NCAP CRS Test Procedure.pdf

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U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FOR

NEW CAR ASSESSMENT PROGRAM

CHILD RESTRAINT SYSTEM RESEARCH TESTING

September 2011

RULEMAKING

Office of Crashworthiness Standards Mail Code: NVS-111

1200 New Jersey Avenue, SE Washington, DC 20590

Note: This test procedure is to be supplemented with and serves as an addendum to related NCAP test procedures. This supplement addresses only the CRS-related matters. The procedures for carrying out individual NCAP tests remain unchanged.

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REVISION CONTROL LOG

FOR

NCAP LABORATORY TEST PROCEDURES

CHILD RESTRAINT SYSTEMS RESEARCH TEST

TEST PROCEDURE

DESCRIPTION REV.

No.

DATE

AMENDMENT

EFFECTIVE

DATE

00 09/01/2011 09/01/2011 Procedure overhauled from previous version and implemented in NCAP iii

NCAP CHILD RESTRAINT SYSTEMS RESEARCH

Laboratory Test Procedure

TABLE OF CONTENTS

PAGE

1. PURPOSE AND APPLICATION

2. GENERAL REQUIREMENTS

2.1 Applicability

2.2 Applicable Tests

2.3 Metric System of Measurement

3. MISCELLANEOUS REQUIREMENTS

4. CALIBRATION OF TEST INSTRUMENTS

5. DEFINITIONS

6. PHOTOGRAPHIC DOCUMENTATION

6.1 Digital Photographs

6.2 Photographic Views

6.3 Real-Time Documentation Video

6.5 Coloring Requirements for Photographic Purposes

6.9 Dummy Targeting

7. PRE-TEST REQUIREMENTS

7.1 Detailed Test and Quality Control Procedures Required

8. TEST EXECUTION

8.1 General Test Conditions

8.2 Operating in-House CRS Test Procedure

8.3 General NCAP CRS Research Test Guidelines

8.4 General NCAP CRS Installation Guidelines

A. Rear-Facing LATCH Installations B. Rear-Facing Seat Belt Installations D. Forward-Facing LATCH Installations E. Forward-Facing Seat Belt Installations F. ATD Positioning: Forward-Facing Installations G. Booster Seat Installations H. ATD Positioning: Booster Seat Installations

8.5 Dummy Measurement Guidelines

A. Measurements for Rear-Facing CRS Research Tests B. Measurements for Forward-Facing CRS Research Tests

9. REPORTS

9.1. Notice of Test Anomaly

9.2. Deliverable Requirements

A. FTP Website B. QuickLook Report C. Quality Control Package D. Draft Test Report E. Final Test Report and Deliverables

9.3. Test Report Requirements

A. Cover Page B. First Page After Cover Page iv

C. Second Page After Cover Page D. Table of Contents E. Test Purpose and Procedure F. Summary of Test Results G. Data Sheets H. Appendix A - Photographs I. Appendix B – Dummy Response Data J. Appendix C – Other Documentation K. Appendix D– ATD Calibration Information L. Appendix E – Test Equipment List and Calibration Information

1. PURPOSE AND APPLICATION

This document is a laboratory test procedure provided by the National Highway Traffic Safety Administration (NHTSA), Office of Crashworthiness Standards (OCWS) for the purpose of presenting guidelines for a uniform testing data and information recording format, and providing suggestions for the use of specific equipment and procedures for contracted testing laboratories. The data correspond to information gathered from child system restraint (CRS) research testing that may be conducted in conjunction with New Car Assessment Program (NCAP) crash tests. The OCWS test procedure is not intended to limit or restrain a contractor from developing or utilizing any testing techniques or equipment that will assist in procuring the required test data. The laboratory test procedure does not constitute an endorsement or recommendation for use of any particular product or testing method. However, applicability of any such testing technique or equipment is subject to prior approval by the Contracting Officer’s Technical Reporesentative (COTR).

If any contractor views any part of the OCWS laboratory test procedure to be in conflict with accepted child restraint system installation techniques or observes deficiencies in the laboratory test procedure, the Contractor is required to advise the COTR and resolve the discrepancy prior to the start of indicant testing or as soon as practicable.

NOTE: This OCWS Laboratory Test Procedure, prepared for the limited purpose of use by independent laboratories under contract to conduct research tests for the New Car Assessment Program (NCAP), are not rules or regulations. In addition, the laboratory test procedure may be modified by the OCWS at any time without notice, and the COTR may direct or authorize contractors to deviate from these procedures, as long as the tests remain within the scope of the contract.

2. GENERAL REQUIREMENTS

This laboratory test procedure provides guidelines for CRS installation and the collection of information regarding their testing in NCAP vehicles for the purposes of research only. There are no minimum performance requirements or any Federal Motor Vehicle Safety Standard (FMVSS)-related requirements associated with the information specifically collected during this testing besides FMVSS calibration requirements related to the specific child dummies, if instrumented. In the absence of instrumentation, visual inspection of the child dummy parts per the calibration procedure is still required.

2.1 Applicability

This procedure is applicable to tests where CRS and child anthropomorphic test devices (ATDs or “dummies”) are installed in vehicles otherwise being tested for NCAP rating purposes, at the discretion of the COTR.

