Side-Impact 20Test 20Procedures.pdf

U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FOR

NEW CAR ASSESSMENT PROGRAM

SIDE IMPACT TESTING

January 2002

SAFETY PERFORMANCE STANDARDS

OFFICE OF CRASHWORTHINESS STANDARDS

ROOM 5313, NPS-10

400 SEVENTH STREET, SW

WASHINGTON, DC 20590

LABORATORY TEST PROCEDURES

TABLE OF CONTENTS

1. PURPOSE AND APPLICATION

2. GENERAL REQUIREMENTS

3. SECURITY

4. GOOD HOUSEKEEPING

5. TEST SCHEDULING AND MONITORING

6. FACILITY AND EQUIPMENT

6.1 Side Impact Test Surface

6.2 Tow Road

6.3 Test Vehicle Preparation Building

6.4 MDB

6.5 Tow and Guidance System

6.6 MDB Velocity Measurement

6.7 MDB Brake Abort System

6.8 Aluminum Honeycomb Barrier Face Units

6.9 Notification of COTR

7. GOVERNMENT FURNISHED PROPERTY (GFP)

7.1 Test Vehicles

7.2 Test Dummies

8. INSTRUMENTATION AND CALIBRATION REQUIREMENTS

8.1 General Requirements

8.2 SID Instrumentation

8.3 SID Calibration

8.4 Drawing List for SID

8.5 Test Vehicle Instrumentation

8.6 MDB Instrumentation

9. PHOTOGRAPHIC DOCUMENTATION

9.1 Ground based cameras

9.2 MDB cameras

9.3 Test Vehicle on-board cameras

9.4 Paint & Chalking Requirements

9.5 Real time Photographic Coverage

9.6 Impact Event Markers

9.7 Photographic Targets and Tape

9.8 Vehicle Information Placards

9.9 Crash Film Heading and Sequence

9.10 Still Photographs

10. DEFINITIONS

LABORATORY TEST PROCEDURES

TABLE OF CONTENTS (con’t.)

11. TEST EXECUTION

11.1 Test Vehicle Preparation

11.2 Dummy Preparation, Positioning and Placement

11.3 Side Impact Test Condition

11.4 Honeycomb Face Welding Rod Alignment

11.5 Moving Deformable Barrier Impact Face Crush Measurements

12. TEST DATA DISPOSITION

12.1 Performance Requirements

12.2 Data Processing

12.3 Fir 100 Filter

12.4 Computer Data Tape

12.5 Data Loss (Retest)

12.6 Partial Payment

12.7 Data Retention by Contractor

13. REPORTS

13.1 Monthly Status Reports

13.2 Laboratory Notice of Test Failure to OVSC Report

13.3 Final Test Report

14. DATA SHEETS

15. FORMS

APPENDICES:

I. Laboratory Configuration and Performance Verification Procedure

1. SID Laboratory Configuration and Performance Verification Procedure

2. SID/H3 Laboratory Configuration and Performance Verification Procedure

II. Positioning Procedure for SID

III. Aluminum Honeycomb Crush Strength Certification

IV. User’s Manual for SID

V. Data Acquisition System Qualification Requirements and Test Procedure

VI. User’s Manual for SID/H3

VII. SID/H3 Drawing List

VIII. Upper Neck Load Cell Polarity Check

IX. Head Nine-Accelerometer Array Polarity Check

1. PURPOSE AND APPLICATION

The Office of Crashworthiness Standards (OCWS) provides contracted laboratories with Laboratory Test Procedures (TP’s) which serve as guidelines for obtaining crash test data. The data are used to support OCWS Consumer information program in providing consumers with comparative crash test information.

The purpose of the OCWS Laboratory Test Procedures is to present a uniform testing and data recording format, and provide suggestions for the use of specific equipment and procedures. Any contractor interpreting any part of an OCWS 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 Technical Representative (COTR) and resolve the discrepancy prior to the start of testing.

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

The procedure must include a step-by-step description of the methodology to be used. The contractor’s test procedure shall contain a complete listing of test equipment and a detailed check-off list. There shall be no contradiction between the OCWS laboratory test procedure and the contractor’s in-house test procedure. The list of test equipment shall include instrument accuracy and calibration dates.

Contractors are required to supply all equipment and instrumentation necessary to properly conduct vehicle side impact testing according to this test procedure. The Government will furnish the contractor with test vehicles and non-instrumented test dummies. The contractor will be responsible to provide everything else necessary to conduct testing. This will include, but is not limited to, such things as the Moving Deformable Barrier (MDB), Aluminum Honeycomb Barrier Faces, and all instrumentation (including accelerometers) necessary to collect data from the test dummies, MDB and test vehicle.

The OCWS 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 crash test data.

