PoP).

· PoP Extension End Date: The new period of performance end date (PoP) if the delivery order end date has been extended.

· Total Award: The total funds awarded on the delivery order.

· Invoiced: Subtotal of items invoiced on the delivery order thus far. This field should contain a function to calculate the sum of the Line Total column described under “Left” Chart Key below.

· Balance: The remaining funds on the delivery order. This field should contain a function to calculate the difference between Total Award and Invoiced.

“Left Side” of Chart:

The “left side” of the chart should be located below the header information described above. These columns headers are static and each listed below should be included.

· Test Item: For the item being invoiced, list the vehicle year, make and model (if a vehicle), or provide other identifying information for a separate test item (e.g., review of test procedures).

· NHTSA or Item Number: Indicate the NHTSA number, serial number, or other related identifier describing the item being invoiced.

· Test Type(s) or Item Description: Provide a short description…