NCAP Lab Procedure 2011-Final w Appendices.pdf

U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FOR

NEW CAR ASSESSMENT PROGRAM

FRONTAL IMPACT TESTING

June 2011

OFFICE OF VEHICLE SAFETY

OFFICE OF CRASHWORTHINESS STANDARDS

1200 NEW JERSEY AVE, SE

ROOM W43-410

WASHINGTON, DC 20590

This publication is distributed by the U.S. Department of Transportation, National

Highway Traffic Safety Administration, in the interest of information exchange.

The opinions, findings and conclusions expressed in this publication are those of the author(s) and not necessarily those of the Department of Transportation or the

National Highway Traffic Safety Administration. The United States Government assumes no liability for its contents or use thereof. If trade or manufacturers' name or products are mentioned, it is because they are considered essential to the object of the publication and should not be construed as an endorsement. The

United States Government does not endorse products or manufacturers.

NCAP LABORATORY TEST PROCEDURE

TABLE OF CONTENTS

1. PURPOSE AND APPLICATION

2. GENERAL REQUIREMENTS

3. SECURITY

3.1 RULES FOR CONTRACTORS

4. GOOD HOUSEKEEPING

5. TEST SCHEDULING AND MONITORING

6. FACILITY AND EQUIPMENT – PRETEST REQUIREMENTS

6.1 TOW ROAD

6.2 TEST VEHICLE PREPARATION BUILDING/STRUCTURE

6.3 TOW AND GUIDANCE SYSTEMS

6.4 FIXED COLLISION BARRIER

6.5 TEST VEHICLE VELOCITY MEASUREMENT

6.6 TEST BRAKE ABORT SYSTEM

6.7 STATIC ROLLOVER DEVICE

7. GOVERNMENT FURNISHED PROPERTY (GFP)

7.1 TEST VEHICLES

7.2 ANTHROPOMORPHIC TESTING DEVICES

7.3 LOAD CELL BARRIER

8. CALIBRATION AND TEST INSTRUMENTATION

9. PHOTOGRAPHIC DOCUMENTATION

9.1 CAMERAS

9.2 COLORING REQUIREMENTS FOR PHOTOGRAPHIC PURPOSES

9.3 VEHICLE AND DUMMY PHOTOGRAPHIC COVERAGE (REAL-TIME)

9.4 IMPACT EVENT MARKERS

9.5 PHOTOGRAPHIC TARGETS AND TAPE FOR TEST VEHICLE

9.6 TARGET VEHICLE INFORMATION PLACARDS

9.7 DOCUMENTATION VIDEO TITLE AND SEQUENCE

9.8 DOCUMENTATION VIDEO RECORDING AND EDITING

9.9 STILL PHOTOGRAPHS

10. DEFINITIONS

11. TEST EXECUTION

11.1 TEST VEHICLE PREPARATION

11.2 TEST DUMMY PREPARATION, POSITIONING, AND PLACEMENT

11.3 LOAD CELL BARRIER PREPARATION

11.4 VEHICLE MEASUREMENTS

11.5 ELECTROMAGNETIC INTERFERENCE

12. TEST DATA DISPOSITION

12.1 TEST DATA LOSS

12.2 DATA PROCESSING

12.3 RECOMMENDED DATA TRACE ORDER

12.4 PERFORMANCE REQUIREMENTS – NOTIFICATION OF TEST RESULTS

12.5 NCAP TEST DELIVERABLES

12.6 DATA RETENTION BY THE CONTRACTOR

12.7 DATA AVAILABILITY TO THE PUBLIC

LIST OF FIGURES

FIGURE 1 - TYPICAL FRONTAL NCAP RIGID BARRIER IMPACT TEST FACILITY

FIGURE 2 - CAMERA POSITIONS FOR FRONTAL IMPACTS

FIGURE 3 - REFERENCE PHOTO TARGETS

FIGURE 4 - REFERENCE PHOTO TARGETS, CONT'D

FIGURE 5 - VEHICLE ACCELEROMETER LOCATIONS

FIGURE 6 - DUMMY MEASUREMENTS FOR FRONT SEAT PASSENGERS

FIGURE 7 - EXTERIOR VEHICLE MEASUREMENTS

FIGURE 8 - DOOR OPENING WIDTH AND WHEELBASE MEASUREMENTS

FIGURE 9 - DRIVER COMPARTMENT MEASUREMENTS

FIGURE 10 - FLOORBOARD INTRUSION MEASUREMENTS

FIGURE 11 - VEHICLE CRUSH PROFILE MEASUREMENTS

APPENDICES

APPENDIX A PART 572E (50TH PERCENTILE MALE) DUMMY PERFORMANCE

CALIBRATION TEST PROCEDURE

APPENDIX B PART 572O (5TH PERCENTILE FEMALE) DUMMY PERFORMANCE

APPENDIX C PART 572N (6-YEAR OLD) DUMMY PERFORMANCE

APPENDIX D PART 572P (3-YEAR OLD) DUMMY PERFORMANCE

APPENDIX E PART 572R (12-MONTH-OLD) DUMMY PERFORMANCE

APPENDIX F DRIVER AND PASSENGER DUMMY SEATING AND POSITIONING

PROCEDURES

APPENDIX G REDUNDANT ACCELEROMETERS – RECOMMENDED PRACTICE

APPENDIX H FOOT INSTRUMENTATION – RECOMMENDED PRACTICE