2.2 Applicable Tests

Vehicles will be primarily tested to the requirements contained herein in conjunction with the dynamic requirements for frontal, side moving deformable barrier (MDB), and side pole NCAP tests. The CRS-related research testing may not interfere with the laboratory’s ability to meet the requirements set forth in the related procedures for any of the governing NCAP barrier tests. Also, the test facility must be adequate to conduct the governing NCAP dynamic tests as described in their related test procedures. The facility must meet the minimum requirements regarding weighing capability, speed measurement systems, test surface, tow-road, abort system, barriers, and all other requirements, regardless of the addition of CRS for research testing.

2.3 Metric System of Measurement

Section 5164 of the Omnibus Trade and Competitiveness Act (Pub. L. 100-418) establishes that the metric system of measurement is the preferred system of weights and measures for trade and commerce in the United States. Executive order 12770 directs Federal agencies to comply with the Act by converting regulatory standards to the metric system after September 30, 1992. In a final rule published on March 15, 1990 (60 FR 13639), NHTSA completed the first phase of metrication, converting English measurements in several regulatory standards to the metric system. Since then, metrication has been applied to other regulatory standards (63 FR 28912) and will be applied to data collection related to this research procedure.

Accordingly, this OCWS laboratory test procedure includes revisions to comply with governmental directives in using the metric system. For any testing equipment that is not available for direct measurement in metric units, the test laboratory shall calculate the exact metric equivalent by means of a conversion factor carried out to at least five significant digits before rounding consistent with the specified metric requirement.

All final NCAP test reports are required to include metric measurements.

NOTE: The methodology for rounding measurement in the test reports shall be made in accordance with ASTM E29-06b, “Standard Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications.”

3. MISCELLANEOUS REQUIREMENTS

Requirements such as SECURITY, GOOD HOUSEKEEPING, TEST SCHEDULING AND MONITORING, TEST DATA DISPOSITION, and GOVERNMENT FURNISHED PROPERTY should be followed per the corresponding NCAP test procedure.

4. CALIBRATION OF TEST INSTRUMENTS

Before the Contractor initiates the CRS research test program within NCAP, a test instrumentation calibration system must be implemented and maintained in accordance with established calibration practices. In addition to the requirements set forth in the CALIBRATION OF TEST INSTRUMENTS section of the corresponding NCAP test procedure, the calibration system shall include a minimum of the following:

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

B. All measuring instruments and standards applicable to this test shall be calibrated by the Contractor, or a commercial facility, against a higher order standard at periodic intervals not exceeding 12 months for instruments and 12 months for the calibration standards except for static types of measuring devices such as rulers, weights, etc., which shall be calibrated at periodic intervals not exceeding two years. 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 shall 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.

F. All such records shall be readily available for inspection when requested by the COTR. The calibration system shall need the acceptance of the COTR before NCAP testing commences.

G. Test equipment shall receive a system functional check out using a known test input immediately before and after the test. This check shall be recorded by the test technician(s) and submitted with the Final Test Report.

H. Anthropomorphic test devices (ATDs) shall be calibrated before and after every NCAP test. The calibrations and calibration check shall be submitted with the final report.

NOTE: In the event instrumentation is used, and an ATD body region exceeds injury criteria outlined for that ATD per FMVSS 213, that region on the ATD must be recalibrated, even though the results are only intended for research purposes.

5. DEFINITIONS

ADD-ON CHILD RESTRAINT SYSTEM

Any portable child restraint system.

BACKLESS CHILD RESTRAINT SYSTEM

A child restraint other than a belt-positioning seat, that consists of a seating platform that does not extend up to provide a cushion for the child’s back or head and has a structural element designed to restrain forward motion of the child’s torso in a forward impact.

BELT-POSITIONING SEAT

A child restraint system that positions a child on a vehicle seat to improve the fit of a vehicle Type II belt system on the child and that lacks any component, such as a belt system or a structural element, designed to restrain forward movement of the child’s torso in a forward impact.

BOOSTER SEAT

A child restraint that is either a backless child restraint system or a belt-positioning seat.

CHILD RESTRAINT ANCHORAGE SYSTEM

See “LATCH”

CHILD RESTRAINT SYSTEM

Any device, except Type I or Type II seat belts, designed for use in a motor vehicle or aircraft to restrain, seat, or position children who weigh 30 kg (66 pounds) or less.

CONTACTABLE SURFACE

Any child restraint system surface (other than that of a belt, belt buckle, or belt adjustment hardware) that may contact any part of the head or torso of the appropriate test dummy, specified in S7, when a child restraint system is tested in accordance with S6.1 of FMVSS 213.

FACTORY-INSTALLED BUILT-IN CHILD RESTRAINT

A built-in child restraint system that has been or will be permanently installed in a motor vehicle before that vehicle is certified as a completed or altered vehicle in accordance with part 567 of 49 CFR Chapter 5, certification requirements for passenger vehicles.

HARNESS

A combination pelvic and upper torso child restraint system that consists primarily of flexible material, such as straps, webbing or similar material, and that does not include a rigid seating structure for the child.

LATCH

Lower Anchorages and Tethers for Children. A vehicle system that is designed for attaching a child restraint system to a vehicle at a particular designated seating position, consisting of: (a) Two lower anchorages meeting the requirements of S9, FMVSS No. 225; and (b) A tether anchorage meeting the requirements of S6, FMVSS No. 225. Hooks on the child restraint system are connected to anchor points that are specifically designed for their attachment.

