Attachment J.1 - Pedestrian Test Procedure (SHOWING TRACK CHANGES).pdf

Rev. 00 DRAFT 01 – 20252026-0607

U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE FOR

NEW CAR ASSESSMENT PROGRAM

PEDESTRIAN IMPACT TESTING

June 2025September 2026

RULEMAKING

Office of Crashworthiness Standards (NRM-110)

1200 New Jersey Ave SE

Washington, DC 20590 i

REVISION CONTROL LOG FOR

NCAP LABORATORY TEST PROCEDURE

PEDESTRIAN IMPACT TESTING

REV. No. DATE DESCRIPTION

00 2025-06 Initial release.

DRAFT

2026-

Incorporate changes from MY2025 validation testing.

ii

Table of Contents

1. Purpose and Application

2. Rules for Contractors

2.1. Security

2.2. Test Access

2.3. Good Housekeeping

2.4. Test Scheduling and Monitoring

2.5. Project Plan

3. General Requirements

3.1. Government Furnished Property (GFP)

A. Test Vehicles B. Test Devices

3.2. Facility and Equipment

A. Test Building/Area B. Data Acquisition System C. High-Speed Cameras D. Test Device Launcher E. Test Device Qualification Area and Fixtures

4. Calibration, Qualification, and Test Instrumentation

4.1. Test Measurements

A. Child/Small Headform and Adult Headform B. Injury Criteria - Upper Leg C. Injury Criteria - Lower Leg

4.2. Calibration System

4.3. Test Devices

A. Adult Headform B. Child Headform C. Upper Legform D. FlexPLI Lower Legform E. PDI-2 Leg Impactor F. Test Device Requalification

5. Photographic Documentation

5.1. High-Speed Digital Cameras

5.2. Real-Time Camera

5.3. Camera Locations

A. Adult Headform Tests B. Child/Small Adult Headform Tests C. Lower Leg Tests D. Upper Leg Tests

5.4. Coloring, Markers, and Other Targets

5.5. Vehicle Information Placards

5.6. Compiled Impact Event Video

5.7. Still Photographs

iii

6. Definitions

6.1. Corner Gauge

6.2. Corner of Bumper (or Bumper Corner)

6.3. Corner Reference Point (CRP)

6.4. Deployable Pedestrian Protection System (DPPS)

6.5. Internal Bumper Reference Line (IBRL)

6.6. Leading Edge

6.7. Lower Bumper Reference Line (LBRL)

6.8. Moveable Hood Top

6.9. Pedestrian Detection Impactor 2 (PDI-2)

6.10. Rear Edge of Hood

6.11. Rear Reference Line (RRL)

6.12. Side Reference Line (SRL)

6.13. Upper Bumper Reference Line (UBRL)

6.14. Wrap Around Distances (WADs)

7. Test Vehicle Preparation

7.1. Test Vehicle Information

7.2. Data from Certification Label

7.3. Data Recorded From FMVSS No. 110 Vehicle Tire Placard, Optional Tire Inflation

Pressure Label, and Sidewalls

7.4. Vehicle Weights

7.5. Vehicle Attitude/Suspension Adjustment

7.6. Vehicle Marking

A. General Guidelines B. Wrap Around Distances (WAD) C. Side Reference Line (SRL) D. Leading Edge Reference Line (LERL) E. Rear Reference Line (RRL) F. Corner Reference Point G. Upper and Lower Bumper Reference Lines H. Bumper Corners, Bumper Test Zone, and Internal Bumper Reference Line (IBRL) I. Internal Bumper Reference Line (IBRL) and Bumper Test Zone J. Marking Headform Impact Area Grid Points K. Identification of the Headform Grid Points L. Marking Upper Legform to WAD775 mm Grid Points M. Marking Lower Legform Grid Points N. Labeling the Upper Legform and Lower Legform Grid Points O. Marking and Labeling the Child Headform to Hood Leading Edge Grid Points

7.7. Headform Point Selection

7.8. Lower Legform to Bumper Point Selection

7.9. Upper Legform to WAD775 mm Point Selection

7.10. Recording Impact Point Locations

8. Deployable Pedestrian Protection Systems

8.1. Physical Testing of the Sensing System

iv

8.2. Timing of System Deployment

A. Non-Deployed Tests B. Fully Deployed C. Dynamic Testing

8.3. Upper Leg to WAD775 Testing with DPPS

9. Headform Tests

9.1. Headform Test Device Setup

A. Instrumentation B. Qualification C. Selection

9.2. Vehicle and Propulsion System Setup

9.3. Pre-Test Photographs and Final Checks

9.4. Pre-Test Setup Approval by COR

9.5. Impact Test

9.6. Post-Test Photographs, Observations, and Repairs

10. Upper Legform to WAD775 mm Tests

10.1. Upper Legform Test Device Setup

A. Instrumentation B. Qualification

10.2. Vehicle and Propulsion System Setup

10.3. Pre-Test Photographs and Final Checks

10.4. Pre-Test Setup Approval by COR

10.5. Impact Test

10.6. Post-Test Photographs, Observations, and Repairs

11. Lower Legform to Bumper Tests

11.1. Lower Legform Test Device Setup

A. Instrumentation B. Qualification

11.2. Vehicle and Propulsion System Setup

11.3. Pre-Test Photographs and Final Checks

11.4. Pre-Test Setup Approval by COR

11.5. Impact Test

11.6. Post-Test Photographs, Observations, and Repairs

12. Test Data Disposition

12.1. Test Data Loss

A. Invalid Test Description B. Invalid Test Notification C. Retest Notification D. Waiver of Retest E. Test Vehicle F. Test Report G. Default H. Conditions for Partial Payment v