APPENDIX I COMPUTER PROGRAMS

APPENDIX J FMVSS 212, 219 (PARTIAL), 301, AND 305 REQUIREMENTS FOR

FRONTAL IMPACT NCAP

APPENDIX K METRIC CONVERSION

APPENDIX L UPPER NECK LOAD CELL POLARITY CHECK

APPENDIX M HEAD NINE-ACCELEROMETER ARRAY POLARITY CHECK

APPENDIX N TEST DELIVERABLES AND REPORT GUIDELINES

APPENDIX O VEHICLE FLOORPAN INSTRUSION

APPENDIX P LOAD CELL BARRIER CONFIGURATIONS

REVISION CONTROL LOG

FOR NCAP LABORATORY

TEST PROCEDURES

FRONTAL RIGID BARRIER IMPACT TEST

TEST

PROCEDURE

NEW CAR ASSESSMENT

PROGRAM

FRONTAL IMPACT

TESTING

DESCRIPTION

REV.

No.

DATE

AMENDMENT

EFFECTIVE

DATE

00 09/22/2010 09/22/2010 Minor changes to procedure. Photo list update and clarifications.

Removal of test reporting requirements from main procedure and insertion in Appendix N.

01 01/13/2010 01/13/2010 Minor changes to procedure. Added information to allow for high resolution barrier. Updated

Appendix G to allow for redundant femur load cells.

02 05/20/2011 06/01/2011 Minor changes to procedure.

Moved load cell barrier information to Appendix P.

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1. PURPOSE AND APPLICATION

The Office of Crashworthiness Standards (OCWS) provides Contractor laboratories with

Laboratory Test Procedures as guidelines for obtaining crash test data. The data are used to provide ratings that allow consumers to compare the crashworthiness of vehicles and make informed purchasing decisions. In addition, it provides market incentives for automobile manufacturers to produce safer vehicles. The purpose of the OCWS

Laboratory Test Procedure is to present a uniform testing and data recording format, and to provide suggestions for the use of specific equipment and procedures. If any

Contractor views any part of an OCWS Laboratory Test Procedure to be in conflict with a Federal Motor Vehicle Safety Standard (FMVSS) or observes deficiencies in a

Laboratory Test Procedure, the Contractor is required to advise the Contracting Officer’s

Technical Representative (COTR) and resolve the discrepancy prior to the start of NCAP testing.

Every Contractor is required to submit a detailed internal test procedure to the COTR before initiating its NCAP 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 with make and model number. The list of test equipment shall include instrument accuracy and calibration dates. All equipment shall be calibrated in accordance with the manufacturer’s instructions. There shall be no contradictions between the Laboratory Test Procedure and the Contractor’s in-house test procedure. Written approval of the in-house test procedures shall be obtained from the

COTR before initiating the NCAP test program. 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 data. These

Laboratory Test Procedures do not constitute an endorsement or recommendation for use of any product or method. However, the application of any such testing technique or equipment is subject to prior approval of the COTR.

NOTE: The NCAP Laboratory Test Procedures, prepared for the limited purpose of use by independent laboratories under contract to conduct NCAP tests for the OCWS, are not rules, regulations, or NHTSA interpretations regarding the meaning of an FMVSS or this procedure. The Laboratory

Test Procedures may not include all of the various FMVSS minimum performance requirements. Recognizing applicable test tolerances, the

Laboratory Test Procedures may specify test conditions that are more or less severe than the minimum requirements of the standard.