2. GENERAL REQUIREMENTS

The New Car Assessment Program (NCAP) side impact test procedure is based on the FMVSS No. 214D test procedure. Whereas the objective of the FMVSS No.214D is to reduce the risk of serious and fatal injury to occupants of passenger cars in side impact crashes, the primary purpose of NCAP side impact program is to provide consumers with the comparative vehicle side protection information in their vehicle purchase decision.

And this will thus provide incentives for vehicle manufacturers to design safer cars.

For all tests under this NCAP side impact test procedure, the contract laboratories are directed to use a special test parameter, which is an impact speed of 61 kph. This is 8 kph greater than the 53 kph impact test speed in the FMVSS No. 214D. This increased speed is specified in order that the NHTSA can obtain new car assessment and research data, and the 61 kph crash test will be viewed as “indicant tests” to the requirements of the FMVSS No. 214D.

3. SECURITY

The contractor shall provide appropriate security measures to protect the OCWS test vehicles, dummies, deformable honeycomb barrier face units and any 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 deformable honeycomb barrier units. Any security problems which arise shall be reported by telephone to the Industrial Property Manager (IPM), Office of Contracts and Procurement, within two working days after the incident. A letter containing specific details of the security problem will be sent to the IPM (with copy to the COTR) within 48 hours.

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 COTR, unless specifically authorized by the COTR or the COTR’s Branch or Division Chief.

The tested vehicles and tested honeycomb barrier faces, protected from the elements, shall be retained by the test contractor for a MINIMUM of 60 days so that OCWS personnel can be given an inspection opportunity.

NO INDIVIDUALS, OTHER THAN CONTRACTOR PERSONNEL DIRECTLY INVOLVED IN THE

TESTING PROGRAM, SHALL BE ALLOWED TO WITNESS ANY OCWS VEHICLE TEST UNLESS

SPECIFICALLY AUTHORIZED BY THE COTR. IT IS THE CONTRACTOR’S RESPONSIBILITY TO

SECURE THE TEST SITE AREA DURING A TEST AND TO SHIELD THE IMPACT AREA FROM THE

PUBLIC VIEW BY THE USE OF CANVAS OR OTHER BLOCKING DEVICES.

Rules for Contractors

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

II. All communications with vehicle manufacturers shall be referred to the OCWS. The contractor shall not release crash test data without the permission of the OCWS.

III. Unless otherwise specified, the vehicle manufacturer’s representative(s) shall only be authorized to visit the contractor’s test facility on the day that the test is scheduled, and the representative(s) must be escorted by OCWS and/or contractor personnel.

IV. 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.

V. 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 OCWS. The contractor’s personnel shall not respond to any questions from the manufacturer’s representatives regarding the OCWS test. All questions shall be referred to the COTR, an OCWS representative present at the test site, or to OCWS.

VI. The contractor shall permit public access to and inspection of the test vehicles and related data during the times specified by the OCWS COTR. OCWS 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 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 OCWS. The contractor shall make his own arrangements with interested parties for expenses incurred beyond providing access and inspection services.

4. 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.

5. TEST SCHEDULING AND MONITORING

The contractor shall submit a test schedule to the COTR prior to testing. Tests shall be completed as required in the contract. The 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. Scheduling shall be adjusted to permit the agency’s other sample motor vehicles to be tested as may be required by the OCWS. All testing shall be coordinated to allow monitoring by the COTR.

6. FACILITY AND EQUIPMENT - PRETEST REQUIREMENTS

6.1 SIDE IMPACT TEST SURFACE

The path of the target vehicle after being struck by the Moving Deformable Barrier (MDB) must be taken into consideration when determining an adequate smooth flat concrete area for the side impact test surface. All four wheels of the test passenger car and all four wheels of the MDB must fall in the same plane, and shall remain in the side impact testing surface area. The COTR should be notified and give prior approval if the test surface is configured such that one or more of the vehicles tires will contact a surface that is not concrete during the test.

6.2 TOW ROAD

The tow road surface must be straight, level, smooth and uniform construction. The tow road must have sufficient length to allow for stabilization of the MDB velocity (zero acceleration) prior to side impact with the test vehicle, and to allow time for the MDB to be stopped from test speed of 61.9 kph ± 0.8 kph in case of a test abort.

6.3 TEST VEHICLE PREPARATION BUILDING (applies to labs with out-door impact surfaces)

In order that the test vehicle can be prepared for side impact testing during hot or cold weather, a permanent wood or metal enclosure must be constructed which is large enough to house the test vehicle and allow for personnel movement around the test vehicle. The temperature inside of the test vehicle must be maintained between 18.9°C and 25.5°C for a minimum of four (4) hours prior to the side impact event. The test dummies shall be allowed to soak for 24 hours (in a controlled environment of 18.9°C to 25.5°C) prior to placement in test vehicle. The preparation enclosure must be removed prior to conducting the side impact test.