12.2. Data Processing

A. Filtering Requirements B. ISO Channel Names

12.3. Recommended Data Trace Order

12.4. Notification of Excessive Injury Values

12.5. Deliverables

12.6. Data and Vehicle Retention by Contractor

13. Appendices

13.1. Appendix A: PADI – Adult Pedestrian Headform

13.2. Appendix B: PADI – Child Pedestrian Headform

13.3. Appendix C: PADI – Upper Legform

13.4. Appendix D: PADI – FlexPLI Legform

13.5. Appendix E: Qualification Procedures for Pedestrian Test Devices

13.6. Appendix F: Deliverable Guidelines

13.7. Appendix G: Pedestrian Model Specifications

vi

List of Figures Figure 1. Wrap-Around Distance (WAD) determination. Image courtesy Euro NCAP Figure 2. WAD lines determination. Image courtesy Euro NCAP Figure 3. Side Reference Line (SRL) determination. Image courtesy Euro NCAP Figure 4. Leading Edge Reference Line (LERL) determination. Image courtesy Euro NCAP Figure 5. Rear Reference Line (RRL) determination. Image courtesy Euro NCAP Figure 6. Modified RRL determination. Image courtesy Euro NCAP Figure 7. Corner Reference Point (CRP) determination. Image courtesy Euro NCAP Figure 8. Upper Bumper Reference Line (UBRL) determination. Image courtesy Euro NCAP Figure 9. Lower Bumper Reference Line (LBRL) determination. Image courtesy Euro NCAP Figure 10. Bumper corner gauge. Reproduced from GTR 9 Amendment 2, Figure 5B Figure 11. Determination of bumper corner with corner gauge. Reproduced from GTR 9 Amendment 2, Figure 5C Figure 12. Orientation of corner gauge. Reproduced from GTR 9 Amendment 2, Figure 5A Figure 13. Marking Internal Bumper Reference Line (IBRL) height. Image courtesy Euro NCAP Figure 14. Bumper grid point determination. Image courtesy Euro NCAP Figure 15. Hood grid point determination. Image courtesy Euro NCAP Figure 16. Hood grid point determination within discontinuities. Image courtesy Euro NCAP Figure 17. Hood grid point deletion within 50 mm of SRLs. Image courtesy Euro NCAP Figure 18. Hood grid point designations. Image courtesy Euro NCAP Figure 19. Marking legform grid points. Image courtesy Euro NCAP Figure 20. Legform grid point designations. Image courtesy Euro NCAP Figure 21 - LERL located between WAD 930 and WAD 1000. Image courtesy Euro NCAP Figure 22. Windshield periphery measurement. Image courtesy Euro NCAP Figure 23. Head Impact Time (HIT) vs. Wrap-Around Distance (WAD) chart example. Image courtesy Euro

NCAP

Figure 24. Head Impact Time (HIT) vs. Wrap-Around Distance (WAD) chart example. Image courtesy Euro

NCAP

Figure 25. Method of aiming headform impactor at grid point. Image courtesy Euro NCAP Figure 26. Alignment of upper leg impactor to vehicle impact point. Image courtesy Euro NCAP Figure 27. Lower legform vertical vehicle alignment. Image courtesy Euro NCAP Figure 28. Lower legform horizontal firing setup. Image courtesy Euro NCAP Figure 29. Lower legform ballistic firing setup. Image courtesy Euro NCAP vii

List of Tables Table 1. Deployable Pedestrian Protection System (DPPS) activation testing conditions Table 2. Headform instrumentation table Table 3. Upper legform instrumentation table Table 4. Lower legform (FlexPLI) instrumentation table Table 5. FlexPLI qualification frequency Table 6. Filtering Requirements Table 7. ISO Channel Names Table 8. Filter class codes for channels

1. PURPOSE AND APPLICATION

The New Car Assessment Program (NCAP) Pedestrian Impact Protection (PedPro) test procedure is based upon the following European New Car Assessment Program (Euro NCAP) test procedures.

Where this test procedure conflicts with the Euro NCAP documents referenced, this test procedure takes precedent.

Euro NCAP Pedestrian Testing Protocol, Version 8.5, October 2018.

Euro NCAP Assessment Protocol—Vulnerable Road User Protection, Part 1—Pedestrian

Impact Assessment, Version 10.0.3, June 2020.

Euro NCAP Pedestrian Headform Point Selection, V2.1, October 2017.

Euro NCAP Film and Photo Protocol, Chapter 8—Pedestrian Subsystem Tests, V1.4, July

2023.

Euro NCAP Technical Bulletin, TB 003, Damped Accelerometers in Pedestrian Protection

Testing, Version 2.1, October 2018.

Euro NCAP Technical Bulletin, TB 008, Windscreen Replacement for Pedestrian Testing, Version 1.0, September 2009.

Euro NCAP Technical Bulletin TB 019, Headform to Bonnet Leading Edge Tests, Version 1.0, June 2014.

Euro NCAP Technical Bulletin TB 024, Pedestrian Human Model Certification, V4.0, January

2024.

The purpose of the pedestrian impact test program is to provide consumers with information on the safety of new vehicles with respect to pedestrian impact protection.

NHTSA provides contracted laboratories with Laboratory Test Procedures which serve as guidelines for obtaining test data. The data are used to support NCAP in providing consumers with safety information. The purpose of the Laboratory Test Procedures is to present a uniform testing and data recording format and to provide suggestions for the use of specific equipment and procedures.

Any Contractor interpreting any part of a Laboratory Test Procedure to be in conflict with any referenced materials or observing any deficiencies in a Laboratory Test Procedure is required to advise the Contracting Officer’s Representative (COR) and resolve the discrepancy prior to the start of testing.

The Laboratory Test Procedures are not intended to limit or restrain a Contractor from developing or utilizing any testing techniques or equipment which will assist in procuring the required test data.