2. GENERAL REQUIREMENTS

This laboratory test procedure is derived from the FMVSS No. 208 test procedure Each vehicle shall be tested by impacting it into an instrumented, fixed, rigid concrete barrier that conforms to the definition in Part 571.3—Definitions, 49 CFR Part 571.3. The contract laboratories are directed by this test procedure to use an impact velocity of 35.0

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± 0.5 mph (56.3 ±0.8 km/h). Any changes to or deviations from this test procedure must be approved by the Contracting Officer's Technical Representative (COTR).

NOTE: Vehicles are tested with a 50 th percentile male Hybrid III in the driver position and a 5 th percentile female Hybrid III placed in the front right outboard seating position. When tested according to the conditions outlined in this test procedure, each 50 th percentile occupant shall comply with the injury criteria listed in section S6 of 49CFR571.208 and each 5 percentile occupant shall comply with injury criteria listed in section S15 of

49CFR571.208.

3. SECURITY

The Contractor shall provide appropriate security measures to protect NCAP test vehicles, dummies, load cell barrier and any GFP during the entire crash test program and shall be responsible for all equipment removed from test vehicles before and after the crash test. Any security problems which arise shall be reported by telephone to the

Industrial Property Manager (IPM), Office of Acquisition Management, within two (2) working days after the incident. A letter containing specific details of the security problem shall be sent to the IPM (with copy to the COTR) within 48 hours. Vehicle equipment thefts or acts of vandalism must be reported to NHTSA authorities immediately. Under no circumstances shall any vehicle components be removed during a visitor inspection unless authorized by OCWS engineers. All data developed from the crash test program shall be protected.

NO INDIVIDUALS OTHER THAN THE CONTRACTOR'S PERSONNEL

DIRECTLY INVOLVED IN THE CRASH TEST PROGRAM SHALL BE ALLOWED

TO WITNESS A FRONTAL NCAP TEST OR INSPECT, PHOTOGRAPH OR

VIDEOTAPE ANY TEST VEHICLE UNLESS AUTHORIZATION IS GRANTED BY

A REPRESENTATIVE FROM THE OCWS. IT IS THE CONTRACTOR'S

RESPONSIBILITY TO SECURE THE TEST SITE AREA DURING A TEST AND

TO SHIELD THE BARRIER IMPACT AREA FROM THE PUBLIC VIEW BY THE

USE OF CANVAS OR OTHER BLOCKING DEVICES.

3.1 RULES FOR CONTRACTORS

A. No vehicle manufacturer's representative(s) or anyone other than the Contractor's personnel working on NCAP contracts and NHTSA personnel shall be allowed to inspect

NHTSA vehicles or witness vehicle preparations and/or crash testing without prior permission of the OCWS. Such permission can never be assumed.

B. All communications with vehicle manufacturers shall be referred to the OCWS, and at no time shall the Contractor release crash test data, videos, or photos without the permission

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of the OCWS.

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

D. 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.

NOTE: No vehicle parts should be tampered with or removed from the vehicle without the consent of the COTR. Individual data plots cannot be viewed by manufacturer representatives until they are reviewed by NHTSA personnel and granted express permission by the COTR.

E. Photographs and video 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 videos of vehicle preparation must be approved by OCWS. The Contractor's personnel shall not respond to any questions from the manufacturer's representatives regarding NCAP. All questions shall be referred to the COTR, an OCWS representative present at the test site, or to OCWS.

F. The Contractor shall permit public access to and inspection of the test vehicles and related data during the times specified by the NHTSA COTR. NHTSA shall advise interested parties that such access and inspection shall be limited to a specified day and hours and require prior approval from the Office of Crashworthiness Standards. The

Contractor shall refer all visit requests from vehicle manufacturer's representatives and consumers to the Office of Crashworthiness Standards. This service shall be included as an incidental part of the crash test program and will not result in any additional cost to the

NHTSA. The Contractor shall make his own arrangements with interested parties for expenses incurred beyond providing access and inspection services. All inquiries by manufacturers concerning NCAP (vehicle, procedures, data, etc.) shall be directed to

OCWS representatives.

