NCAP 20Lab 20Procedure 202004 201-05.pdf

DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FOR

NEW CAR ASSESSMENT PROGRAM

FRONTAL IMPACT TESTING

December 2004

Office of Vehicle Safety

OFFICE OF CRASHWORTHINESS STANDARDS

ROOM 5307, NVS-111

400 SEVENTH STREET, SW

WASHINGTON, DC 20590

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' name or products are mentioned, it is 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.

NCAP LABORATORY TEST PROCEDURE

TABLE OF CONTENTS

1. PURPOSE AND APPLICATION

2. GENERAL REQUIREMENTS

3. SECURITY

4. GOOD HOUSEKEEPING

5. TEST SCHEDULING AND MONITORING

6. TEST DATA DISPOSITION

7. GOVERNMENT FURNISHED PROPERTY (GFP)

8. CALIBRATION OF TEST INSTRUMENTS

9. PHOTOGRAPHIC DOCUMENTATION

10. DEFINITIONS

11. PRETEST AND FACILITY REQUIREMENTS

12. NCAP TEST EXECUTION AND TEST REQUIREMENTS

13. POST TEST REQUIREMENTS

14. TEST REPORTS

15. TEST REPORT DATA SHEETS

ILLUSTRATIONS

1. SIGN CONVENTIONS FOR TEST DUMMIES

2. HEAD INJURY CRITERION

3. CAMERA POSITIONS FOR FRONTAL IMPACTS

4. REFERENCE PHOTO TARGETS

5. TARGET ALIGNMENT

6. SHOULDER BELT CONFIGURATION

7. BELT WEBBING STRETCH

8. LOAD CELL BARRIER

9. TYPICAL NCAP BARRIER IMPACT TEST FACILITY

10. TYPICAL VEHICLE/OCCUPANT IMPACT TEST DATA SYSTEM

APPENDICES

APPENDIX A Part 572E Du mmy Performance Calibration Test Procedure

APPENDIX B Dummy Positioning Procedures for test Dummy Conforming to Subpart E of Part 572

APPENDIX C Redundant Accelerometers - Recommended Practice

APPENDIX D Foot Instrumentation - Recommended Practice

APPENDIX E Computer Programs

APPENDIX F Evaluation of Data Acquisition System Using A Signal Wave Generator

APPENDIX G Metric Conversion

APPENDIX H Upper Neck Load Cell Polarity Check

APPENDIX I Head Nine-Accelerometer Array Polarity Check

1. PURPOSE AND APPLICATION

This laboratory test procedure provides the specifications for conducting New Car Assessment Program (NCAP) and Standard Enforcement Indicant Program 35 mph frontal barrier impact testing under a joint composite program sponsored by the following offices within the National Highway Traffic Safety Administration (NHTSA):

a. Office of Crashworthiness Standards (NVS-110)

b. Office of Vehicle Safety Compliance (NVS-220)

The contract laboratories are directed by this test procedure to use a special test parameter which is an impact velocity of 35 ± .5 mph (NOTE: This is 5 mph greater than the 29.4 ± .5 mph impact velocity specified for FMVSS Nos. 208/212/219/301). This increased impact velocity is specified in order that the NHTSA can obtain new car assessment and research data, and the 35 mph crash tests will be viewed as “indicant tests” for FMVSS Nos. 208, 212, 219 (Partial), and 301. The requirements of this indicant test procedure must be strictly adhered to; however, the test contractors are encouraged to suggest improved testing techniques to assist in procuring the required crash test data. Any changes to or deviations from this test procedure must be approved by the Contracting Officer's Technical Representative (COTR).

All NCAP vehicles shall be tested using all available restraint systems, whether active or passive .

Contractors are required to submit a detailed test procedure to the COTR before initiating the NCAP test program.

The procedure must include step-by-step operations of the methodology to be used for the following (not inclusive):

-- Test vehicle acceptance from dealer or haul-away driver

-- Test vehicle inspection for pre-test data sheet information

-- Dummy configuration and performance verification

-- Instrumentation calibration and data processing

-- Dummy placement in vehicle

-- Dummy positioning in vehicle

-- Camera placement and check-out

-- Load cell barrier data collection

-- Vehicle brake -abort system

-- Vehicle tow and lateral guidance system

-- Test vehicle inspection for post-test data sheet information

-- FMVSS 208 injury criteria data/neck, pelvis, lower leg

-- Test vehicle security and storage

-- FMVSS No. 212 data

-- FMVSS No. 219 data

-- FMVSS No. 301 data

-- Office Of Crashworthiness Standards (OCR) data

The contractor's in-house test procedure must have NHTSA approval prior to conducting the first crash test of a particular fiscal year program. The contractor's test procedure cannot deviate in any way from the NHTSA procedure without the prior approval of the NHTSA COTR.