REAR-FACING CHILD RESTRAINT

A child restraint system, except a car bed, that positions a child to face in the direction opposite to the normal direction of travel of the motor vehicle.

TETHER ANCHORAGE

A user-ready, permanently installed vehicle system that transfers loads from a tether strap through the tether hook to the vehicle structure and that accepts a tether hook.

TETHER STRAP

A strap that is secured to the rigid structure of the seat back of a child restraint system, and is connected to a tether hook that transfers the load from that system to the tether anchorage.

TETHER HOOK

A device, illustrated in Figure 11 of Standard No. 213 (§ 571.213), used to attach a tether strap to a tether anchorage.

TORSO

The portion of the body of a seated anthropomorphic test device, excluding the thighs, that lies between the top of the child restraint system seating surface and the top of the shoulders of the test dummy.

6. PHOTOGRAPHIC DOCUMENTATION

6.1 Digital Photographs

Clear and properly focused digital, color still photographs shall be taken to document the test. Glare or light from any illuminated or reflective surface should be minimized while taking photographs. A tag, label, or placard identifying the test item, NHTSA number (if applicable), date, and whether the photograph was taken prior to the dynamic NCAP test (pre-impact), after the dynamic NCAP barrier test (post-impact), shall appear in each photograph and be legible.

Photographs that are approximately 4 in. x 6 in. (at a minimum) shall be included in the test reports. Two photographs shall be provided on each page and each photograph shall be labeled as to the subject matter in accordance with the list below.

All digital still photographs provided shall be in color, shall include a time/date stamp, shall have a minimum resolution of 1,600 x 1,200 pixels, shall be in a .JPG format, shall be numbered and properly labeled as specified below, and should be posted to the established FTP site as part of the QCPackage.zip file required for the governing NCAP barrier test. The Contractor shall create a separate folder titled “CHILD RESTRAINT RESEARCH” within the QCPackage.zip file, which should contain the required photographs.

Additional photographs should be provided, as necessary, to document test details, a test anomaly, or test failure, and should be organized in a logical succession. Such supplemental photographs shall follow the list of required photographs in numerical order. Alternatively, if more than one photograph is taken for any of the requested views required in the list of photographs included below; such additional photographs can be similarly numbered and labeled in accords with the following numbering convention: No. 00X(a), No. 00X(b), No.

00X(c), etc. Any failure to meet test requirements shall be documented by photographs that are taken at various angles to assure complete coverage.

6.2 Photographic Views

As a minimum, the following test photographs for each CRS installed in the rear seat of an NCAP vehicle shall be included in each vehicle test report submitted by the Contractor. Additional photographs, in the event of anomalies, etc., should be appended to the end of this list and labeled accordingly. Text in italics is for descriptive purposes and need not be included in the photo title.

No. 001 – P# CRS Manufacturer’s Label

(Model and date of manufacture at a minimum should be evident) No. 002 – P# CRS Other Label

(Any other identifying labels found on the CRS such as serial number, lot, etc.)

No. 003 - Pre-Test Frontal View of P# CRS No. 004 - Post-Test Frontal View of P# CRS No. 005 - Pre-Test Rear View of P# CRS No. 006 - Post-Test Rear View of P# CRS No. 007 - Pre-Test Right Side View of P# CRS No. 008 - Post-Test Right Side View of P# CRS No. 009 - Pre-Test Left Side View of P# CRS No. 010 - Post-Test Left Side View of P# CRS No. 011 - Pre-Test View of P# Dummy/CRS Proximity to Seat in Front

(For RF CRS, some indication of how close the leading edge of the CRS or the dummy’s head is to the seat in front should be captured.

For FF CRS/boosters, some indication of how close the dummy’s feet are to the seat in front should be captured)

No. 012 - Post-Test View of P# Dummy/CRS Proximity to Seat in Front (For RF CRS, some indication of how close the leading edge of the CRS or the dummy’s head is to the seat in front should be captured.

For FF CRS/boosters, some indication of how close the dummy’s feet are to the seat in front should be captured)

No. 013 - Pre-Test Front View of P# CRS, Dummy Head (Dummy head and upper portion of seat belt/harness position, including clip, should be shown)

No. 014 - Post-Test Front View of P# CRS, Dummy Head (Dummy head and upper portion of seat belt/harness position, including clip, should be shown)

No. 015 - Pre-Test Front View of P# CRS, Dummy Torso (Dummy torso and lower portion of seat belt/harness position should be shown)

No. 016 - Post-Test Front View of P# CRS, Dummy Torso (Dummy torso and lower portion of seat belt/harness position should be shown)

No. 017 - Pre-Test View of P# Dummy’s Legs/Feet No. 018 - Post-Test View of P# Dummy’s Legs/Feet No. 019 - Pre-Test P# Outboard View

(Taken with doors open, outboard of the installed CRS in question, perpendicular to the CRS)

No. 020 - Post-Test P# Outboard View (Taken with doors open, outboard of the installed CRS in question, perpendicular to the CRS)

No. 021 - Pre-Test P# Outboard Angle View (Taken with doors open, outboard of the installed CRS in question, at angle to the CRS so that the front of the dummy can be seen)

No. 022 - Post-Test P# Outboard Angle View (Taken with doors open, outboard of the installed CRS in question, at angle to the CRS so that the front of the dummy can be seen)

No. 023 - Pre-Test P# Outboard Window View (Taken with doors closed, through window, outboard of the installed CRS in question)

No. 024 - Post-Test P# Outboard Window View (Taken with doors closed, through window, outboard of the installed CRS in question)

No. 025 - Post-Test P# Other Contact 1 (If needed, document other dummy-vehicle contact not covered in the preceding photos)

No. 026 - Post-Test P# Other Contact 2 (If needed, document other dummy-vehicle contact not covered in the preceding photos)

NOTE: The numbering convention shown above must be maintained. It is deliberate and intended to keep the photographs in a specific order when sorting photographs electronically. For the Quality Control Package file, photographs should be labeled with a minimum of the numbering convention shown here; when the final deliverables are submitted, however, the photographs should also be labeled with the text descriptions provided.