6. FACILITY AND EQUIPMENT - PRETEST REQUIREMENTS....Continued

6.4 MOVING DEFORMABLE BARRIER (MDB)

The contractor shall provide a moving deformable barrier (see Figure 1) as specified in FMVSS No. 214. A summary of MDB & honeycomb face details are provided as follows:

A. Total weight of MDB with impact face (for compliance purposes) shall be 1,361 ± 4.5 kg

[1,356.5 - 1,365.5] (configured MDB weight of 1,367.6 kg stated in P587.6(c) of the rule.

B. Overall length of MDB with impact face = 4,115 ± 25 mm

C. Overall length of MDB excluding impact face = 3,632 mm (includes 50.8 mm thick mounting block)

D. Overall width of framework carriage = 1,251 mm

E. Tracking width (centerline to centerline of front or rear wheels) = 1,880 mm

F. Wheelbase for framework carriage = 2,591 ± 25 mm

G. Inertial properties of the MDB (with two cameras and camera mounts and a light trap vane and ballast reduced); the center of gravity (CG) is as follows:

X = (1,123 ± 25) mm rear of front axle

Y = (7.6 ± 25) mm left of longitudinal centerline

Z = (500 ± 25) mm from ground

Moments of inertia (tolerance 5% for testing purposes) are as follows:

Pitch = 2,263 kg-m2

Roll = 508 kg-m2

Yaw = 2,572 kg-m2

H. Shape of honeycomb impact face

Width = 1,676 ± 6 mm

Height = 559 ± 6 mm

Ground Clearance = 279 ± 3 mm

Depth at Bumper Height = 483 ± 6 mm

Depth at upper impact face = 381 ± 6 mm

I. Force-deflection properties (crush strength) for honeycomb impact face shall be 310 ± 17 kpa and 1,690 ± 103 kpa for the bumper.

J. Position of four wheels on framework carriage = (27 ± 1) degrees

All Measurements in millimeters

FIGURE 1

6.5 TOW AND GUIDANCE SYSTEM

The tow system must be capable of ensuring that the Moving Deformable Barrier (MDB) shall impact the test vehicle at a speed of 61.9 ± 0.8 kph. The MDB shall be continuously towed up until 305 mm from impact (tolerance window of 610 mm to 152 mm). The tow cable attachment device must release from the tow cable within the tolerance window. The MDB velocity measurement shall be taken after cable release.

The cable attaching the MDB to the tow system shall be made from steel cable. The length of this cable shall not change significantly (± 25 mm) from test to test.

A lateral guidance system is required to assure that the MDB shall impact the side of the target or test vehicle at the designated angle even though the MDB is crabbed to an angle of 27 ± 1 degrees with the forward line of motion. It must also assure that the MDB impact the test vehicle within ± 50 mm of the vertical reference line, as specified in the standard.

VERTICAL IMPACT LINE

For passenger vehicles, the vertical impact reference line shown in (figure 2) is 940 mm ± 5 mm forward of the center of the test vehicles wheelbase when the test vehicle’s wheelbase ≤ 2,896 mm. If the wheelbase is greater than 2,896 mm, then the vertical impact reference line is 508 mm ± 5 mm rearward of the test vehicle’s front axle centerline.

For multipurpose vehicles (sport utility vehicles), light trucks, and vans, when the test vehicle’s wheelbase is ≤ 2,489 mm, the vertical impact line is 305 mm ± 5 mm rearward of the centerline of the test vehicles front axle. If the wheelbase is greater than 2,489 mm but less than 2,896 mm, then the vertical impact reference line is 940 mm ± 5 mm forward of the test vehicle’s wheelbase centerline. If greater than 2,896 mm then the vertical impact line is 508 mm ± 5mm rearward of the test vehicle’s wheelbase centerline.

NOTE: For different wheelbase versions of the same model vehicle the impact reference point may be found (at the manufacturers option) by the following: Select the shortest wheelbase vehicle of the different versions of the same model and locate on it the impact reference line as described above.

Measure the distance between the seating reference point and the impact reference line.

Maintain the same distance between the seating reference point and the impact reference line for the shortest wheelbase version of the model.

FIGURE 2

HORIZONTAL IMPACT LINE

The tow system shall be designed so that the MDB may consistently impact the target vehicle within ± 20 mm of the ideal horizontal impact line. See Section 11.4 for more details.

6.6 MOVING DEFORMABLE BARRIER (MDB) VELOCITY MEASUREMENT

The MDB shall impact the side of the target or test vehicle at the predetermined speed and the MDB’s velocity shall be approximately constant (zero acceleration) for the last 1.5 meters of crabbed forward motion before impact. The final velocity shall be measured after tow system release within 150 mm of impact (release window tolerance is 610 mm to 150 mm). The reported impact velocity shall take into consideration all of the response characteristics of the entire velocity measurement system utilized in its determination.