2. GENERAL REQUIREMENTS

2.1 REQUIREMENTS FOR THE OFFICE OF CRASHWORTHINESS STANDARDS (OCS)

2.1.1 FMVSS 208

The NCAP test procedure is based on the FMVSS No. 208 test procedure except for (not inclusive) an increased impact speed, the use of all available restraints, incorporation of a load cell barrier, and recording of seat belt performance data, pelvic acceleration, lower leg injury measures, foot accelerations, and the use of redundant head and chest accelerometers. All data acquisition and processing shall be in accordance with the current SAE recommended practice J211, “Instrumentation for Impact Testing”. The Contractor Furnished data acquisition and processing system shall be tested and satisfy the “qualification test” specified in APPENDIX F.

OCCUPANT CRASH PROTECTION requirements are specified in terms of head and chest accelerations and upper leg axial forces measured an laboratory calibrated Part 572 Subpart E dummies in barrier impact collisions as shown below:

-- Head Injury Criterion (HIC) -- (FMVSS 208 - cannot exceed 1000 HIC) where AR = [Ax

2 + AY 2 + AZ

2]1/2 Resultant Acceleration magnitude in g units at the dummy head c.g. as shown in Figures 1 and 2 t1 and t2 are any two points in time during the impact event which are separated by not more than a 36 millisecond time which would maximize the HIC integration.

HIC =

t2-t1 t2 t1

AR dt

2.5

(t2-t1)

Chest Criterion-- (FMVSS 208 - cannot exceed 60 G's)

The maximum peak resultant acceleration at the dummy's chest center of gravity over a 3 millisecond interval.

Chest deflection - (FMVSS 208 - cannot exceed 76.2mm)

Femur Force Criterion-

The compressive force transmitted axially through each upper leg or femur - (FMVSS 208 - cannot exceed 10008 Newtons)

2.1.2 FMVSS 212

This standard establishes windshield retention requirements for motor vehicles during crashes. Vehicles equipped with passive restraints must retain 50 percent of each side of the windshield on each side of the longitudinal centerline after they are subjected to a 30 mph frontal barrier impact. Vehicles not equipped with passive restraints must retain not less than 75 percent of the windshield during the 30 mph frontal barrier impact.

2.1.3 FMVSS 219 - - Partial

This standard specifies limits for the displacement of vehicle components into the windshield area during a crash.

In “Protected Zone” Below “Protected Zone”

Vehicle Component Penetration

Maximum of 0.25 inch into template Must not penetrate inner surface of windshield

The word “partial” is used since the Std. 219 Styrofoam windshield protected zone template has been eliminated for all NCAP 35 mph frontal impact tests in order that the forward motion of the driver and passenger dummies can be filmed through the vehicle's windshield. However, the lower boundary of the protected zone shall be marked on the windshield glass, which accounts for a partial standard test.

2.1.4 FMVSS 301

This standard specifies requirements for the integrity of motor vehicle fuel systems.

A. Frontal Impact - -

TIME MAX. FLUID SPILLAGE

From impact until vehicle motion ceases 1 ounce by weight

For 5 minute period after vehicle motion ceases 5 ounces by weight

For the next 25 minutes 1 ounce by weight/minute

B. Static Rollover - -

TIME MAX. FLUID SPILLAGE

For 5 minute period from onset of rotation at each 90° position 5 ounces by weight

For 6th minute 1 ounce by weight

For 7th minute (if required) 1 ounce by weight

For 8th minute (if required) 1 ounce by weight

2.1.5 NCAP SPECIFIC

Front seat belt performance data including lap and shoulder belt loads, belt stretch, and spoolout.

High speed film documentation

Interior compartment intrusion dimensional data

Redundant head and chest accelerations

Pelvic accelerations

2.2 Requirements for the Office of Crashworthiness Research (OCR)

− Load Cell Barrier shall be installed and instrumented for each test.

− Data shall be collected, reduced and processed from the 36 barrier face load cells.

− Data shall be collected, reduced and processed from nine uniaxial accelerometers mounted at specified location on the test vehicle.

− Data shall be collected, reduced and processed from the neck six-axis load cell.

− Data shall be collected, reduced and processed from lower leg instrumentation.

− Data shall be collected, reduced and processed from foot accelerometers.

− Test vehicle pre-test and post-test dimensional data.

2.3 Requirements for the National Center for Statistics and Analysis, Accident Investigation Division (AID)

Test Vehicle post-test damage description as shown in The Sample Test Report.

SIGN CONVENTIONS FOR

PART 572 SUBPART B AND E TEST DUMMIES

3. SECURITY

The contractor shall provide appropriate security measures to protect NCAP test vehicles, dummies, load cell barrier and any GFP during the entire crash test program, and shall be responsible for all equipment removed from test vehicles before and after the crash test. Vehicle equipment thefts or act of vandalism must be reported to NHTSA authorities immediately. Under no circumstances shall any vehicle components be removed during a visitor inspection unless authorized by OCS engineers. All data developed from the crash test program shall be protected.

NO INDIVIDUALS other than the contractor's personnel directly involved in the crash test program shall be allowed to witness a 35 mph frontal barrier impact test, inspect, photograph or video tape any test vehicle unless authorization is granted by a representative from the OCS. It is the contractor's responsibility to secure the test site area during a test and to shield the barrier impact area from the public view by the use of canvas or other blocking devices.