These Laboratory Test Procedures do not constitute an endorsement or recommendation for use of any product or method. However, the application of any such testing technique or equipment is subject to prior approval by the COR. The Laboratory Test Procedures may be modified by NHTSA at any time without notice, and the COR may direct or authorize Contractors to deviate from these procedures as long as the tests remain within the scope of the contract and are performed in a manner consistent with the NCAP PedPro test protocol.

https://cdn.euroncap.com/cars/assets/tb_024_pedestrian_human_model_certification_v40_e73ea01593.pdf https://cdn.euroncap.com/cars/assets/tb_024_pedestrian_human_model_certification_v40_e73ea01593.pdf https://cdn.euroncap.com/cars/assets/tb_019_headform_to_ble_v10_0_94085bc9_76d7_4dab_af81_e59e9ed747aa_662a09da4c.pdf https://cdn.euroncap.com/cars/assets/tb_019_headform_to_ble_v10_0_94085bc9_76d7_4dab_af81_e59e9ed747aa_662a09da4c.pdf https://cdn.euroncap.com/cars/assets/tb_008_windscreen_replacement_v10_0_b4576306_91fe_4aa9_bf9c_5e5d0883e95e_ae8f4f11f2.pdf https://cdn.euroncap.com/cars/assets/tb_008_windscreen_replacement_v10_0_b4576306_91fe_4aa9_bf9c_5e5d0883e95e_ae8f4f11f2.pdf https://cdn.euroncap.com/cars/assets/euro_ncap_film_and_photo_protocol_v14_6181774d71.pdf https://cdn.euroncap.com/cars/assets/euro_ncap_film_and_photo_protocol_v14_6181774d71.pdf https://cdn.euroncap.com/cars/assets/euro_ncap_pedestrian_point_selection_v21_f71bc6de53.xlsm https://cdn.euroncap.com/cars/assets/euro_ncap_assessment_protocol_vru_v1003_e0e0b0f01b.pdf https://cdn.euroncap.com/cars/assets/euro_ncap_assessment_protocol_vru_v1003_e0e0b0f01b.pdf https://cdn.euroncap.com/cars/assets/euro_ncap_pedestrian_testing_protocol_v85_201811091256001913_a719d74dc0.pdf https://cdn.euroncap.com/cars/assets/tb_003_damped_accelerometers_v21_201811141155467810_f765a67875.pdf https://cdn.euroncap.com/cars/assets/tb_003_damped_accelerometers_v21_201811141155467810_f765a67875.pdf

2. RULES FOR CONTRACTORS

2.1. Security

The Contractor must provide appropriate security measures to protect the test vehicles, dummies, test devices, and other 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 to the COR and NHTSA Property Manager within two (2) working days after the incident.

The Contractor shall protect and segregate the data that evolves from testing before and after each vehicle test. No information concerning the vehicle testing program shall be released to anyone except the COR, unless specifically authorized by the COR, the Contracting Officer (CO), or the COR’s Division Chief or Office Director.

No individuals, other than Contractor personnel directly involved in the testing program, shall be allowed to witness any NHTSA vehicle test unless specifically authorized by the COR. It is the Contractor’s responsibility to secure the test site area during a test and to shield the test area from the public view by the use of canvas or other blocking devices.

2.2. Test Access

No vehicle manufacturer’s representatives or anyone other than the Contractor’s personnel working on the NHTSA contract and NHTSA personnel shall be allowed to inspect the NCAP vehicles or witness vehicle preparations without prior permission from NHTSA. Such permission can never be assumed.

All communications with vehicle manufacturers shall be referred to NHTSA. The Contractor shall not release test results or data without NHTSA’s permission.

The Contractor shall permit public access to and inspection of the test vehicles and related data during the times specified by the NHTSA COR. NHTSA shall advise interested parties that such access and inspection shall be limited to a specified day and specified hours and require prior approval from NHTSA. This service shall be included as an incidental part of the test program and will not result in any additional cost to NHTSA. The Contractor shall make their own arrangements with interested parties for expenses incurred beyond providing access and inspection services.

2.3. Good Housekeeping

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

2.4. Test Scheduling and Monitoring

The Contractor shall submit a test schedule to the COR prior to testing. Tests shall be completed as required in the contract. The COR will make adjustments to the test schedule in cases of unusual circumstances such as inclement weather or difficulty experienced by the agency in the procurement of a particular vehicle make and model.

Scheduling shall be adjusted to permit vehicles to be tested to other Federal Motor Vehicle Safety Standards (FMVSSs) or to other laboratory test procedures as may be required by NHTSA. All testing shall be coordinated with the COR to allow monitoring by the COR and/or other Agency personnel if desired.

2.5. Project Plan

Every Contractor is required to submit a detailed project plan to the COR before initiating the test program. The project plan must include a step-by-step description of the methodology to be used.

The Contractor’s project plan shall contain check-off sheets and a complete listing of test equipment and instrumentation used to conduct the PedPro tests. The list of test equipment shall include make, model, instrument accuracy, and calibration dates. All equipment shall be calibrated in accordance with the manufacturer’s instructions. There shall be no contradictions between the Laboratory Test Procedure and the Contractor’s project plan. Written approval of the Contractor’s project plan shall be obtained from the COR before initiating the PedPro test program.

3. GENERAL REQUIREMENTS

3.1. Government Furnished Property (GFP)

A. Test Vehicles

The Contractor has the responsibility of accepting NHTSA-provided test vehicles from new car dealers, leasing companies, or vehicle transporters. In all instances, the Contractor acts on NHTSA’s behalf when signing an acceptance of test vehicles. The Contractor must check to verify the following:

All options listed on the “window sticker” are present on the test vehicle.

Tires and wheel rims are the same as listed.

There are no dents or other interior or exterior flaws.

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

The glove box contains an owner’s manual, warranty documents, consumer information, and extra set of keys.

The proper fuel filler cap is supplied on the test vehicle (if applicable).

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

The odometer reflects that the vehicle has been driven ≤ 200 miles (322 km).