NOTE: The test laboratory’s name or logo shall not appear in any photographs.

6.3 Real-Time Documentation Video

As part of the real-time documentation video required for each NCAP barrier test, any CRS and their ATDs should be made visible before and after the impact, with the doors both open and closed. See the test procedure for the accompanying crash test for the requirements specific to each documentation video.

6.4 High-Speed Video Documentation

The appropriate mounting locations for documenting the movement of CRS in NCAP tests will be largely dependent upon the type of governing NCAP test.

Their location will be additionally dependent upon the number and location of CRS being installed in the vehicle. The following are some general guidelines for camera locations used specifically for CRS coverage in each governing NCAP test

A. Frontal NCAP

Camera locations will be at the discretion of the COTR and may change depending on the type and locations of CRS as well as types of ATD.

Footage MUST BE collected at a minimum rate of 1000 fps. In most cases, if two outboard CRS are installed, cameras will be mounted on each rear outboard window sill such that the movement of the ATD and CRS installed on the opposite side of the vehicle can be seen. In addition, two off-board cameras that would otherwise be positioned for normal Frontal NCAP testing can be positioned so that they also capture the movement of each CRS and ATD. In this case, cameras normally used for the steering wheel camera views may be used to document the child ATD movement, provided the cameras can record 1000 fps.

B. Side MDB NCAP depending on the type and locations of CRS as well as types of ATDs.

Footage MUST BE collected at a minimum rate of 1000 fps. CRS installed in NCAP Side MDB tests will normally be on the non-struck side of the vehicle. At a minimum, the onboard rear passenger camera should be positioned so that it captures not only the rear passenger on the struck side of the vehicle but the CRS and ATD on the non-struck side as well.

At the guidance of the COTR, cameras may also be mounted from the roof at locations amenable to the type of CRS and/or ATD being used.

C. Side Pole NCAP depending on the type and locations of CRS as well as types of ATDs.

Footage MUST BE collected at a minimum rate of 1000 fps. CRS installed in NCAP Side Pole tests may be located in any rear seat location.

At a minimum, an onboard camera should be positioned on the non-struck side of the vehicle so that it captures any CRS and ATDs installed in the rear seat. At the guidance of the COTR, cameras may also be mounted from the roof at locations amenable to the type of CRS and/or ATD being used.

6.5 Coloring Requirements for Photographic Purposes

A. The governing NCAP test procedure should describe the painting requirements for both the interior and underbody. Rear seat vehicle interior surfaces can be painted with flat white paint to better view child ATD contact locations.

B. Parts of the anthropomorphic testing devices 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. Because the types and locations of child ATDs tested under research in NCAP will vary, the following color schemes are simply suggestions. The laboratory should have a minimum of four (4) chalk colors available for use. Discretion should be used when painting ATD body parts that have the potential to come in contact with one another or a common surface during an event. The following color schemes should be adjusted accordingly.

CHALKING SCHEME FOR REAR-FACING CHILD TEST DUMMIES

Dummy Part Position P3 Position P4 Top of Head Color 1 Color 3

Face Color 2 Color 4 Left Foot Color 3 Color 1

Right Foot Color 4 Color 2

CHALKING SCHEME FOR FORWARD-FACING CHILD TEST DUMMIES

Dummy Part Position P3 Position P4 Top of Head Color 1 Color 3

Face Color 2 Color 4 Back of Head Color 3 Color 2

Left Knee Color 3 Color 2 Right Knee Color 4 Color 1 Left Foot Color 4 Color 1

Right Foot Color 3 Color 2

6.6 Child Dummy Calibration

The child dummies used in the CRS tests shall be certified prior to their test program, and before and after every research test they are being used in. ATDs must also be calibrated if injury levels exceed any established Injury Assessment

Reference Value (IARV) limits, or the dummy has been in storage for thirty (30) days or more during a testing program. The dummy part or parts exceeding the injury limit will be re-certified prior to the next test. The dummies will be visually inspected prior to each test once the program begins. If instrumentation is provided and to be used in these research tests, dummy calibration shall be conducted according to the following 49 CFR 572 requirements:

Dummy Size 49 CFR 572 Calibration Procedure 12 Month Old Subpart R

3 Year Old Subpart P 6 Year Old, Unweighted Subpart N 6 Year Old, Weighted Subpart S

10 Year Old To Be Provided by COTR

6.7 Instrumentation

Unless otherwise instructed, the contractor should record data from all instrumentation the child ATDs are supplied with. In some cases, child ATDs may arrive uninstrumented. The following table contains the channels each child ATD is most likely to be instrumented to record.