Impact velocity shall be measured by no less than two sets of timing devices such as photocells, break wires, laser beams, etc., and the timing devices shall be accurate to within ± 0.08 kph and be calibrated by an instrument traceable to the National Institute of Standards and Technology. Recorded values in these timing devices shall be permanently documented on film or photo.

6.7 MOVING DEFORMABLE BARRIER (MDB) BRAKE ABORT SYSTEM

The MDB shall be equipped with an onboard brake abort system. Abort criteria consists of MDB velocity, data acquisition and instrumentation system readiness, and stability of the MDB on the tow road. It is recommended that the first two criteria are to be automatically monitored by the test control system while the third is manually monitored by the test director. For added safety, a manual abort shall be available from start, until the point at which the MDB is impossible to stop without impacting the test vehicle.

6.8 ALUMINUM HONEYCOMB BARRIER FACE UNITS

The contractor has the responsibility of procuring certified aluminum honeycomb barrier face units from the honeycomb manufacture which meet the crush strength specifications required by the standard. Each honeycomb barrier will be used for only one test, thus the contractor shall procure one barrier face for each vehicle being tested plus one extra barrier face in case something unexpectedly happens to a barrier face. The contractor shall conduct detailed inspection of the honeycomb barrier for shipping damage. The contractor shall retain a copy of the barrier manufacturers test data used to certify the barrier face and make it available for review by the COTR. This shall consist of certification information for the 310 and 1,690 kpa barrier face portions. The contractor shall have the equipment or access to equipment that will allow them to test honeycomb samples according to the test procedure called out in Appendix III “Aluminum Honeycomb Crush Strength Certification”, to ensure the samples provided meet the requirements of the standard. See Page 1 of Appendix III for more details.

6.9 NOTIFICATION OF COTR

The COTR must be notified within 24 hours after a test vehicle or a group of certified aluminum honeycomb face units have been delivered.

NOTE: The tested vehicles and tested honeycomb barrier faces, protected from the elements, shall be retained by the test contractor for a MINIMUM of 60 days so that OCWS personnel can be given an inspection opportunity.

7. GOVERNMENT FURNISHED PROPERTY (GFP)

7.1 TEST VEHICLES

The Contractor has the responsibility of accepting test vehicles from either new car dealers or vehicle transporters. In both instances, the contractor acts in the OCWS’s behalf when signing an acceptance of test vehicles. If a vehicle is delivered by a dealer, 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. Spare tire, jack, lug wrench and tool kit (if applicable) is located in the vehicle cargo area.

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

A ‘Vehicle Condition’ form (refer to section 15) will be supplied to the contractor by the COTR when the test vehicle is transferred from the new car dealer or between test contracts. The upper half of the form describes the vehicle in detail, and the lower half provides space for a detailed description of the post test condition. Vehicle Condition forms must be returned to the COTR with the copies of the Final Test Report or the reports will NOT be accepted.

7.2 TEST DUMMIES

An adequate number of non-instrumented Part 572 Subpart F side impact test dummies (SIDs) and Part 572 Subpart M side impact dummies with hybrid three head and neck (SID/H3) will be furnished to the contract laboratory by the OCWS. 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 12.8°C and 29.4°C. The Contractor will check the dummy components for damage when performing the calibrations. The COTR will be kept informed of the dummies condition in order that replacement parts can be provided. The contractor shall keep a detailed record for each test dummy, describing parts replaced and the results of calibration tests. The government has the option to choose either the SID or the SID/H3 test dummy to use in a particular case, as determined by the COTR.

8. INSTRUMENTATION AND CALIBRATION REQUIREMENTS

8.1 GENERAL REQUIREMENTS

Before the Contractor initiates the OCWS test program, a test instrumentation calibration system will 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 to exceed twelve

(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.

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)

E. Records of calibration for all test instrumentation shall be kept by the contractor in a manner which 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. The calibration system will need the acceptance of the COTR before testing commences.

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

NOTE: In the event of a test failure (i.e. failure to meet FMVSS No. 214D performance requirements) or data anomaly, additional calibration checks of some critically sensitive test equipment and instrumentation may be required. The necessity for the calibration will be at the COTR’s discretion and will be performed without additional cost.

8.2 TEST DUMMY INSTRUMENTATION

The full vehicle test concept requires the use of human surrogates to determine the injury levels listed above.

The Part 572 Subpart F Side Impact Dummy (SID) and the Part 572 Subpart M Side Impact Dummy with Hybrid three head and neck (SID/H3) have been chosen as appropriate Anthropomorphic Testing Devices

(ATD).