The VIN on the Supplemental Report 2 – Vehicle Condition Report in Appendix F:

Deliverable Guidelines Report Sheet matches the VIN on the vehicle.

The vehicle is equipped as specified by the COR.

The Contractor shall check for damage that may have occurred during transit. The COR is to be immediately notified of any damage via telephone. Damaged vehicles shall not be prepared for testing until the COR provides approval.

GFP vehicles shall not be driven by the Contractor on public roadways unless authorized by the

COR.

A Supplemental Report 2 – Vehicle Condition Report in Appendix F: Deliverable Guidelines shall be completed by the Contractor and submitted to the COR. The “pre-test” sheet is used to describe the vehicle as initially accepted and shall be provided to the COR within two (2) working days of vehicle receipt, along with a copy of the vehicle’s “window sticker” (Monroney label). The “post-test” sheet provides space for a detailed description of the post-test condition of the vehicle and shall be submitted as part of the “Quality Control Package.”

B. Test Devices

The Government will furnish the Contractor with an adequate number of adult headform, child headform, upper leg, FlexPLI lower leg, and PDI-2 test devices. The test devices will be instrumented with sensors as specified. Contractors are required to supply all other equipment and instrumentation necessary to properly conduct PedPro testing according to this test procedure.

Test devices shall be stored in a secured room which is kept between 18.916°C and 25.524°C (66.0°F and 77.9°F) and 10-70 percent relative humidity.

The Contractor shall check the device components for damage after each PedPro test and notify the NHTSA COR if any damage is found. The COR will be kept informed of the devices’ conditions so that replacement parts can be provided in a timely manner. The Contractor shall keep a detailed record for each device, describing parts replaced and the results of the qualification tests.

3.2. Facility and Equipment

A. Test Building/Area

The building or area used to conduct the PedPro tests shall be temperature-controlled and large enough to house the test vehicle, test equipment, and instrumentation while allowing room for personnel to move freely around the test vehicle. The temperature inside the impact test building/area must be maintained between 16°C (60.8°F) and 24°C (75.2°F) with a relative humidity between 10 and 70 percent for a minimum of four (4) hours prior to lower legform tests and two (2) hours prior to headform and upper legform tests.

B. Data Acquisition System

The Contractor-furnished data acquisition system shall have a sufficient number of channels available for recording and processing signals from the test devices and vehicle sensors starting at least 20 ms before test device launch and continuing for at least 200 ms post-impact. The system must record time histories of the instrumentation specified for each test device used in the test. Each data channel shall be comprised of a sensor, signal conditioner, data acquisition device, and interconnecting cables, and must conform to the appropriate section of SAE Recommended Practice SAE J211/1. The data acquisition system must be capable of syncing signals relative to device launch and impact with vehicle as well as syncing with the high-speed camera system.

C. High-Speed Cameras

The Contractor-furnished high-speed cameras shall be capable of recording at least 1,000 frames per second for the duration of the impact test. The high-speed camera system shall be capable of being synced with the data acquisition system. The Contractor shall ensure sufficient lighting such that the high-speed video is properly exposed.

D. Test Device Launcher

The test area shall include test equipment capable of attaching and then propelling the pedestrian devices in free flight or in a linear guided fashion as required by the test procedures.

The equipment shall be capable of syncing time zero (impactor to vehicle contact) with data acquisition and video. The launcher equipment shall be sufficiently adjustable as to meet the required impact locations, speeds, and angles specified by the test procedure.

E. Test Device Qualification Area and Fixtures

The Contractor may be required to perform qualification tests in-house to ensure accurate data collection. The test procedures and fixtures shall comply with requirements stated in Section

4.2. The qualification area shall be capable of having a stabilized temperature of 18°C to 22°C (64.4°F to 71.6°F) and a relative humidity between 10% and 70%. Test device qualification procedures can be found in Appendix E: Qualification Procedures for Pedestrian Test Devices.

4. CALIBRATION, QUALIFICATION, AND TEST INSTRUMENTATION

4.1. Test Measurements

The PedPro tests are designed to assess the injury risk of interactions between the front end of a vehicle and a pedestrian. The subject vehicle is marked in a prescriptive way to identify test locations and test devices representing an adult head, child head, adult upper leg, and adult lower leg are impacted into the front end of the vehicle. The test devices measure injury criteria which are then used to assess the vehicle’s performance.

A. Child/Small Headform and Adult Headform

(1) Head Injury Criterion (HIC15)

The head injury criterion is computed from the resultant acceleration (AR) in g units at the dummy head’s center of gravity. The following expression describes HIC15:

Where AR= [AX

2 + AY

2 + AZ

2]1/2 and t2 and t1 are any two points in time during the impact event which are separated by no more than 15 ms.

HIC15 for headform impacts shall not exceed 1700.

B. Injury Criteria - Upper Leg

(1) Femur Bending Moment

The femur bending moment injury criterion reported is the maximum of any of the test device’s three bending moments (upper, middle, or lower).

The maximum femur bending moment shall not exceed 350 Nm (258.1 lb-ft).

(2) Femur Force

The sum of the upper and lower femur forces shall not exceed 6,000 N (1,349 lb.).

C. Injury Criteria - Lower Leg

(1) Tibia Bending Moment

The tibia bending moment injury criterion reported is the maximum of any of the test device’s four tibia bending moments (T1, T2, T3, or T4).

The maximum tibia bending moment shall not exceed 340 Nm (250.8 lb-ft).

(2) Medial Collateral Ligament (MCL) Elongation

The maximum MCL elongation measurement shall not exceed 22 mm (0.87 in.).

(3) Anterior Cruciate Ligament (ACL) and Posterior Cruciate Ligament (PCL) Elongation

The maximum ACL and/or PCL elongation measurements shall not exceed 10 mm (0.39 in.).