Dummy Size Potential Channels

12 Month Old Head: X,Y,Z, Z Redundant Accelerations

Upper Neck: X,Y,Z Forces and X,Y,Z Moments Chest: X,Y,Z Accelerations

3 Year Old

Head: X,Y,Z, Z Redundant Accelerations Upper Neck: X,Y,Z Forces and X,Y,Z Moments

Chest: X,Y,Z Accelerations and Deflection Pelvis: X, Y, Z Accelerations

6 Year Old, Weighted & Unweighted

Head: X,Y,Z, Z Redundant Accelerations Upper Neck: X,Y,Z Forces and X,Y,Z Moments

Chest: X,Y,Z Accelerations and Deflection Pelvis: X, Y, Z Accelerations

Femur: Z Force

10 Year Old

Head: X,Y,Z, Accelerations Upper Neck: X,Y,Z Forces and X,Y,Z Moments

Shoulder: X, Z Forces Chest: X,Y,Z Accelerations and Deflection

Lumbar Spine X,Y,Z Forces and X,Y,Z Moments Pelvis: X,Y,Z Accelerations and Iliac Forces

Femur: X, Z Forces

In addition to recording ATD responses, the COTR may direct the Contractor to install a number of CRS- and restraint-related instrumentation during the research test. These may include the following:

Shoulder Belt Force (if installed using vehicle seat belts) Lap Belt Force (if installed using vehicle seat belts) Tether Strap Force LATCH Belt Force (if installed using LATCH Lower Anchors) CRS Acceleration X CRS Acceleration Y CRS Acceleration Z CRS Base Acceleration X CRS Base Acceleration Y CRS Base Acceleration Z

6.8 Dummy Clothing Requirements

When needed, the Contractor should machine-wash dummy clothing, other than the shoes, in 71°C (160°F) to 82°C (180°F) water, and machine-dry at 43°C (110°F) to 54°C (130°F) approximately 30 minutes. Shirt sleeve may be cut off at the elbows to improve the visibility of the dummy head during maximum excursion.

The most recent child ATD clothing requirements per FMVSS 213, S9 should be followed for any NCAP CRS research testing. The following outlines these requirements at the time of this procedure’s publication:

Dummy

Size

FMVSS 213

Reference

Description

12 Month Old

S9.1(c)

The dummy is clothed in a cotton-polyester based tight fitting sweat shirt with long sleeves and ankle long pants whose combined weight is not more than

0.25 kg (0.55 lb).

3 Year Old S9.1(e)

The dummy is clothed in thermal knit waffle-weave polyester and cotton underwear, a size 4 long-sleeved shirt (three-year-old dummy), a size 4 pair of long pants having a mass of 0.090 kg (0.2 lb) and cut off just far enough above the knee to allow the knee target to be visible, and size 8 canvas oxford style sneakers weighing not more than 0.26 kg (0.57

lb) each.

6 Year Old Weighted & Unweighted

S9.1(f)

The dummy is clothed in thermal knit waffle-weave polyester and cotton underwear, a size 5 long-sleeved shirt having a mass of 0.090 kg (0.2 lb), a size 4 pair of long pants having a mass of 0.090 kg

(0.2 lb) and cut off just far enough above the knee to allow the knee target to be visible, and size 13M canvas oxford style sneakers weighing not more than 0.43 kg (0.95 lb) each.

10 Year Old

N/A To be Provided by the COTR

6.9 Dummy Targeting

Photographic targets are required to identify the movement of dummy reference points. Adhesive-backed paper or fabric targets having a pattern that facilitates identifying and tracking of reference points in high speed movies are required.

ATD targeting requirements per the following should typically be used in NCAP CRS research tests. Additional targeting per the COTR may also be suggested.

A. 12-MONTH-OLD DUMMIES: Photographic targets are required to identify the head center of gravity of the twelve-month-old dummy, which is located on either side of the dummy head at the head accelerometer mounting block bolt.

B. 3-YEAR-OLD, 6-YEAR-OLD (WEIGHTED AND UNWEIGHTED),

and 10-YEAR-OLD DUMMIES: Photographic targets are required to identify the head center of gravity and the pivot points of the knees of these dummies. The head center of gravity is identified by the head center of gravity reference pin, which protrudes from each side of the head. Note that the head center of gravity target is not used for maximum forward excursion measurements. It may be used, however, along with a second target placed on the head to facilitate determination of maximum head/torso angle. The knee pivot-points are defined by the centers of the knee pivot bolts and are used for maximum forward excursion measurements.

7. PRE-TEST REQUIREMENTS

Prior to conducting the NCAP CRS RESEARCH test, the Contractor shall:

A. Verify the training of technicians for performance of this test, and specifically, that each technician responsible for installing the CRS in the NCAP vehicle is a currently-certified Child Passenger Safety Technician (CPST). It is highly recommended that the Contractor use at least two (2) CPST-certified technicians to verify proper CRS installation.

B. Verify the calibration status of test equipment, C. Review applicable revisions of related NCAP test procedures (frontal, side

MDB, or side pole), D. Review vehicle Owner’s Manual (or equipment mfg. instructions), as well as accompanying Child Restraint instructions

7.1 Detailed Test and Quality Control Procedures Required

Prior to conducting the research test, if requested by the COTR, the Contractor may be required to submit a detailed in-house compliance test procedure (to the COTR) which should include:

A. A step-by-step description of the methodology to be used.

B. A written Quality Control (QC) Procedure which shall include calibrations, the data review process, report review, and the people assigned to perform QC on each task.