The SID and SID/H3 are designed for lateral impacts. The basic design for the SID is derived from the Part 572 B dummy with a redesigned chest assembly and without arms. The chest assembly consists of 5 ribs with ballast plates to compensate for the arm weight. A hydraulic piston (damper) is laterally oriented between the ribs and spine on the struck side. The basic design for the SID/H3 is derived from the Part 572 F and the Part 572 E dummy. The dummy is similar to the SID with the exception of an instrumented head and neck. The SID and SID/H3 are generally configured for left side impact. For a right side impact, the damper must be rotated 180 degrees from the configured orientation. The test vehicle may be impacted on either side. The COTR will decide whether the test should be conducted on the left or right side.

The SID and SID/H3 will be instrumented with Endevco Model 7264-2000g uniaxial accelerometers (configured for Y axis sensitivity according to impact condition, redundant accelerometers are required and their locations are clearly indicated in the SID Users Manual) located in the following positions for a left side impact (see Figures 3 thru 5 on following pages):

A. Left Upper Rib (LUR)

B. Left Lower Rib (LLR)

C. Lower Spine (T12)

D. Pelvis Assembly (PEV)

E. For the SID/H3 Head accelerometers and Neck load cells should be installed as indicated in

Appendix 5 (Users manual for SID/H3 dummy).

8. INSTRUMENTATION AND CALIBRATION REQUIREMENTS....Continued

FIGURE 3

FIGURE 4

FIGURE 5

8.3 SIDE IMPACT DUMMY (SID) CALIBRATION

Dummy Configuration and Performance Verification Testing

All GFE Part 572 F test dummies shall be calibrated (pre and post-test) by the contractor ON-SITE using the procedures found in APPENDIX IA of this laboratory test procedure. For SID/H3 see APPENDIX IB.

All calibration data shall be recorded on the data sheets provided and submitted with the Final Test Report as outlined in section 13 of this test procedure.

The test dummies shall be clothed with form fitting cotton mid-calf length pants and short sleeve shirts during the calibration test and also during the NCAP test.

NOTE: The SID and SID/H3 shock absorber shall be calibrated prior to initiating the test program. It is not necessary to calibrate the shock absorber after every impact, but it shall be calibrated after 5 exposures or in the event there is a problem with obtaining acceptable calibration data for the upper or lower ribs.

8.4 DRAWING LIST FOR SIDE IMPACT DUMMY (SID)

In addition to the Part 572B drawings, OCWS COTR will provide the contractor, upon request, any or all of the following SID drawings. For SID/H3 part list see APPENDIX VI.

SID-002 - Lumbar (Molded) SID-003 - Lumbar Flange SID-004 - Thoracic Assembly SID-005 - Thorax to Lumbar Adaptor Assembly SID-006 - Lumbar Adaptor SID-007 - Thorax Assembly Bottom Plate SID-008 - Thorax Assembly Bottom Plate Locator SID-009 - Lower Thoracic Spine Accelerometer (T12) Mounting Platform SID-010 - Thorax Assembly Side Plate SID-011 - Thorax Assembly Front Block SID-012 - Thorax Assembly Back Block SID-013 - Thorax Assembly Top Plate SID-014 - Upper Thoracic Spine Accelerometer (T1) Base Plate SID-015 - Front Partition Plate --DELETED SID-016 - Rear Partition Plate --DELETED SID-017 - Side Plate Tapping Block -- DELETED SID-018 - Side Impact Rib Assembly SID-019 - Side Impact Rib (Steel Portion) SID-020 - Sternum Center Bar SID-021 - Sternum Plate (Urethane) SID-022 - Top and Bottom Sternum Bar SID-023 - Sternum Ballast SID-024 - Rib Bar SID-025 - Front Rib Ballast SID-026 - Rear Rib Ballast SID-027 - Rib Bar Right Side Ballast SID-028 - Rib Bar Left Side Ballast SID-029 - Rib Ballast Cushion SID-030 - Rib Reinforcement SID-031 - Sternum Ballast Upper and Lower Washer Bar SID-032 - Rib Cage Support Angle SID-033 - Rib Attaching Hinge SID-034 - Hinge Mounting Block SID-035 - Rib Cage to Hinge Bar SID-036 - Upper Thoracic Spine Accelerometer (T1) Plate SID-037 - Upper Thoracic Spine Accelerometer (T1) Mount SID-038 - Lower Thoracic Spine Accelerometer (T12) Mount SID-039 - Lower Thoracic Spine Accelerometer (T12) Cover SID-040 - Rib Wrap Assembly SID-041 - Outer Rib Pad SID-042 - Inner Rib Pad