Rules for Contractors

1. No vehicle manufacturer's representative(s) or anyone other than the contractor's personnel working on the NCAP Contracts and NHTSA personnel, shall be allowed to inspect NHTSA vehicles or witness vehicle preparations and/or crash testing without prior permission of the Office of Crashworthiness Standards (OCS). Such permission can never be assumed.

2. All communications with vehicle manufacturers shall be referred to the OCS, and at no time shall the contractor release crash test data without the permission of the OCS.

3. Unless otherwise specified, the vehicle manufacturer's representatives shall only be authorized to visit the contractor's test facility on the day that the test is scheduled, and the representatives must be escorted by NHTSA and/or contractor personnel.

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

5. Photographs and videotapes of the test vehicle, associated test equipment and test event shall be allowed. However, test personnel shall not be included in any photographic coverage, and videotaping of vehicle preparation must be approved by OCS. The contractor's personnel shall not respond to any questions from the manufacturer's representatives regarding NCAP. All questions shall be referred to the COTR, an OCS representative present at the test site, or to OCS.

6. VISITATIONS -

The contractor shall permit public access to and inspection of the test vehicles and related data during the times specified by the NHTSA COTR. 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 the Office of Crashworthiness Standards. The contractor shall refer all visit requests from vehicle manufacturer's representatives and consumers to the Office of Crashworthiness Standards. This service shall be included as an incidental part of the crash test program and will not result in any additional cost to the NHTSA. The contractor shall make his own arrangements with interested parties for expenses incurred beyond providing access and inspection services. All inquiries by manufacturers concerning the NCAP (vehicle, procedures, data, etc.) shall be directed to OCS representatives.

4. GOOD HOUSEKEEPING

The contractor will maintain the entire test area including the tow road, area around barrier, vehicle pre-test preparation facility, instrumentation building, and dummy configuration and performance verification test laboratory in a clean, organized and painted condition. All test instrumentation must be setup in an orderly manner consistent with good engineering practices.

5. TEST SCHEDULING AND MONITORING

The contractor shall commence crash testing within four (4) weeks after receipt of the first test vehicle.

Subsequent crash tests will be conducted, if requested, at a minimum of one (1) vehicle crash test per week.

The NHTSA COTR will make adjustments to the crash 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. All testing shall be coordinated to allow monitoring by the COTR.

6. TEST DATA DISPOSITION

The contractor shall make all crash test data available within two hours after the crash test event if so requested by Agency personnel. Under no circumstances shall this data be furnished to non-Agency personnel. The contractor shall analyze the preliminary test results as directed by the COTR.

6.1 Computer Data Tape and Final Hard-Copy

The contractor shall deliver to OCS the final data tape/diskette, digital printouts, and plots within one (1) week after the crash test.

6.2 Test Report

6.2.1 NEW CAR ASSESSMENT PROGRAM test report shall include all of the items shown in the Sample

Test Report. The contractor shall submit eleven (10) CD’s and one (1) paper copy of the NCAP test report to the following address:

U. S. Department of Transportation National Highway Traffic Safety Administration Safety Performance Standards Office of Crashworthiness Standards (NVS-110) 400 Seventh St., S.W., Room 5307 Washington, DC 20590

6.2.2 Report Submission

All final test reports shall be submitted to the above listed NHTSA office within one week after final NHTSA’s approval and recommendation to the report.

NCAP data shall be submitted in METRIC format according to the specifications contained in

APPENDIX G.

6.2.3 Preliminary Data Submission

A. Quick look containing the following preliminary information (see attached sample). The contractor should deliver following preliminary data and information to the NCAP within one day either via email or fax.

- Driver and Passenger HIC and 3ms Chest G (including T1 and T2)

- Driver and Passenger Chest Displacement, Nij, and Femur Loads

- Vehicle Test Speed, Curb Weight, and Test Weight

- Presence of Vehicle Safety Features, including:

- Antilock Brakes (ABS)

- Pretensioners

- Load Limiters

- Adjustable Seatbelt Anchors

- Automatic Door Locks (ADL)

- Airbag Deployment Status

- FMVSS Regulation Status

- Door Lock Status

- Other Notable Test Effects and Safety Concerns

B. Quick QC requirement. These requirements are due within one week from the test. The contractor must provide all photos, few movies, and data within a week from the test.

Photographs

The photographic documentation is provided in JPEG (Joint Photographer Expert Group) Format. This is currently the most widely used format for photographic quality images.

1. All images are provided in a High-resolution form. This is a scanned photograph of at least

300 dpi and having a pixel size of 1200 x 1600. Images may be provided in a medium resolution, which has a pixel size of 600 x 800. A further lower resolution at a size of 320 x 240 pixels can be provided as needed. It should also contain the crash event image for web that has a size of 180 x 300 pixels. These image sizes should be consistent with what is already being provided on the NCAP final CD Test Report.