C. A complete listing of test equipment with instrument accuracy and calibration dates.

D. Detailed check-off lists to be used before, during, and after the test as well as during data review. These lists shall include all test procedure requirements and any additional requirements pertaining to the installation of the CRS and the ATDs in those CRS. Each separate check-off sheet shall identify the laboratory, test date, vehicle, and test technicians. These sheets shall be used to document that all requirements and procedures have been complied with. If requested, these sheets shall be submitted with the test report.

E. There shall be no contradiction between the OCWS Laboratory Test

Procedure and the Contractor's in-house test procedure.

8. TEST EXECUTION

8.1 General Test Conditions

Unless otherwise specified in this procedure or by the COTR, all tests and measurements conducted throughout the course of NCAP CRS research testing shall follow the related NCAP test procedure. No NCAP test conducted with the addition of child restraints for research purposes should contain practices that contradict or interrupt the intent of the original test being conducted for consumer information purposes.

8.2 Operating in-House CRS Test Procedure

Prior to conducting any CRS research test, contractors may be required to submit a detailed in-house test procedure to the COTR which should include a step by step description of the methodology to be used as described in SECTION

7.1. Written approval may be required from the COTR before initiating the research program so that all parties are in agreement.

8.3 General NCAP CRS Research Test Guidelines

The types of CRS, ATDs, and/or their placement position in the rear seats of NCAP vehicles for research purposes will vary depending on the needs of the agency and will be at the discretion of the COTR. The following are potential testing variables the contractor needs to be aware of and prepared to handle when conducting NCAP CRS research:

A. Any child ATDs currently or in consideration of being incorporated in Part

572 may be provided to the Contractor for use in NCAP CRS research.

ATDs may be provided with or without instrumentation. The Contractor must be able to calibrate and/or otherwise maintain whatever child ATDs the COTR provides in a manner consistent with the requirements for adult ATDs used in the NCAP and other guiding documents such as calibration procedures published under FMVSS.

B. Any CRS available in the general market may be used for research testing. The COTR may provide the CRS, or the Contractor may be responsible for procuring it. The Contractor must be certain when acquiring a CRS model that it contains the particular features (or “trim line”) being requested by the COTR, if any such guidance is provided.

Any difficulties in CRS acquisition must be expressed to the COTR in a timely manner, such that no testing delays result.

8.4 General NCAP CRS Installation Guidelines

This section describes some general considerations to be taken into account when installing the child restraint in the vehicle and the ATD in the child restraint for dynamic impact testing. Follow all recommended child seat and vehicle manufacturer instructions. Use the setup information below ONLY as a guideline. It is highly recommended that the Contractor use at least 2 certified Child Passenger Safety Technicians (CPSTs) when performing installations for in-vehicle research testing. In this, one can perform the installation and the other can confirm the installation is correct.

A. Rear-Facing LATCH Installations

1. Place the child restraint facing rearward on the vehicle seat, with or without a base if one exists, at the direction of the COTR.

2. If a carry handle is present, place it in the manufacturer’s recommended position that is least likely to interfere with the back of the seat in front of the CRS.

3. Locate the lower LATCH anchorages in or near the vehicle seat bight.

The installer may have to remove a plastic cover to access them.

4. After ensuring that the CRS LATCH straps are routed through the correct (rear-facing) belt path according to the manufacturer’s instructions and are not twisted, use the lower LATCH attachments to secure the CRS to the vehicle’s lower anchorages.

5. While pushing down on the child restraint, pull the free end of the LATCH belt to eliminate the slack in the system and secure a tight fit, which is normally defined as less than 1” of movement side to side or front to back when pulling at the belt path.

6. If a level indicator exists, ensure that the CRS is at the proper angle as suggested by that device (or otherwise by the manufacturer). If no level indicator exists, ensure the CRS is at a 45° angle.

7. If the CRS is not at the proper angle, adjust the CRS base or foot (if one or both exist). A pool noodle or towel may be used prior to step 3 if the Contractor consults with the COTR first.

8. If any of these steps or proper installation cannot otherwise be achieved, contact the COTR.

B. Rear-Facing Seat Belt Installations

1. Place the child restraint facing rearward on the vehicle seat, with or without a base if one exists at the direction of the COTR.

2. If a carry handle is present, place it in the manufacturer’s recommended position that is least likely to interfere with the back of the seat in front of the CRS.

3. Locate the seat belt and its retractor for the seating location the CRS is being installed in.

4. While ensuring that the seat belt is not being twisted, feed the seat belt latch plate through the correct (rear-facing) belt path and insert the latch plate into the corresponding buckle.

5. Pull the shoulder belt all the way out of the retractor until the automatic locking retractor (ALR) is engaged.

6. While pushing down on the child restraint, pull the shoulder belt to eliminate the slack in the system such that the any additional belt length is fed back into the retractor and secure a tight fit, which is normally defined as less than 1” of movement side to side or front to back when pulling at the belt path.

7. If a level indicator exists, ensure that the CRS is at the proper angle as suggested by that device (and thereby, by the manufacturer). If no level indicator exists, ensure the CRS is at a 45° angle.

8. If the CRS is not at the proper angle, adjust the CRS base or foot (if one or both exist). A pool noodle or towel may be used prior to step 3 if the Contractor consults with the COTR first.