SID-043 - Rib Bar Washer Strip SID-046 - Anti-bottoming Pad Spacer -- DELETED SID-047 - Rib Routing Tube -- DELETED SID-048 - Upper Thoracic Spine Accelerometer (T1) Routing Tube --DELETED SID-049 - Lower Thoracic Spine Accelerometer (T12) Routing Tube --DELETED SID-050 - Middle Shoulder Foam SID-051 - Upper Shoulder Foam SID-052 - Lower Shoulder Foam SID-053 - Rib Cage General Layout SID-054 - Shock Absorber (Damper) Gate SID-055 - Shock Absorber (Damper) Pivot Pin SID-056 - Shock Absorber Mounting Frame SID-057 - Shock Absorber Support Angle SID-058 - Shock absorber Mount Nylon Washers SID-059 - Potentiometer Mounting Bracket and Ring -- OPTIONAL SID-060 - Shock Absorber Cap and Rod End -- DELETED SID-061 - Shock Absorber to Rib Bar Attaching Shaft and Spacer SID-062 - Shock Absorber to Rib Bar Attaching Clevis SID-063 - Shoulder Plate SID-064 - Rib Cage Support Details SID-065 - Outer Skin Zipper Assembly SID-066 - Outer Skin SID-067 - Front Zipper Assembly SID-068 - Rear Zipper Assembly SID-069 - Arm Foam SID-070 - Tapered Socket Head Bolt Listing SID-071 - Socket Head Bolt Listing SID-072 - Flat Head Socket Bolt Listing SID-073 - Machine Screw Listing SID-074 - Hex Nut Listing SID-075 - Washer Listing SID-076 - Lower Rib Bar Accelerometer Mount --DELETED SID-077 - Shock Absorber Rod End SID-078 - Upper Knee Post SID-079 - Lower Knee Post

SID-081 - DELETED

SID-082 - DELETED

SID-083 - Thoracic Shock Absorber Test Procedure and Specifications SID-084 - Rib Ballast Nut Plate SID-085 - Rib Bar Cushion

SID-086 - DELETED

SID-087 - Pelvis Structure and Flesh Assembly (2 Pages) SID-088 - Lumbar Pelvic Adaptor SID-089 - Linear Potentiometer -- OPTIONAL SID-090 - SID Pelvic Accelerometer-- Mount

8.5 TEST VEHICLE INSTRUMENTATION

FIGURE 6

The following accelerometers shall be attached to the test vehicle (see Figure 6 above).

#1 Triaxial accelerometer mounted on the opposite side to the impacted side sill at the front seat to provide Ax, Ay and Az data.

#2 Triaxial accelerometer mounted on the opposite side to the impacted side sill at the rear seat to provide

Ax, Ay and Az data.

#3 Triaxial accelerometer mounted on the rear floorpan above the axle to provide Ax, Ay and Az data.

#4 Uniaxial accelerometer mounted on the impacted side sill in line longitudinally with the center of the widest portion of the rear door and located under the sill inward of pinch welds to provide Ay data.

#5 Uniaxial accelerometer mounted on the impacted side sill in line longitudinally with the center of the widest portion of the front door and located under the sill inward of pinch welds to provide Ay data.

#6* Uniaxial accelerometer mounted on the impacted front door on the centerline and approximately 430 mm above the ground to provide Ay data.

#7 Uniaxial accelerometer mounted in the rear occupant compartment to provide Ay data.

#8* Uniaxial accelerometer mounted mid-rear of the impacted front door and 430 mm above the ground to provide Ay data.

#9* Uniaxial accelerometer mounted on the impacted front door upper centerline and approximately 685 mm above the ground to provide Ay data.

#10* Uniaxial accelerometer mounted mid-rear of the impacted rear door and approximately 685 mm above the ground to provide Ay data.

#11* Uniaxial accelerometer mounted on the impacted rear door upper centerline approximately 685 mm above the ground to provide Ay data.

#12 Uniaxial accelerometer mounted on the impacted lower B-Post (located 1/3 the distance from the floor to the bottom of the doors window opening) to provide Ay data.

#13 Uniaxial accelerometer mounted on the impacted middle B-Post (located 2/3 the distance from the floor to the bottom of the doors window opening) to provide Ay data.

#14 Uniaxial accelerometer mounted on the impacted lower A-Post (located 1/3 the distance from the floor to the bottom of the doors window opening) to provide Ay data.

#15 Uniaxial accelerometer mounted on the impacted middle A-Post (located 2/3 the distance from the floor to the bottom of the doors window opening) to provide Ay data.

#16 Uniaxial accelerometer mounted on the front seat track nearest the impacted door and approximately aligned with the dummy’s H-point to provide Ay data.

#17 Uniaxial accelerometer mounted on the rear seat structure (if easily accessible) nearest the impacted door and approximately aligned with the dummy’s H-point to provide Ay data.

#18 Triaxial Accelerometer mounted on the floor at the vehicle CG to collect Ax, Ay, and Az data.