2. The list of photos should be all pre- and post-test photos that are required in the final test report.

Movies We would prefer that movies be in the MPEG format. However, we will also accept AVI’s or QuickTime movies. Regard less of format, the clip should be without sound and should only contain a few milliseconds prior and after the crash event. The necessary clips are listed below:

Frontal (3 clips):

Left and right side of vehicle and pre test shots of vehicle.

Side (4 clips):

Pre shots of vehicle, off board rear ¾ view, driver view on board, rear seat on board.

Driver on board can be substituted with barrier view.

Data

Test data is also included on this QC CD. This data will conform to the current NHTSA Data Tape Format. Header files should also be included.

Test Lab Logo/Name 'MY' NHTSA Frontal NCAP Test Summary 'MY'/'Vehicle Name'/'Body Style'/'NHTSA No.' 'Test Date'

Value T1 T2 Value T2

Driver Primary Driver Redundant Passenger Primary Passenger Redundant

Left Right Right

Units Value Units Value Pretensioner MPH kph Load Limiter lb kg Adj. Anchors lb kg ABS

ADLs

212 - Windshield Periphery Retention Knee Side Curtain 219 (partial) - Windshield Zone Intrusion

HIC Values Chest Clip

Driver (P1) Passenger (P2)

Test Details Vehicle Safety Features Passenger (P2)

T1

Other Notable Test Effects and Safety Concerns:

Driver (P1) Passenger (P2)

Driver (P1)

Vehicle Test Speed Vehicle Curb Weight Vehicle Test Weight

English Units Metric Units

301 - Fuel System Integrity

Nine Axis Head

Front

Driver (P1) Passenger (P2)

Standards Measured Post-test Airbag Deployment

Test Vehicle Doors

Doors Latched (Post-test)

Left Peak Femur Forces (Lbs) Peak Femur Forces (N)

Chest Displacement Can Disable ADLs Using Owner's Manual Doors Locked (Pre-test)

6.3 Test Film

The contractor shall provide five (5) copies of digital movie in CD or five (5) copies of the 16mm color movie film for each crash test. The crash test movie shall be mailed directly to the OCS within four (4) weeks of the vehicle crash test. The master print for each of the crash test films shall be retained by the contractor, but will be made available to the OCS upon request.

6.4 Data Loss

6.4.1 Conditions for RETEST

The Part 572E test dummies and the test vehicle are instrumented in order to obtain data needed for the New Car Assessment Program (NCAP). The dummy data from 35 mph frontal barrier impact tests, specifically from those channels providing Head Injury Criteria (HIC), Chest Acceleration (Gs), and left side/right side femur loads for evaluation against FMVSS No. 208 injury criteria, and the visual record of dummy kinematics are absolutely essential to NCAP. An invalid NCAP test is one which does not conform precisely to all requirements/specifications of the NCAP Laboratory Test Procedure and Statement of Work applicable to the test.

The contracting officer of NHTSA is the only NHTSA official authorized to notify the contractor that a retest is required.

No test report is required for any test which is determined to be invalid unless NHTSA specifically decides to require the Contractor to submit such report. Invalidated test reports will not be publicly released.

RETEST CONDITIONS

Failure of the contractor to obtain the above data and to maintain acceptable limits of test parameters in the manner outlined in this test procedure shall require a retest at the expense of the contractor and will include the cost of the vehicle replacement and retest at the contractor's expense. The provisions of this paragraph apply to, but are not limited to, the contractor maintaining proper speed tolerance (35 ± .5 mph), vehicle seat cushion and back positioning, dummy positioning, correct lap and shoulder belt positioning, and test data acquisition, reduction, and processing.

The contractor shall also be responsible for obtaining usable data from all eight (8) primary channels from each of the two Part 572 test dummies placed in each vehicle front outboard designated seating position (DSP). Failure to produce such data shall also be at the expense of the contractor and shall include vehicle replacement and retest unless the Office of Market Incentives determines that the dummy data loss occurred through conditions beyond reasonable and foreseeable control of the contractor. Should it become necessary for the contractor to procure another test vehicle, it must have identical equipment and options as the original GPE vehicle. THE ORIGINAL GFE VEHICLE REMAINS THE PROPERTY OF NHTSA. THE RETESTED VEHICLE BECOMES THE PROPERTY OF THE CONTRACTOR. The retested vehicle shall be retained without fee by the testing facility until its disposal is authorized by the COTR.

6.4.2 Conditions for PARTIAL PAYMENT

The contractor shall exercise reasonable and foreseeable control to insure that no data is lost or rendered useless. If some non-critical data (such as camera failure, film breakage) and critical data (acceleration and load data) are not obtained for the crash test and the test is accepted by the Agency, the Agency will not pay for the missing or lost data.

6.5 Data Retention by Contractor

The contractor shall retain at no extra cost to the agency, reproducible copies of all data tapes (analog and digital), 16mm movie films, and still photograph negatives.

6.6 Data Availability to the Public

The contractor shall provide interested parties with copies of test report, test CD’s, test data tapes, test films, and test still photographs, at a reasonable cost to the purchaser, but only after, the Office of Crashworthiness Standards representative has advised the contractor that the results of that particular New Car Assessment Program test have been released to the public by the Agency.