9. If any of these steps or proper installation cannot otherwise be

C. ATD Positioning: Rear-Facing Installations

For child restraints with multiple harness slots, use the slot that would position the harness belts at (or slightly below) the ATD’s shoulders.

Position the dummy so that the head and neck are properly supported.

Place the shoulder straps over the shoulder of the dummy and have the back and bottom of the dummy placed flat against the child restraint. Pull down the shoulder straps and attach them to the buckle located in the middle of the harness. Make sure that the shoulder straps are secure and tense (usually so that the webbing cannot be pinched together, but check manufacturer instructions for the best determination of harness tightness).

Center the chest clip just below the armpit area of the dummy and make the proper connection. Check to see if the chest clip is tight. If any of these steps or proper installation cannot otherwise be achieved, contact the COTR.

D. Forward-Facing LATCH Installations

1. Place the child restraint facing forward on the vehicle seat. Adjust the kickstand, if one exists, according to the manufacturer’s instructions.

2. Align the back of the child safety seat with the back seat of the test vehicle so that the LATCH hooks located on the bottom of the child safety seat can be easily connected to the lower anchorages in the test vehicle.

3. Locate the lower LATCH anchorages in or near the vehicle seat bight.

The installer may have to remove a plastic cover to access them.

4. After ensuring that the CRS LATCH straps are routed through the correct (forward-facing) belt path according to the manufacturer’s instructions and are not twisted, use the lower LATCH attachments to secure the CRS to the vehicle’s lower anchorages.

5. If a top tether is present, connect it to the appropriate anchor in the vehicle (unless the COTR has instructed against it).

6. While pushing down on the child restraint, pull the free end of the LATCH belt to eliminate the slack in the system and secure a tight fit, which is normally defined as less than 1” of movement side to side or front to back when pulling at the belt path. Pull the top tether adjustor tightly to contribute to the tightness of fit. Also make sure that the seat angle of the back seat of the test vehicle and the seat angle of the child restraint system are aligned so that the gap between the two is minimized.

7. If any of these steps or proper installation cannot otherwise be

E. Forward-Facing Seat Belt Installations

1. Place the child restraint facing forward on the vehicle seat. Adjust the kickstand, if one exists, according to the manufacturer’s instructions.

2. Align the back of the child safety seat with the back seat of the test vehicle so that the seat belt may be routed properly through the CRS belt path.

3. Locate the seat belt and its retractor for the seating location the CRS is being installed in.

4. While ensuring that the seat belt is not being twisted, feed the seat belt latch plate through the correct (forward-facing) belt path and insert the latch plate into the corresponding buckle.

5. If a top tether is present, connect it to the appropriate anchor in the vehicle (unless the COTR has instructed against it).

6. Pull the shoulder belt all the way out of the retractor until the automatic locking retractor (ALR) is engaged.

7. While pushing down on the child restraint, pull the shoulder belt to eliminate the slack in the system such that the any additional belt length is fed back into the retractor and secure a tight fit, which is normally defined as less than 1” of movement side to side or front to back when pulling at the belt path. Pull the top tether adjustor tightly to contribute to the tightness of fit. Also make sure that the seat angle of the back seat of the test vehicle and the seat angle of the child restraint system are aligned so that the gap between the two is minimized.

8. If any of these steps or proper installation cannot otherwise be

F. ATD Positioning: Forward-Facing Installations

For child restraints with multiple harness slots, use the slot that would position the harness belts at (or slightly above) the ATD’s shoulders.

Position the dummy in the child safety seat so that the head and neck are properly supported and that the knees of the dummy are over the edge of the seat. Place the shoulder straps over the shoulders of the dummy and have the back and bottom of the dummy placed flat against the child seat.

Pull down the shoulder straps and attach them to the buckle located in the middle of the harness. Make sure that the shoulder straps are secure and tense (usually so that the webbing cannot be pinched together, but check manufacturer instructions for the best determination of harness tightness).

Center the chest clip just below the armpit area of the dummy and make the proper connection. Check to see if the chest clip is tight. If any of these steps or proper installation cannot otherwise be achieved, contact the COTR.

G. Booster Seat Installations

1. Place the booster seat facing forward on the vehicle seat.

2. Align the back of the booster seat with the back seat of the test vehicle so that the seat belt may be used correctly.

3. If any of these steps or proper installation cannot otherwise be

H. ATD Positioning: Booster Seat Installations

Position the dummy in the child safety seat so that the head and neck are properly supported and the knees of the dummy are over the edge of the seat. The back and bottom of the dummy should be placed flat against the booster seat and seat back. Locate the seat belt and its retractor for the seating position the CRS is being installed in. Position the seat belt over the dummy so that the lap belt lies across the upper part of the dummy’s thighs and the shoulder belt is placed across the mid-chest and shoulder. If applicable, use only the shoulder belt positioners that are provided with the belt-positioning booster.

8.5 Dummy Measurement Guidelines

The following measurement should be taken and recorded on the appropriate data sheet(s). If the center position in the vehicle is used, the Contractor should still attempt to take measurements in the Y-Z plane and indicate which side of the vehicle those measurements are taken to.

When a level is to be used, it is to ensure that the line containing the two points described is either parallel or perpendicular to the ground. If a measurement to be made is less than 10 inches ignore the directions to use a level and approximate a level measurement. Also, when a measurement is to be taken to or from the center of a bolt on the dummy, take the measurement from the center of the bolt hole if the bolt is recessed.