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

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. All

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testing shall be coordinated to allow monitoring by the COTR.

6. FACILITY AND EQUIPMENT – PRETEST REQUIREMENTS

6.1 TOW ROAD

A. The tow road should be at least 500 feet in length and terminate at the face of the non-energy-absorbing barrier as shown in FIGURE 1. The first 100 feet (approximate) from the head of the tow road will be used to accelerate the test vehicle up to the specified velocity without exceeding 0.5g, which would affect the positioning of the P572 test dummies in the test vehicle. The second 100 feet (approximate) of tow road shall be used for dummy stabilization. At this juncture, the test vehicle should have reached the desired impact velocity and should be experiencing zero acceleration. The remaining 300 feet (approximate) of tow road will be used for test vehicle speed stabilization.

B. The width of the tow road should be approximately 8 to 14 feet and should be straight and level so that the test vehicle does not oscillate vertically in excess of 0.29 G's.

C. A photographic pit will be located in the tow road at the stationary barrier face so that structural crush and possible fluid leakage of Stoddard solvent can be photographed during the impact event. The pit shall be covered using the following guidelines:

1. Use a material that allows for use of pit cameras.

2. The covering and its supports should simulate road strength in case the vehicle structure should come in contact with it during the NCAP test.

3. The entire pit should be covered except for the area needed for the tow system to operate.

4. Precautions must be taken to ensure there is no electromagnetic interference generated by the pit cover material.

6.2 TEST VEHICLE PREPARATION BUILDING/STRUCTURE

The following applies to labs with outdoor impact surfaces. In order that the test vehicle can be prepared for crash testing at the head of the tow road during hot or cold weather, the Contractor shall have a temperature-controlled building constructed which is large enough to house the test vehicle and allow for government, vehicle manufacturer, and laboratory personnel to move around the test vehicle. The building climate control must be capable of maintaining the ambient air temperature between 20.6°C and 22.2°C (69°F and 72°F).

6.3 TOW AND GUIDANCE SYSTEMS

A. A guidance system is required to assure that the test vehicle impacts the barrier at the proper angle. At most laboratories, a monorail running down the center of the tow road is used to guide a dolly to which the vehicle is connected. NO HARD POINT

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CONNECTIONS BETWEEN THE MONORAIL AND TEST VEHICLE WILL BE

ALLOWED.

B. A ―soft‖ lateral guidance system is required to assure that the test vehicle will impact the barrier face at the designated 90° angle (straight perpendicular impact). It is suggested that the Contractor's lateral guidance system include steel cables or chains extending from the vehicle lower 'A' arms or front frame rails to the monorail dolly or shoe. The dolly will ride on the monorail and may engage the tow cable through a set of gripper jaws. The dolly will be stopped at the end of the tow road monorail or at the head of the photographic pit releasing the vehicle cables or chains at the same time allowing the vehicle to proceed to the barrier face for impact.

C. A ―soft‖ connection (seat belt webbing, steel cables, chains, etc.) between the tow cable attachment device and the test vehicle front frame assembly shall be provided by the

Contractor. NO HARD POINT CONNECTIONS BETWEEN THE TOW CABLE

AND THE TEST VEHICLE SHALL BE ALLOWED. The tow cable attachment shall release from the cable so that the vehicle will roll into the barrier at a constant velocity

(no acceleration).

D. The tow system must be capable of ensuring that the test vehicle shall impact the barrier face at a speed of 56.3 km/h ± 0.8 km/h, or range of 55.5. km/h to 57.1 km/h (35.0 mph ±

0.5 mph, or range of 34.5 to 35.5 mph).

FOR THE VEHICLE TOWING AND LATERAL GUIDANCE SYSTEMS, THE

PERFORMANCE REQUIREMENT OF “SOFT” CONNECTIONS IS CONSTRUED

TO BE SYSTEMS WHICH DO NOT OBSTRUCT OR RESTRAIN THE VEHICLE

STRUCTURAL DEFORMATION DURING IMPACT. SYSTEMS THAT FAIL TO

COMPLY WITH THIS REQUIREMENT ARE INTERPRETED AS SYSTEMS WITH

'HARD-POINT' CONNECTIONS, AND ARE GROUNDS FOR RETEST.

IN ADDITION, ENGAGEMENT OF THE VEHICLE TOWING AND GUIDANCE

SYSTEMS SHALL NOT ALTER THE NATURAL ATTITUDE OF THE VEHICLE.