6.7 Indicant Failure Notification

Any indication of a “test failure” to the requirements of FMVSS Nos. 208, 212,219 (Partial), or 301 shall be communicated by telephone to COTR within 24 hours of the crash test.

NOTE: In the event of a failure, a post-test calibration check of some critically sensitive test equipment and instrumentation may be required for verification of accuracy. The necessity for the calibration shall be at the COTR's discretion and shall be performed without additional cost.

7. GOVERNMENT FURNISHED PROPERTY (GFP )

ACCEPTANCE OF TEST VEHICLES

The Contractor has the responsibility of accepting NHTSA provided test vehicles from either new car dealers or vehicle transporters. In both instances, the Contractor acts in the NCAP's behalf when signing an acceptance of test vehicles. The Contractor must check to verify the following:

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

B. Tires and wheel rims are the same as listed.

C. There are no dents or other interior or exterior flaws.

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

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

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

G. Verify that spare tire, jack, lug wrench, and tool kit (if applicable) is located in the vehicle cargo area.

The Contractor shall check for damage that may have occurred during transit. The COTR is to be notified of any damage prior to preparation of the vehicle for testing.

NOTIFICATION OF COTR

The COTR must be notified within 24 hours after a vehicle has been delivered.

TEST DUMMIES

Part 572 Subpart E test dummies will be furnished to the contract laboratory by the NCAP. The dummies shall be stored in an upright, seated position with the weight supported by the internal structure of the pelvis. The dummy's head shall be held upright without supporting the weight of the dummy by using an eye-bolt that can be secured in the top of the head. These dummies shall be stored in a secured room which is kept between 55°F and 85°F. The Contractor will check the dummy components for damage when performing the calibration and complete a Dummy Damage Checklist that will be included in the final report, if requested. The COTR will be kept informed of the dummies condition in order that replacement parts can be provided.

Dummy Configuration and Performance Verification Testing

All GFE Part 572E test dummies, (normally four) shall be configuration and performance verification tested by the contractor ON-SITE using the test procedures found in APPENDIX A of this laboratory test procedure after each of the following occurrences:

a. Prior to the initiation of the crash test program.

NOTE: The post-test verification tests from a previous fiscal year's crash test program cannot be considered to be the pre-test verification for the following fiscal year's test program if a time period of more than one (1) month has elapsed or if the test dummies have been used for other tests.

b. In the event of a structural failure of one of the dummy's components (clavicle, rib, femur ball, etc.) during its use in a vehicle crash test.

c. In the event that the dummy's acceleration-time traces obtained during a previous vehicle crash test usage show any unexplainable abnormalities. An OCS engineer should be notified immediately of all abnormalities and explanations that would indicate that a dummy verification test is not required under this final test report.

d. After every three (3) vehicle crash test usages in which no abnormalities or failures have occurred.

e. After each vehicle crash test usage in which one or more of the FMVSS No. 208 injury criteria maximum allowable limits were exceeded such as a HIC greater than 1000, chest Gs of more than 60 for a time interval greater than 3 milliseconds, or femur loads greater than 2250 pounds.

NHTSA will supply contract laboratories with the following equipment:

1. New test vehicles

2. Part 572E test dummies

3. A load cell barrier assembly that will include 36 load cells

4. Instrumented Lower Legs

5. 6-Axis Neck Load Cells

NOTE: Contractor will furnish all dummy and vehicle instrumentation, and all data acquisition, reduction, and processing equipment except as indicated above.

DUMMY DAMAGE CHECKLIST - HYBRID III DUMMY

(To be included in test report with dummy calibrations)

Dummy Serial No. ________________________ Project No._____________________________

GENERAL CHEST DISPLACEMENT ASSEMBLY

OK Damaged Begin with a general cleaning OK Damaged q q Outer skin on entire dummy (gashes, rips, etc.)

q q Bent shaft q q Head -Check that ballast is secure q q Slider arm riding correctly, in track q q Gashes, rips, general appearance, etc. TRANSDUCER LEADS q q Neck -Broken or cracks in rubber q q Torn cables q q Check that upper neck bracket is firmly attached to lower neck bracket

ACCELEROMETER MOUNTINGS (head, thorax, pelvis) q q Three rubber bumpers in place q q Check for secure mounting q q Spine - Broken or cracks in rubber KNEES q q Check for looseness at the condyle joint q q Check outer skin, insert and casting (without removing insert) q q Nodding blocks - cracked or out of position q q Knee sliders - Wires intact q q Ribs - Check all ribs and rib supports for damage (bent or broken) q q Knee sliders - Rubber returned to “at rest” position q q Check damping material or separation or cracks

LIMBS

OTHER q q Check for normal movement and adjustment q q PELVIS q q q q Inspect for breakage, esp. at iliac crest

NOTE: If upon visual examination, damage is apparent in any of these areas, the appropriate engineer or engineering technician is to be consulted for a decision on repair or replacement of parts.