4.2. Calibration System

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

(1) Standards for calibrating the measuring and test equipment will be stored and used under appropriate environmental conditions to assure their 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 not exceeding six

(6) months for accelerometers and potentiometers and 12 months for strain gauges and load cells. Records, showing the calibration traceability to the National Institute of Standards and Technology (NIST), shall be maintained for all measuring and test equipment.

An accelerometer must be calibrated prior to six (6) months if there is any indication from calibration checks that there may be a problem with a particular accelerometer.

(3) All instrumentation, test equipment, and measuring standards will be labeled with the following information:

a. Date and place of last calibration

b. Date of next scheduled calibration

c. Name of the technician or commercial facility performing the calibration

d. Full-scale measurement range

e. Accuracy and tolerance over the entire measurement range (or within the range used for testing)

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

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

b. Measurement range

c. Accuracy

d. Calibration interval

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

f. The actual procedures and sheets used to perform the calibrations

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

(6) All such records shall be readily available for inspection when requested by the COR. The calibration system will need approval of the COR before testing commences.

(7) The Contractor-furnished data acquisition and processing system for recording signals from test dummies and vehicle sensors in PedPro tests shall be given a functional check using a known test input prior to each test. This check shall be recorded by the test technician(s) and submitted to the COR upon request.

(8) A polarity check should be conducted for all test device and vehicle sensors prior to the test to ensure that all data is accurately recorded and reported.

(9) An instrumentation calibration system capable of performing individual tests on all data channels used in acquiring the required test data shall conform to the appropriate section of the most recent version of SAE J211/1.

(10)Test devices shall be qualified according to the following schedule:

a. Headform impactors must be qualified once prior to beginning the testing program and every 20 impacts thereafter. Impactors shall be requalified if more than one (1) year has elapsed since the previous qualification or if the transducer output, in any impact, has exceeded the specified lower performance criteria by 20%.

b. FlexPLI impactors must be qualified using the quasi-static test once prior to beginning the testing program and once every 12 months thereafter. Additionally, FlexPLI impactors must be qualified using the inverse impact test procedure once after every 20 impacts. If any injury value has exceeded the specified lower performance criteria by 20%, the FlexPLI impactor shall be subject to the pendulum qualification test prior to its next impact.

c. Upper legform impactors shall be qualified once prior to beginning the testing program and every 20 impacts thereafter. Impactors shall be requalified if more than one (1) year has elapsed since the previous qualification or if the transducer output, in any impact, has exceeded the specified lower performance criteria by 20%.

d. In the event of an elevated injury criterion (as compared to established limits), data anomaly, or exceptionally hard contact during testing, the test device must be inspected for damage and then re-qualified. Additional calibration checks of critically sensitive test equipment and instrumentation may be required for verification of accuracy. The necessity for the calibration will be at the COR’s discretion and will be performed without additional cost.

4.3. Test Devices

The NCAP PedPro test procedure requires the use of test devices representing human body parts to determine the injury levels associated with impacts with each vehicle design. The NCAP PedPro tests utilize the following test devices and instrumentation:

A. Adult Headform

Specifications for the adult headform can be found in Appendix A: PADI – Adult Pedestrian Headform.

The adult headform test device shall be instrumented with the following:

Tri-axial head accelerometers o Accelerometers are to have a damping ratio between 0.2 and 0.71

B. Child Headform

Specifications for the child headform can be found in Appendix B: PADI – Child Pedestrian Headform.

The child headform test device shall be instrumented with the following:

Tri-axial head accelerometers o Accelerometers are to have a damping ratio between 0.2 and 0.71

C. Upper Legform

Specifications for the upper legform test device can be found in Appendix C: PADI – Upper Legform.

The upper legform test device shall be instrumented with the following:

Upper and lower force transducers Three moment transducers

D. FlexPLI Lower Legform

Specifications for the FlexPLI legform test device can be found in Appendix D: PADI – FlexPLI Legform.

The FlexPLI lower legform test device shall be instrumented with the following:

Four knee potentiometers Four tibia load cells Uni-axial knee accelerometer

E. PDI-2 Leg Impactor

The Pedestrian Detection Impactor 2 (PDI-2) is used to ensure proper functionality of the sensing system for deployable pedestrian protection systems. The legform is comprised of a carbon fiber tube with a metal core and outer foam cover. The PDI-2 leg impactor is not instrumented. And has the following physical specifications:

Total mass: 6730 ± 30 g (14.8 ± 0.07 lb) Total Height: 1000 ± 2 mm (39.4 ± 0.08 in) CG Height: 650 ± 5 mm (25.6 ± 0.20 in) Iyy: 0.378 kg*m2 (8.97 lb*ft2) Outer Diameter: 76 to 148 ± 1 mm (2.99 to 5.82 ± 0.04 in)

The PDI-2 may be used in a “drive-test” or “launcher-test” configuration. In a drive-test configuration the PDI-2 is placed upright on a test track and the subject vehicle is driven into the legform. In a launcher-test configuration the PDI-2 is launched and impacts the vehicle in free flight in a vertical orientation ±2° with an impact height 22 mm above ground. PDI-2 tests should be conducted at 20-2325°C (68.0-73.4°F) with a 425-570% relative humidity.

The device should be requalified annually or after 80 impacts, whichever comes first. The device should also be visually inspected between impacts for damage to the foam and cracks in the tube.

The leg should be rotated between subsequent tests to ensure homogeneous usage.

More information may be found in the PDI-2 User Manual supplied with the test device from the manufacturer.

F. Test Device Requalification

Test device qualification requirements and schedules are outlined in Appendix E: Qualification Procedures for Pedestrian Test Devices.