MODIFICATION OF ANY KIND TO THE TEST VEHICLE FOR TOWING

PURPOSES, SUCH AS WELDING, DRILLING, ETC IS PROHIBITED.

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6.4 FIXED COLLISION BARRIER

The basic fixed collision barrier must conform to the definition in Part 571.3—

Definitions, 49 CFR Part 571.3, and at a minimum should consist of a reinforced concrete structure, 6 feet high, 6 feet thick, and 12 feet wide, weighing approximately 100,000 pounds. The Government furnished property (GFP) load cell barrier shall be firmly attached to the reinforced concrete structure prior to every test unless otherwise directed by OCWS.

6.5 TEST VEHICLE VELOCITY MEASUREMENT

A. The speed of the test vehicle must be controlled to obtain and maintain the vehicle speed in the range of 56.3 km/h ± 0.8 km/h, or range of 55.5. km/h to 57.1 km/h (35.0 mph ±

0.5 mph, or range of 34.5 to 35.5 mph).

B. Primary test vehicle impact speed measurement may be achieved by the use of break wires, photocells, or laser beams located within 5 feet of the barrier. Usually, 2 sets of

Figure 1 - Typical Frontal NCAP Rigid Barrier Impact Test Facility

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break wires or 2 photocell transmitters and receivers are used in the final speed trap, which records the time, on an electronic counter, for the test vehicle to travel the last 5 feet before barrier impact. The test vehicle's velocity shall be constant (zero acceleration or deceleration) for a minimum of the last 5 feet of travel before impact. The final velocity shall be measured when the front of the test vehicle is within 1 foot of the barrier face, and the reported impact velocity will take into consideration all of the response characteristics of the entire velocity measurement system utilized in its determination.

C. Impact velocity will be measured by no less than 2 sets of timing devices and the timing devices shall be accurate to within plus or minus .08 km/h (0.05 mph). The basis for the speed measurement (time and distance) shall be calibrated by an instrument traceable to the National Institute of Standards and Technology (NIST). The impact velocity shall be permanently recorded, at a minimum by the photograph taken to satisfy the requirements of this procedure’s Appendix N, Test Deliverables and Report Requirements. Another method of permanently documenting the velocities recorded by these timing devices is highly encouraged. A source of battery power as a backup for these devices is also recommended.

D. A timing device shall monitor the velocity of the test vehicle to permit aborting the test if the vehicle's speed is outside of the specified velocity range. A third timing device may be placed along the tow road at a sufficient distance from the barrier face for monitoring the velocity of the test vehicle and permitting aborting of the test if the vehicles speed is outside the velocity range specified below. If the contractor is capable of documenting the velocity recorded by this third device it may be also used as a third verification of test velocity in any test.

E. Test vehicle impact speed measurement can also be estimated from the high speed video.

While the test vehicle is resting against the barrier face for pre-test preparations, a stadia pole will be placed directly in line with one of the 12-inch photographic targets as viewed through the broadside camera bore sight.

6.6 TEST BRAKE ABORT SYSTEM

A. The laboratory shall provide an abort system capable of bringing the vehicle to a controlled stop.

B. An aborted test can be restarted only after notification is given to the COTR, and dummy positioning and vehicle preparation items affected by the abort have been redone.

6.7 STATIC ROLLOVER DEVICE

The laboratory shall provide a static rollover device, used to conduct an FMVSS No. 301 and/or FMVSS No. 305 test, which must be capable of rotating the impacted test vehicle about it longitudinal axis, with the axis kept horizontal, to each successive increment of

90°, 180°, and 270° at a uniform rate. 90° of rotation must take place within 1 to 3 minutes.

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7. GOVERNMENT FURNISHED PROPERTY (GFP)

7.1 TEST VEHICLES

A. The Contractor has the responsibility of accepting NHTSA-provided test vehicles. The

Contractor acts on NHTSA’s behalf when signing an acceptance of test vehicles. The

Contractor must check to verify the following:

1. All options listed on the ―window sticker‖ are present on the test vehicle.

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

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

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

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

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

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

8. The Contractor shall check for damage that may have occurred during transit. The

COTR is to be notified of any damage prior to preparation of the vehicle for testing.