Repair or Replacement approved by:

Signature Date

Comments on repair or replacement of parts:

8. CALIBRATION AND INSTRUMENTATION

Before the Contractor initiates the NCAP test program, a test instrumentation calibration system must be implemented and maintained in accordance with established calibration practices. Guidelines for setting up and maintaining such calibration systems are described in MIL-C-45662A, “Calibration System Requirements.” The calibration system shall be set up and maintained as follows:

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

B. All measuring instruments and standards shall be calibrated by the Contractor, or a commercial facility, against a higher order standard at periodic intervals not exceeding 6 months for instruments and 12 months for the calibration standards. Records, showing the calibration traceability to the National Institute of Standards and Technology (NIST), shall be maintained for all measuring and test equipment. The calibration frequency can be increased if deemed necessary by NHTSA. Calibration procedures must conform to SAE Standard J211, Instrumentation for Impact Testing. The following is a recommended practice for accelerometer calibration (refer to J211):

1. FREQUENCY RESPONSE - The accelerometer sensitivity is monitored as the frequency is cycled from approximately 10 to 10000 HZ. The sensitivity should remain fixed.

2. LINEARITY - The accelerometer placed on a shaker table, is cycled from 5g to 100g at100HZ.

There should be minimal sensitivity variation throughout the cycle as described in SAE J211. The sensitivity of the accelerometer should also be compared to previous calibration values, and to the manufacturer's initial submitted value. If a variation greater than approximately 2 to 5% (not specified) is recorded, than the accelerometer should not be used. In addition, the zero offset of the unit should be compared to previous values.

3. TRANSIENT WIDE BAND FREQUENCY DROP TEST - For this test, the accelerometer alongside a known standard and utilizing a drop tower, is dropped from varying heights. The accelerometer output is compared to the standard. In this setup, both frequency response and the amplitude linearity can be checked. The amplitude frequency response should beat a minimum up to CLASS 1000 as defined by SAE J211. The amplitude response of the accelerometer from the different drop heights can be used to compute the amplitude linearity tolerance. The drop heights are arbitrary, but it is recommended that the accelerometer be dropped from at least one height which produces a g level that is greater than that expected in the actual test environment.

4. SENSOR HISTORY - A sensor calibration history should be maintained. During each calibration, prior values should be referenced. If wide disparities exist between values, then the sensor should not be used.

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

(1) Date of calibration

(2) Date of next scheduled calibration

(3) Name of the technician who calibrated the equipment

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

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

(2) Measurement range

(3) Accuracy

(4) Calibration interval

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

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

E. Records of calibration for all test instrumentation shall be kept by the Contractor in a manner that assures the maintenance of established calibration schedules. All such records shall be readily available for inspection when requested by the COTR and shall be included in the final test report as shown in APPENDIX A. The calibration system will need the acceptance of the COTR before NCAP testing commences.

F. Test equipment shall receive a pre- and post-test zero and calibration check. This check shall be recorded by the test technician(s) and submitted with the final report as described in section 11.13.

G. Anthropomorphic test devices shall be calibrated according to the schedule indicated in part 7 above. The calibrations and calibration check shall be submitted with the final report.

H. The Contractor Furnished data acquisition and processing system for recording signals from ATD and vehicle sensors in vehicle test shall be qualified by performing the qualification test as specified in APPENDIX F, “Data Acquisition System Qualification Requirements and Test Procedure.”

NOTE: In the event of a failure to meet the standard's minimum performance requirements additional calibration checks of some critically sensitive test equipment and instrumentation may be required for verification of accuracy.

The necessity for the calibration will be at the COTR's discretion and will be performed without additional cost.

LOAD CELL BARRIER

Calibration

Load cells shall be calibrated on an “as needed” basis and on a semi-annual schedule. Need shall be established by pre- and post-test shunt calibration. If bridge balance remains unchanged (pre- and post-test) and if full-scale shunt calibration results in the same factor, then the transducer characteristics are within calibration. If loads become suspect, linearity of the load cell shall be checked with a universal compression testing machine. If the load cell is non-linear or if pre- and post-test calibration results in a “drift” the load cell shall be returned to the manufacturer for check-out and calibration. Notify the COTR whenever calibration problems arise.

Maintenance

Load cells are prone to corrosion when exposed to damp environments. Therefore, extra precautions shall be taken to prevent moisture entering the cells. CAUTION: Weep holes are provided for equalization of barometric pressure and must be directed downward. If cells are found with the hole pointing upward, the cell must be removed and calibrated by compression testing and if non-linear, returned to the manufacturer.

The load cell barrier shall be covered between tests. When the load cell barrier will not be used for a period of time, it shall be removed from the barrier area and placed in a dry storage area. The plywood blocks shall be intact and completely bonded to the backup support. If these blocks receive significant damage during crash testing, they shall be replaced/repaired such that a full surface is present.