5. PHOTOGRAPHIC DOCUMENTATION

5.1. High-Speed Digital Cameras

The Contractor shall document each impact event in color with at least one two high-speed digital camera that operates at a minimum of 1,000 frames per second (fps) and records starting at least 20 ms before the test device is propelled and ending at least 200 ms after each test device contacts the vehicle. The minimum resolution for the cameras must be 1024 1920 x 1024 1080 pixels. The Contractor is encouraged to use a higher frame rate when recording the event if the equipment is capable of doing so without sacrificing image quality. The Contractor is also encouraged to use additional (back-up) cameras in case of primary camera failure.

The Contractor shall report the location of each high-speed camera on the appropriate Data Sheet in the Final Test Report.

The background of the video frame shall be as plain as possible, without test equipment or personnel visible. If necessary, a plain, light colored, non-reflective screen shall be placed behind the vehicle test area. The test laboratory’s logo should not appear in the high-speed videos.

The test area must be equipped with sufficient lighting to provide the proper exposure. Glare or lights showing on any glass area must be minimized so that the view of the test device and vehicle during the test is visible. The Contractor shall minimize shadows to the extent possible. A time zero mark must be registered in the frame to indicate when the impact occurs.

Digital videos from each camera shall be provided with the Quality Control package in .avi, .wmv, or .mpeg format with a standard or generally available codec. Other types of files can be used if prior approval is granted by the COR.

5.2. Real-Time Camera

The Contractor shall use a real-time camera to document the impact event. Real-time footage shall be shot in color at 24, 30, or 60 frames per second. The digital file delivered to NHTSA shall be .avi, .mpeg, or .wmv with a standard and generally available codec. The test laboratory’s name and logo should not appear in the real-time video.

5.3. Camera Locations

A. Adult Headform Tests

The A high-speed camera for adult headform tests shall be perpendicular to the vehicle centerline at a height appropriate so that the impact location can be well seen. The camera may be at the left or right side, as appropriate. Alternatively, tests on the windshield may be filmed from the vehicle’s interior provided that the camera’s mount does not damage or alter the vehicle’s interior.

A second high speed camera shall be located either overhead perpendicular to the ground plane or in front of the vehicle perpendicular to the vehicle’s longitudinal plane and provide a clear view of the impact event.

B. Child/Small Adult Headform Tests

The A high-speed camera for child headform tests shall be perpendicular to the vehicle centerline at a height appropriate so that the impact location can be well seen. The camera may be at the left or right side, as appropriate.

A second high speed camera shall be located either overhead perpendicular to the ground plane or in front of the vehicle perpendicular to the vehicle’s longitudinal plane and provide a clear view of the impact event.

[C.] Lower Leg Tests

The A high-speed camera for lower leg tests shall be perpendicular to the vehicle centerline at the height of the impact pointknee joint. The launcher should be visible. The camera may be at the left or right side, as appropriate, but must be aligned precisely enough to measure the leg angle (±2°) at impact.

A second high-speed camera shall be located overhead perpendicular to the ground plane and must be aligned precisely enough to measure the leg rotation at impact.

C.[D.] Upper Leg Tests

The high-speed camera for upper leg tests shall be perpendicular to the vehicle centerline at the height of the impact point. The impactor should be completely visible. The camera may be at the left or right side, as appropriate.

A second high speed camera shall be located either overhead perpendicular to the ground plane or in front of the vehicle perpendicular to the vehicle’s longitudinal plane and provide a clear view of the impact event.

5.4. Coloring, Markers, and Other Targets

To the extent possible, vehicle surfaces in the area of testing should be a light and uniform color and may be painted if absolutely necessary to achieve acceptable video quality. The test devices are not required to be painted, but a small dot of paint or chalk or other transferable marking may should be used to assist in locating the actual impact location.

A time zero indicator must be synchronized with the event time zero point (when the test device contacts the vehicle). A strobe or flash bulb may be used such that it illuminates at time zero in the field of view of each high-speed camera. Alternatively, if the test lab’s equipment allows, the timestamp on the high-speed video can should indicate a time zero point.

5.5. Vehicle Information Placards

Test vehicle information placards shall be positioned so that at least one placard will be visible and legible in each of the cameras’ field of view. The following information shall be shown:

The test vehicle’s NHTSA number (or other assigned vehicle number, as appropriate)

The words “NCAP PedPro Test” The PedPro test device and test location such as “UL +2” for an upper leg test at position +2 Date of the impact test Vehicle model year, make, and model

The test laboratory’s name and logo shall not appear on the vehicle information placards.

5.6. Compiled Impact Event Video

The Contractor shall create a video file for each camera used to record an impact event. Each individual video file shall be supplied with the “Quality Control Package” and final deliverables package.

The Contractor shall also provide one compiled video for each test device/vehicle model pair (the adult and child heads should be combined). The compiled videos shall include title headings prior to each impact run describing the test type and location.

5.7. Still Photographs

Clear and properly focused digital photographs in .jpg format shall be taken to document the test.

Information placards with the information provided in Section 5.5, Vehicle Information Placards, shall be present in each photograph. Additionally, the Contractor shall add an indication of whether the photograph was taken pre-test or post-test.

The photograph names shall be as follows:

As-Delivered: to be taken after vehicle is received before markup is completed

Right Side View of Test Vehicle as Delivered Right Front ¾ View of Test Vehicle as Delivered Front View of Test Vehicle as Delivered Left Front ¾ View of Test Vehicle as Delivered Left Side View of Test Vehicle as Delivered Monroney Label Vehicle Certification Label Tire Placard

Markup Photos: to be taken after markup is completed including test points

Overhead View of Full Hood WAD1000-2100 Markup Overhead View of Driver Side Hood WAD1000-2100 Markup Overhead View of Passenger Side Hood WAD1000-2100 Markup Frontal View of Full Windshield Markup Frontal View of Driver Side Windshield Markup Frontal View of Passenger Side Windshield Markup Frontal View of Driver Side Leading Edge Markup Frontal View of Center of Leading Edge Markup