A. Measurements for Rear-Facing CRS Research Tests

The following measurements are to be made within a vertical longitudinal plane:

HZ – Head to Roof Taken from the point where the dummy's nose meets his forehead (between his eyes) to the point on the roof directly above it. Use a level.

NB – Nose to Front of Rear Seat

Taken from the tip of the dummy's nose to the closest point on the front of the rear seat.

CB – Chest to Front of Rear Seat

Place a tape measure on the tip of the dummy's chin and rotate five inches of it downward toward the dummy to the point of contact on the transverse center of the dummy's chest. Then measure from this point to the closest point on the front of the rear seat.

KB – Knee to Seat Back Taken from the dummy’s knee to the closest point on the rear seat.

TB – Toe to Seat Back (not shown in diagram) Taken from the dummy’s toe to the closest point on the rear seat.

The following measurements are to be made within a vertical transverse plane:

HS – Head to Side Window

Taken from the point where the dummy's nose meets his forehead (between his eyes) to the outside of the side window. In order to make this measurement, use a level and roll the window down to the exact height which allows a level measurement.

CD – Chest to Door Using a level, measure from the center of the dummy’s chest clip to the closest point on the vehicle door.

AD – Arm to Door Using a level, measure from the outer surface of the bolt on the outboard bicep to the closest point on the vehicle door.

HD – H-point to Door Using a level, measure from the H-point on the dummy to the closest point on the vehicle door.

KK – Knee to Knee

Measure the distance between the outboard knee clevis flange surfaces.

This measurement may not be exactly transverse.

FF – Foot to Foot Measure the distance between the feet of the child dummy while in the

CRS.

The following angles are to be measured:

SA – Seat Back Angle

Find this angle using the instructions provided by the manufacturer. If the manufacturer doesn't provide clear instructions contact the COTR.

B. Measurements for Forward-Facing CRS Research Tests

X-Z View

The following measurements are to be made within a vertical longitudinal plane:

HZ – Head to Roof Taken from the point where the dummy's nose meets his forehead (between his eyes) to the point on the roof directly above it. Use a level.

NB – Nose to Seat Back

Taken from the tip of the dummy's nose to the closest point on the seat back in front of him.

CB – Chest to Seat Back

Place a tape measure on the tip of the dummy's chin and rotate five inches of it downward toward the dummy to the point of contact on the transverse center of the dummy's chest. Then measure from this point to the closest point on the front seat back.

KB – Knee to Seat Back Taken from the dummy’s knee to the closest point on the seat back in front of him.

TB – Knee to Seat Back Taken from the dummy’s toe to the closest point on the seat back in front of him.

The following measurements are to be made within a vertical transverse plane:

HS – Head to Side Window

Taken from the point where the dummy's nose meets his forehead (between his eyes) to the outside of the side window. In order to make this measurement, use a level and roll the window down to the exact height which allows a level measurement.

CD – Chest to Door Using a level, measure from the center of the dummy’s chest clip (or sternum if the CRS does not have a chest clip) to the closest point on the vehicle door.

AD – Arm to Door Using a level, measure from the outer surface of the bolt on the outboard bicep to the closest point on the vehicle door.

HD – H-point to Door Using a level, measure from the H-point on the dummy to the closest point on the vehicle door.

Measure the distance between the outboard knee clevis flange surfaces.

This measurement may not be exactly transverse.

FF – Foot to Foot Measure the distance between the feet of the child dummy while in the

CRS.

The following angles are to be measured:

SA – Seat Back Angle

Find this angle using the instructions provided by the manufacturer. If the manufacturer doesn't provide clear instructions contact the COTR.

9. REPORTS

9.1. Notice of Test Anomaly

Any indication of a test anomaly shall be communicated by telephone to the COTR within 24 hours with written notification mailed within 48 hours (Saturdays and Sundays excluded). In the event of a test anomaly, 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 costs to the

OCWS.

9.2. Deliverable Requirements

Required deliverables for the test are discussed in this section.

A. FTP Website

To expedite data transfer between the Contractor and NHTSA, a File Transfer Protocol (FTP) website will be made available to Contractors.

1. Accessing the FTP Site

The Point of Contact at each test facility will receive an e-mail with the FTP site address and a unique username and password to access the website. A new password will be issued on the 1st of each month or at some other regular interval of time. Any FTP client can be used to access and upload data.

2. Uploading Test Data

Associated test documentation (test data, photos, videos, reports, etc.)

required for each relevant deliverable must be placed in organized and labeled folders such that each folder’s contents are easily recognizable. Once the data is organized, the Contractor shall place all folders into ONE (1) .zip file per test via the FTP website. In the case of NCAP CRS research, the associated files will be uploaded as part of the associated NCAP crash test deliverables. The .zip file should then be uploaded using an FTP client.

To ensure successful transfers, please contact your network administrator and confirm that FTP transfers are permitted. Set your FTP client program to upload in passive (PASV) mode and set the “file exists” action to “skip”.

NOTE: If the Contractor is experiencing difficulty uploading the test data to the FTP site, it is the Contractor’s responsibility to alert the COTR in order to arrange for a download from the FTP site instead.

B. QuickLook Report

A separate QuickLook report is not needed for the CRS-related data. In addition, no CRS-related information is needed on the standard NCAP crash test QuickLook.

C. Quality Control Package

The Quality Control Package is a .zip file that includes all of the information necessary for quality control review.