Recorders and Equipment

Normal practice shall be employed with recorders and equipment calibrations for load cells. When load cells are calibrated, a system calibration procedure shall be employed where the load cell is calibrated in the system used for amplifying/recording the load cell output signal. Alternately, the system maybe calibrated separately, but this is not the desired method.

9. PHOTOGRAPHIC DOCUMENTATION

Each 35 mph frontal barrier impact test shall be documented on 16-millimeter (mm) color movie film at a speed as close to 1000 frames-per-second (fps) as possible, except for the 24 fps real-time cameras. Glare or lights showing on any glass area (closed windows or vents) must be minimized so that views of the dummies during the test are visible for film analysis.

A timing mark (usually LED) must be registered on the film edge a minimum of every 10 milliseconds

(ms) and a time zero impact mark (usually LED) must be registered on the film to indicate when contact with the barrier is made in order to permit vehicle and dummy kinematic analysis on a film analyzer. It is preferable that the timing and impact marks be located on separate sides of the film frame. The Contractor shall report all camera locations along with camera speeds and lens focal lengths on the appropriate final report data sheets. Camera locations will be referenced to the barrier face and monorail centerline with the X, Y, and Z coordinates of the film surface recorded for each camera (FIGURE 3).

The vehicle interior may require auxiliary on-board lighting to ensure adequate film exposure.

9.1 CAMERAS REQUIRED

CAMERA 1

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

CAMERA 2

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

CAMERA 3

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

CAMERA 4

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

CAMERA 5

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

CAMERA 6

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

CAMERA 7

High-speed right side view camera to cover the entire right side of the test vehicle during the impact event.

The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle.

CAMERA 8

High-speed right side view camera positioned adjacent to the vehicle's A-post to document the passenger dummy's head movement in the windshield area during the impact event and windshield zone intrusion.

The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle.

CAMERA 9

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

CAMERA 10

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

CAMERA 11

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

CAMERA 12

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

CAMERA 13

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

CAMERA 14

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

CAMERA 15

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

CAMERA 16

High-speed left side on-board camera positioned on the vehicle's rear floorpan to document the movement of the driver's belt system webbing at the retractor unit during the impact event.

CAMERA 17

High-speed right side on board camera positioned on the vehicle's rear floorpan to document the movement of the passenger's belt system webbing at the retractor unit during, the impact event.

NOTE: The outside rearview mirrors may be removed to eliminate any camera view obstructions.

9.2 COLORING REQUIREMENTS FOR PHOTOGRAPHIC PURPOSES

A. Vehicle interior surfaces such as the instrument panel, A-post trim panels, door trim panels, console, etc., shall be painted with flat white paint. The air bag indicator light on the dash shall NOT be painted so as to be visible prior to testing.

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

C. Parts of the driver and passenger dummies shall be coated with colored chalk/water solutions to show contact points with the vehicle's interior, with their own components (such as head to knee contact), and with each other. The chalk/water solution shall be applied after final dummy positioning.

CHALK COLORS TO BE USED ON TEST DUMMIES

DUMMY PART

DRIVER

PASSENGER

Nose

Red

Yellow

Lips

Face

Blue

Top of Head

Back of Head

Left Knee

Right Knee

Blue (FMVSS 208 uses Red)

Lower Steering Wheel Rim

N/A

NOTE: Face chalk should extend below the chin.

D. The driver dummy and passenger dummy clothes shall be contrasting colors so that the motion of each dummy can be identified during film analysis.

E. Tires and wheels should be painted with two white perpendicular lines to reveal tire motion.

9.3 PHOTOGRAPHIC COVERAGE OF FUEL FILLER CAP INSTALLATION

The removal, installation and tightening of the vehicle's fuel filler cap and the cap's rotation to its locked position by Contractor's personnel will be documented. This 16mm color movie film footage shall appear in the final released movie print to show that the filler cap was properly installed and tightened prior to the crash test.

9.4 PHOTOGRAPHIC COVERAGE OF STODDARD SOLVENT SPILLAGE

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

9.5 VEHICLE AND DUMMY PHOTOGRAPHIC COVERAGE

The real-time camera (24 fps) shall be used to document the pretest and post test condition of the test vehicle in addition to the pretest and post test positions of both test dummies (including marks showing the fore and aft seat position) and placement of the lap and shoulder belts on these dummies. The positions of the belt load cells shall be documented along with the tape supports for the shoulder belt load cells.

Particular attention must be exercised to fully document the proper closing of all vehicle doors, including any rear hatchback or tailgate.

9.6 IMPACT EVENT MARKER

Strobe lights or taped photo-flash bulbs (cloth tape on bulb exterior to form small slit for light passage) will be placed in the field -of-view of all 17 cameras to mark “time zero” for the vehicle to- barrier impact event.