Frontal View of Passenger Side Leading Edge Markup Driver Side View of Side Reference Line – Front Half Driver Side View of Side Reference Line – Rear Half Passenger Side View of Side Reference Line – Front Half Passenger Side View of Side Reference Line – Rear Half Driver Side Rear Reference Line Close-up View Center Rear Reference Line Close-up View Passenger Side Rear Reference Line Close-up View Driver Front Corner Reference Point Close-up View Passenger Front Corner Reference Point Close-up View Driver Rear Corner Reference Point Close-up View Passenger Rear Corner Reference Point Close-up View Hood Open – Underside of Hood Hood Open – Engine Bay View of Front End (Bumper) Markup – Bumper On View of Front End (Bumper) Markup – Bumper Off Left Side Vehicle Front End (Bumper) Close-up View – Bumper On Left Side Vehicle Front End (Bumper) Close-up View – Bumper Off Center Vehicle Front End (Bumper) Close-up View – Bumper On Center Vehicle Front End (Bumper) Close-up View – Bumper Off Right Side Vehicle Front End (Bumper) Close-up View – Bumper On Right Side Vehicle Front End (Bumper) Close-up View – Bumper Off

For each Headform Test: ensure test point is visible in photos if it is on a new vehicle component

Pre-test Overall Vehicle Right Front ¾ View Pre-test Overall Vehicle Front View Pre-test Overall Vehicle Left Front ¾ View Pre-test Impact Point Right Front ¾ View Pre-test Impact Point Front View Pre-test Impact Point Left Front ¾ View Pre-test Windshield Inside View (for windshield impacts only) Pre-test Impactor on Launcher View Post-test Overall Vehicle Right Front ¾ View Post-test Overall Vehicle Front ¾ View Post-test Overall Vehicle Left Front ¾ View Post-test Impact Point Right Front ¾ View Post-test Impact Point Front View Post-test Impact Point Left Front ¾ View Post-test Windshield Inside View (for windshield impacts only)

Post-test Impactor View Post-test Vehicle Damage View (to include damage not visible from the outside; e.g., under hood bracket)

For each Upper Legform Test: ensure test point is visible in photos if it is on a new vehicle component

Pre-test Overall Vehicle Right Side ¾ View Pre-test Overall Vehicle Right Side View Along WAD775 Pre-test Overall Vehicle Left Side ¾ View Pre-test Overall Vehicle Left Side View Along WAD775 Pre-test Impact Point Front View Pre-test Impact Point Front View at Symmetric Point (point symmetric to the target point on the opposite side of the vehicle) Pre-test Front View of HoodWAD775 (entire width of vehicle) Pre-test Impactor on Launcher View Pre-test Right View with Impactor Aligned to Impact Point Pre-test Left View with Impactor Aligned to Impact Point Post-test Overall Vehicle Right Side ¾ View Post-test Overall Vehicle Right Side View Along WAD775 Post-test Overall Vehicle Left Side ¾ View Post-test Overall Vehicle Left Side View Along WAD775 Post-test Impact Point Front View Post-test Front View of WAD775 (entire width of vehicle) Front View of Hood Post-test Impactor View Vehicle Damage View (to include damage not visible from the outside; e.g., under hood bracket)

For each Lower Legform Test: ensure test point is visible in photos if it is on a new vehicle component

Pre-test Overall Vehicle Right Side ¾ View Pre-test Overall Vehicle Right Side View Along IBRL Pre-test Overall Vehicle Left Side ¾ View Pre-test Overall Vehicle Left Side View Along IBRL Pre-test Impact Point Front View Pre-test Front View at Symmetric Impact Point Pre-test Front View of HoodIBRL (entire width of vehicle) Pre-test Impactor on Launcher View Post-test Overall Vehicle Right Side ¾ View Post-test Overall Vehicle Right Side View Along IBRL Post-test Overall Vehicle Left Side ¾ View Post-test Overall Vehicle Left Side View Along IBRL

Post-test Impact Point Front View Pre-test Front View of HoodIBRL (entire width of vehicle) Post-test Impactor View Vehicle Damage View (to include damage not visible from the outside; e.g., under bumper bracket)

6. DEFINITIONS

6.1. Corner Gauge

A rigid, 236 mm x 236 mm (9.29 in. x 9.29 in.) square gauge tool used to determine the corner of bumper points. See Section 7.6.H.

6.2. Corner of Bumper (or Bumper Corner)

The transversal position of the vehicle’s point of contact with a corner gauge. See Section 7.6.H.

This is different from the corner reference point (CRP).

6.3. Corner Reference Point (CRP)

The intersections of the hood leading edge and the hood/A-pillar outboard edges (side reference lines). See Section 7.6.F.

6.4. Detection Test Area

The detection test area is defined in GTR No. 9 Amendment 3. This is the area designated to detect a pedestrian in order to activate a deployable system. The width of the detection test area is the Relevant Vehicle Width (RVW), minus 12.5% of the RVW (but not more than 250 mm) from each side. The detection test area must not be smaller than the area inboard of the corners of bumper (CoB) minus 42 mm on each side, as measured horizontally and perpendicular to the longitudinal median plane of the vehicle. See Section 7.6.H.

6.5. Deployable Pedestrian Protection System (DPPS)

An active system that deploys to protect a struck pedestrian. DPPS may function upon contact or if contact is imminent. DPPS may include, but are not limited to, pedestrian air bags and pop-up hoods.

6.6.[6.5.] Internal Bumper Reference Line (IBRL)

A geometric trace defining the location of rigid interior structures lying beneath the vehicle’s bumper fascia. This may include bumper beams, lower rails, or cross beam structures, provided that the beam has a minimum thickness of 1 mm (0.04 in.) for steel and 2 mm (0.08 in.) for aluminum.

6.7.[6.6.] Leading Edge

The front upper outer structure, including the hood and wings, the upper side members of the headlight surround, and any other attachments. See Section 7.6.D.