NOTE: Installation of these accelerometers (6, 8, 9, 10, 11) shall follow instructions provided by vehicle manufacturers. Otherwise, consult with COTR for direction and final decision.

8.6 MOVING DEFORMABLE BARRIER (MDB) INSTRUMENTATION

A. The following accelerometers mounted at the MDB’s center of gravity to provide Ax, Ay and Az data -- refer to Figure 7 below.

B. Bi-axial accelerometers shall be mounted on the left side of the frame member along the rear axle centerline to provide Ax and Ay data.

C. Contact switches shall be installed on the right and left side of the MDB honeycomb Bumper. Note these two switches are in addition to the one installed on the test vehicle.

FIGURE 7

NOTE: Accelerometer #2 is placed on the left side of MDB for an impact into the left (driver) side of a test vehicle and is placed on the right side of the MDB when impacting the right (passenger) side of the test vehicle.

9. PHOTOGRAPHIC DOCUMENTATION

Each 61 kph side impact test shall be documented on 16 mm color movie film at a minimum speed of 1,000 frames-per-second (fps) 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 must be registered on the film edge a minimum of every 10 milliseconds (ms) and a time zero impact mark must be registered on the film to indicate when contact is made in order to permit vehicle and dummy kinematic analysis on a film analyzer.

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

The contractor shall report the locations of all cameras along with camera speeds and lens focal lengths on the appropriate final report data sheet. Camera locations shall be referenced to the target vehicle struck side and the leading edge of the MDB with the X, Y and Z coordinates of the lens recorded for each camera.

FIGURE 8

9. PHOTOGRAPHIC DOCUMENTATION....Continued

9.1 GROUND BASED CAMERAS REQUIRED (refer to Figure 8, preceding)

(1) Camera No. 1 -- high-speed overhead camera to view target vehicle dynamics and positioned directly above the impact plane between the target vehicle and the MDB.

(2) Camera No. 2 -- high-speed overhead camera to provide close-up view of the impact plane

(should include view of photo targets on centerline of test vehicle and photo targets on top of MDB barrier face) and positioned adjacent to Camera No. 1.

(3) Camera No. 5 -- high-speed right side view camera to cover both the MDB and the target vehicle during the side impact event.

(4) Camera No. 6 -- high-speed left side view camera to cover the motion of the target vehicle after impact.

(5) Camera No. 10 -- real-time (24 fps) camera to provide pretest, test, and post test coverage.

9.2 MOVING DEFORMABLE BARRIER (MDB) ON-BOARD CAMERAS REQUIRED

(1) Camera No. 3 -- high-speed camera positioned along the impact face’s left vertical edge to cover target vehicle impact point during side impact event.

(2) Camera No. 4 -- high-speed camera positioned on MDB’s centerline to view struck side of test vehicle during the side impact event.

9.3 TEST VEHICLE ONBOARD CAMERAS REQUIRED

(1) Camera No. 7 -- high-speed camera to provide front view of the front SID through the vehicle’s windshield from above the engine compartment.

(2) Camera No. 8 -- high-speed camera to view across the test vehicle’s occupant compartment to record the lateral motion of the front dummy during and after side impact.

(3) Camera No. 9 -- high-speed camera to view across the test vehicle’s occupant compartment to record the lateral motion of the rear dummy during and after side impact.

9.4 COLORING REQUIREMENTS FOR PHOTOGRAPHIC PURPOSES:

A. Vehicle interior surfaces such as the A, B, C-posts and trim panels, impacted interior door trim panels, etc., shall be painted with flat white paint. The area around the steering hub and instrument panel where air bag deploys, if so equipped, shall NOT be painted. In addition, the air bag indicator light on the dash shall NOT be painted so as to be visible prior to testing.

B. Parts of the driver and passenger dummies shall be coated with colored chalk/water solutions to show contact points with the vehicle’s door and interior components. The chalk/water solution shall be applied after final dummy positioning.

CHALK COLORS TO BE USED ON TEST DUMMIES

DUMMY PART DRIVER PASSENGER

Face

Blue

Red

Top of Head

Yellow

Back of Head

Left Hip

Left Shoulder

9.5 VEHICLE AND DUMMY PHOTOGRAPHIC COVERAGE (REAL-TIME)

The real-time camera (24 fps) shall be used to document the pretest and post test condition of the test vehicle and MDB in addition to the pretest and post test positions of both test dummies including the placement of the lap and shoulder belts on these dummies. 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 MARKERS

It is strongly recommended that in-camera light emitting diodes (LEDS) be used to record the side impact event time zero point. If this is not possible, strobe lights or taped flash bulbs shall be placed in the field-of-view of all nine high-speed cameras to mark the time zero point. The contractor shall use pressure switches attached to the test vehicle or MDB’s impact face in order to trigger the time zero indicators.