The Contractor shall use barrier face or vehicle mounted pressure switches which will be contacted by the forward most component of the test vehicle, such as bumper guards, in order to trigger the 'time zero” indicators. Light from the impact detectors SHOULD NOT COVER MORE THAN 3 FRAMES OF HIGH-SPEED FILM. Suggested locations for impact detectors or “time zero” markers areas follows:

A. Vehicle's roof panel along longitudinal centerline above windshield header

B. Top surface of vehicle's instrument panel along longitudinal centerline

C. Adjacent to engine oil pan

D. Adjacent to vehicle's fuel tank

9.7 REFERENCE TARGETS

9.7.1 Reference photographic targets shall be rigidly mounted on the test vehicle and attached to the barrier assembly as shown in Figures 3 and 4. The primary moving reference targets Al and A2 MUST BE mounted 24 inches (609.6mm) apart on a flat rectangular panel, and be firmly fixed to a structure of the vehicle that remains undisturbed by the crash, such as the vehicle roof. The panel must be in the same plane as the plane of motion (Figure 5). The setup rotation of the panel within the motion plane is unimportant.

To insure against unexpected displacements of the car top, the backup moving reference targets C1 and C2 should also be attached to undisturbed portions of the vehicle, such as the vehicle door or body, and must also be 24 inches (609.6mm) apart.

One 1-inch wide checkerboard tape should be applied down center of vehicle, including top of hood, roof, and deck lid. Also apply tape down both sides of vehicle approximately 4 inches above wheel opening.

Photographic targets should be placed at one-foot intervals along the side of the vehicle along the 1-inch tape. Target placement should be documented.

Stadia poles or similar fixed ground reference targets are to be positioned vertically from the roadway surface on the driver and passenger sides of the vehicle (in the camera view, and at about door midpoint), to assist in high speed film evaluation of the event.

9.7.2 The dummies shall have targets on each side of the head with the center of the target as close as possible to the center of gravity of the head in the x and z direction (relative to the measuring directions of the accelerometers). Targets shall be placed on the outboard shoulder of each dummy. Cut away a section of the sleeve (do not remove the sleeve) of the dummy and place the target as high up on the arm as possible at the intersection of the arm and the shoulder.

9.7.3 The top portion of the steering wheel shall have tape with 1-inch squares (the squares having alternating colors like black and yellow) placed on it.

Figure 3

Figure 4

Figure 5

Figure 5

9.8 INFORMATIONAL PLACARDS

Vehicle identification placards shall be positioned so that at least 1 placard will be visible in the field-of-view for each of the 17 cameras. The following information will be shown:

A. Vehicle's NHTSA Number

B. The words “NCAP 35 MPH FRONTAL”

C. Date of crash test

D. Name of contract laboratory

E. Vehicle year, make and model

9.9 CRASH FILM TITLE AND ENDING

The 16mm crash test movie film shall include the following title frames:

A. “The following 35 mph frontal barrier impact test was conducted under contract with the National Highway Traffic Safety Administration by (name and location of test laboratory)”

B. 35 MPH FRONTAL BARRIER IMPACT TEST

TEST VEHICLE MODEL YEAR, MAKE AND MODEL

NHTSA No. CXXXXX

DATE OF IMPACT EVENT

CONTRACT NO.: DTNH22-9X-X-XXXXX

C. The ending frame shall state “THE END”

9.10 FILM EDITING

The film shall be edited in the following sequence:

A. Title

B. Pretest Coverage

C. Real Time Pan Coverage

D. All high speed coverage in numerical order as shown in Figure 3

E. Post test Coverage

F. Rotating Fixture Coverage (a minimum 10 seconds “burst” during 0 to 90 degree roll)

G. “The End”

All fuel system, windshield, seat back, or any vehicle failures shall be completely documented.

9.11 STILL PHOTOGRAPHS

Provide still photographs (8 x 10 or 81/2 x 11 inch color prints properly focused for clear images) of pretest and post-test condition of entire vehicle deformation and details that pertain to the tested standards.

Photographs of all areas of the test vehicle that may be of importance to the frontal barrier impact test should be taken in excess and developed only if the need aris es.

The following still photographs are required for the NCAP test:

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

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

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

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

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

F. Pretest and post-test windshield view

G. Pretest and post-test engine compartment view

H. Pretest and post-test fuel filler cap view

I. Pretest and post-test front underbody view1

J. Pretest and post-test rear underbody view1

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

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

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

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

O. Pretest and post-test driver dummy and vehicle interior view with the door open

P. Pretest and post-test passenger dummy and vehicle interior view with the door open

Q. Dummy contact point(s) vehicle and dummy

R. Pretest and post-test view of the knee bolsters

* S. Pretest and post-test view of the steering column shear capsule if any part of it is visible. Do NOT disassemble any parts to take these photographs.

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

* U. Pretest and post-test view of the steering column intersecting the firewall from the inside of the vehicle.

Take the best photograph possible without removing any parts.

* V. Pretest and post-test under hood view of the steering column intersecting the firewall.

Take the best photograph possible without removing any parts.

W. Photograph of ballast installed in vehicle

X. Post-test Stoddard solvent spillage location view, if required

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

Z. Photograph of certification label

AA. Photograph of tire placard

BB. Photograph of the impact

* Photographs NOT required in Final Report

1 NOTE:

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

Still photographs: 8 by 10-inch color prints

One (1) copy of a color 8 by 10-inch side…