6.8.[6.7.] Lower Bumper Reference Line (LBRL)

The geometric trace defining the lower edge of significant points of pedestrian contact with the bumper. See Section 7.6.G.

6.9.[6.8.] Moveable Hood Top

All structures connected to the hood that move with the whole assembly when activated in a pedestrian impact.

6.10.[6.9.] Pedestrian Detection Impactor 2 (PDI-2)

The test tool used to determine whether a deployable pedestrian detection system will function if a vehicle impacts a pedestrian. The PDI-2 represents the hardest-to-detect (HTD) pedestrian.

6.11.[6.10.] Rear Edge of Hood

The most rearward point of a moveable hood top when it is closed.

6.12.[6.11.] Rear Reference Line (RRL)

The geometric trace of the most rearward point of contact between a 165 mm (6.50 in.) sphere and the frontal upper surface when the sphere is moved across the frontal upper surface while also maintaining contact with the windshield. See Section 7.6.E.

6.13. Relevant Vehicle Width (RVW)

Relevant Vehicle Width (RVW) is defined in GTR No. 9 Amendment 3 and is the maximum width of the vehicle without device for indirect vision (side mirrors), measured on or in front of a vertical transverse plane passing through the front axle of the vehicle. See Section 7.6.H.

[6.12.] Side Reference Line (SRL)

The geometric trace along the vehicle’s outboard edges defining the headform test area. See Section 7.6.C.

6.14.[6.13.] Upper Bumper Reference Line (UBRL)

The geometric trace defining the upper edge of the bumper. See Section 7.6.G.

6.15.[6.14.] Wrap Around Distances (WADs)

The distance from a point on the ground vertically below the frontmost face of the bumper to various points on the vehicle front end, determined by using a flexible tape measure or graduated wire held taut in the vertical longitudinal plane. See Section Error: Reference source not found.

7. TEST VEHICLE PREPARATION

7.1. Test Vehicle Information

Using the owner’s manual, information provided by the COR, and any other data available, determine the following vehicle information and record it on Data Sheet No. 1 of Appendix F:

Deliverable Guidelines:

NHTSA No. or other Identification Number (supplied by COR) Vehicle model year, make, model, and body style Trimline Body color

VIN

Current odometer reading (in km and mi) Engine data to include displacement (CID, liters, or cc), type and number of cylinders, and placement (longitudinal or lateral) Fuel tank capacity (if applicable) Transmission data, to include type (manual or automatic) and number of speeds Final drive (rear, front, or four-wheel drive) Bumper options (such as tow hooks) Presence of a deployable pedestrian protection system o Note: If there is a deployable pedestrian protection system present on the vehicle model, please refer to Section 8 for further details.

7.2. Data from Certification Label

Record the following vehicle information from the vehicle’s certification label on Data Sheet No. 1 of Appendix F: Deliverable Guidelines:

Manufacturer Build date (or month and year of manufacture) Vehicle type Gross vehicle weight rating (GVWR) (in kg) Gross axle weight rating (GAWR) for the front and rear of the vehicle (in kg)

7.3. Data Recorded From FMVSS No. 110 Vehicle Tire Placard, Optional Tire Inflation Pressure Label, and Sidewalls

Record the following vehicle information from the vehicle’s tire placard, optional tire inflation pressure label, and/or tire sidewalls on Data Sheet No. 1 of Appendix F: Deliverable Guidelines:

Designated seating capacity (DSC) Vehicle capacity weight (VCW) (in kg) Rated cargo and luggage weight (RCLW) (in kg)

a. RCLW = VCW – (68.04 kg x DSC) Maximum tire pressure for both the front and rear tires (in kPa). Verify that this pressure exceeds or is equal to the recommended cold tire pressure listed on the vehicle placard.

Recommended cold tire pressure for both the front and rear tires (in kPa) Recommended tire size for both the front and rear tires Size of tires, including aspect ratio, radial, and wheel diameter. Verify that the tire size(s) meet the manufacturer’s specifications as listed on the vehicle placard or optional tire label.

Tire manufacturer Tire model name Treadwear, traction grade, and temperature grade Tire type and width Load index and speed symbol Tire material DOT safety codes Approximate tire condition (wear on tread, etc.)

Note: Account for reduced load capacity, if applicable.

7.4. Vehicle Weights

If applicable, siphon fuel from the tank and run the car until it has run out of fuel.

Refill the fuel tank with fuel, or an equivalent, to the manufacturer’s specified fuel tank capacity, if applicable. Record capacity of fuel tank in Data Sheet No. 1.

Check the oil and other vehicle fluids and fill to the maximum level, if necessary.

Ensure the vehicle has the spare tire and associated tools if supplied with the vehicle. No other weight should be on the vehicle.

Ensure tires are filled to the manufacturer’s specifications for half load. Record as “mark up tire pressure” in Data Sheet No. 1.

Remove the front license plate and bracket if they are removable from the vehicle. They are not to be installed for markup or testing.

Measure the front and rear axle weights and determine the total weight of the vehicle. This is the “unladen curb weight” of the vehicle. Record these values in Data Sheet No. 1.

Adjust both front seats to their mid-fore/aft position. If there is no notch in the mid-fore/aft position, use the first notch immediately rearward of the mid-position.

Place a 75 kg (165.3 lb.) mass on the driver’s seat and a 75 kg (165.3 lb.) mass on the front passenger’s seat.

7.5. Vehicle Attitude/Suspension Adjustment

Ensure the front wheels are in the straight ahead position.

If the suspension is adjustable, ensure the vehicle is at the attitude for travelling 40 km/h

(24.9 mph). Refer to the vehicle owner’s manual and/or information supplied by the COR.

Roll the vehicle forwards by a distance of at least 1 m (39.4 in.). Roll the vehicle backwards by a distance of at least 1 m (39.4 in.). Repeat for three complete cycles.