9.7 PHOTOGRAPHIC TARGETS AND TAPE FOR MDB AND TEST VEHICLE

FIGURE 9

A. Twenty-five millimeter (1”) wide yellow/black checkerboard tape shall be placed along the struck side of the test vehicle (as shown in Figure 9) and at the following five levels above the ground surface --

(1) LEVEL 1 -- axle centerline height (or side sill top height)

(2) LEVEL 2 -- occupant H-Point height

(3) LEVEL 3 -- mid-door height

(4) LEVEL 4 -- window sill height

(5) LEVEL 5 -- top of window height

In addition, the tape will be used to mark the longitudinal and vertical impact lines on the struck side of vehicle. This tape should be extended across the hood or cowl top of the vehicle (90° angle to the vehicle longitudinal centerline) to provide a reference line for the overhead film coverage (tape will be aligned with two MDB left side frame targets to verify 90° impact angle).

B. Photographic targets [102 mm diameter (4”)] shall be placed on the struck side of the test vehicle every 300 mm along the LEVEL 4 tape line and at the front top left side and rear top left side of the MDB frame.

C. Other targets shall be placed on the test vehicle as shown in Figure 9.

D. Tape shall be placed on the barrier face as shown on in Figure 10.

E. CG marker and other known location markers shall be visible on the MDB in the overhead view.

F. Photographic targets [102 mm diameter (4”)] shall be placed on the MDB at the rear cross member accelerometer location on the left side of the frame.

G. Tape on top left surface of honeycomb barrier and tape on top of test vehicle along impact line will be used to document initial impact location.

H. Two [102 mm (4”)] diameter targets will be placed on top of barrier face 400 mm from barrier centerline.

FIGURE 10

9.8 TARGET VEHICLE INFORMATION PLACARDS

Test vehicle identification placards shall be positioned so that at least one placard will be visible in each of the 10 camera’s field of view. The following information shall be shown:

A. Target vehicle’s NHTSA number

B. The words “55/28 kph 90° NCAP Side Impact”

C. Date of the side impact test

D. Name of contract laboratory

E. Vehicle year, make and model

9.9 CRASH FILM TITLE HEADING & SEQUENCE:

The contractor shall submit 3 copies of the 16mm color movie film for each crash test two weeks from the date 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 OCWS upon request.

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

A. The following NCAP Side Impact Test was conducted under the contract with the National

Highway Traffic Safety Administration by (laboratory name, city, state).

B. 55/28 kph 90° NCAP SIDE IMPACT (MOVING DEFORMABLE BARRIER) Test Vehicle Model Year, Make and Model NHTSA No. MXXXXX Date of Impact Event Contract No.: DTNH22-0X-X-XXXXX

C. The ending frame shall state “THE END”.

The film shall be edited in the following sequence:

1. Title

2. Pretest Coverage

3. Real Time Pan Coverage

4. All high speed coverage

5. Post test Coverage

6. Any vehicle failures or anomalies

7. “The End”

9.10 STILL PHOTOGRAPHS

Photographs shall be color, 203 mm x 254 mm (8” x 10”), and legible. A tag, label or placard identifying the test vehicle model as well as the deformable barrier and NHTSA number, if applicable, shall appear in each photograph and be legible. The test vehicle and deformable barrier shall show the test date. Each photograph shall be labeled as to subject matter. As a minimum the following photographs shall be included:

A. Pretest and post test frontal views of the target vehicle

B. Pretest and post test rear views of the target vehicle

C. Pretest and post test side views of the struck side of the target vehicle showing initial contact point longitudinally and vertically on the target vehicle

D. Pretest close-up view of welding rod impact point

E*. Pretest and post test frontal views of the impactor face

F*. Pretest and post test left side views of the impactor face

G*. Pretest and post test right side views of the impactor face

H*. Pretest and post test top views of the impactor face

I. Pretest overhead view of the MDB positioned against the side of the target vehicle at the ideal impact point

J. Pretest and post test occupant compartment views showing the SID positions and the available clearance between the dummy and the struck door, as well as positions of belt restraints (photographs with door closed and with door open)

K. Pretest left side view of MDB with impact face in position

L. Pretest right side view of MDB with impact face in position

M. Post test close-up view of impact point target showing impact location

N. Pretest view of MDB showing (right and left side) contact switches in place

O. Pretest and post test views of front inner door panel

P. Pretest and post test views of rear inner door panel

Q. Close-up view of vehicle’s certification label

R. Close-up view of vehicle’s tire information placard or label

S. Post test overhead view of the MDB and the target vehicle

* - These photographs of the impactor face shall be taken with the impactor face placed on a checkerboard background (see Figures 11 & 12).

FIGURE 11