7.2 ANTHROPOMORPHIC TESTING DEVICES

An adequate number of Part 572 Subpart E (50

Percentile Male) test dummies and Part

572 Subpart O (5 th

Percentile Female) test dummies will be furnished to the contract laboratory by the NCAP.

In addition, Part 572 Subpart N (6-year old), Subpart P (3-year old), and Subpart R (12-month-old) test dummies will be provided if needed. The dummies will be instrumented with 6-axis neck load cells and instrumented lower legs; all other dummy instrumentation shall be provided by the Contractor. The Subpart E (50th male), O (5th female), and N

(6-year old) dummies shall be stored in an upright sitting position with the weight supported by the internal structure of the pelvis. The dummies shall be held upright by using a strap around the chest or the base of the neck so that the neck is not supporting the weight of the dummy. If used, Subpart P (3-year-old), and R (12-month-old) dummies shall be stored in a hanging position using the bracket and positioning shown in figures 1 and 2. The dummies shall be stored in a secured room, which is kept between

55ºF and 85ºF and 10-70% relative humidity.

The Contractor shall check the dummy components for damage after each crash test and complete a Dummy Damage Checklist that will be included with the post test dummy calibration. The COTR will be kept informed of the dummies’ condition in order that replacement parts can be provided.

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The Contractor shall keep a detailed record for each dummy, describing parts replaced and the results of calibration tests.

7.3 LOAD CELL BARRIER

A barrier will be provided to the contract laboratory by the NCAP. Details on some typical load cell barriers can be found in Appendix P, Load Cell Barrier

Configurations

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8. CALIBRATION AND TEST INSTRUMENTATION

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

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

B. All measuring instruments and standards shall be calibrated by the Contractor, or a commercial facility, against a higher order standard at periodic intervals not exceeding 12 months for instruments and 12 months for the calibration standards. Records, showing the calibration traceability to the National Institute of Standards and Technology (NIST), shall be maintained for all measuring and test equipment.

1. Accelerometers shall be calibrated at a minimum of every six months or after a vehicle fails to meet any minimum performance requirements or after any indication from calibration checks or recent test data that there may be a problem with the accelerometer (whichever comes sooner).

2. Load cells shall be calibrated at a minimum of every twelve months or after a vehicle fails to meet any minimum performance requirements or after any indication from calibration checks or recent test data that there may be a problem with the load cell

(whichever comes sooner).

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

1. Date of calibration

2. Date of next scheduled calibration

3. Name of the technician who calibrated the equipment

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

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

2. Measurement range

3. Accuracy

4. Calibration interval

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

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

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

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F. All such records shall be readily available for inspection when requested by the COTR.

The history of the record shall be updated in an electronic file. The calibration system will 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 before and after the test. This check shall be recorded by the test technician(s) and submitted with the final 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 an ATD body region exceeds the performance standards required by FMVSS 208, that region on the ATD must be recalibrated.

I. The Contractor-Furnished data acquisition shall have a sufficient number of channels available for recording and processing signals from ATD and vehicle sensors. It must record time histories of the head and chest acceleration, chest displacement, neck forces and moments, right and left femur axial loads, and any additional instrumentation specified for each test dummy used in the test. Each data channel shall be comprised of a sensor, signal conditioner, data acquisition device, and all interconnecting cables, and must conform to the most recent requirements of SAE Recommended Practice J211-1.

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

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

J. An instrument calibration system capable of performing individual tests on all data channels used in acquiring the acceleration and force data shall conform to the appropriate section of the most recent version of SAE J211-1.

K. A full-face GFE load cell barrier will be mounted onto the face of the Contractor's fixed barrier assembly. All questions regarding the load cell barrier assembly, maintenance and calibration shall be directed to:

Safety Performance Standards

Office of Crashworthiness Standards (NVS-110)

1200 New Jersey Avenue, SE

Washington, D.C. 20590

(202) 366-1740

L. Load cells shall be calibrated on an ―as needed‖ basis and a minimum of one (1) time per year. Accelerometers shall be calibrated on an ―as needed‖ basis and a minimum of once every six (6) months. Need shall be established by pre- and post-test shunt calibration. If

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bridge balance remains unchanged (pre- and post-test) and if full-scale shunt calibration results in the same factor, then the transducer characteristics are within calibration. If loads become suspect, linearity of the load cell shall be checked with a universal compression testing machine. If the load cell is non-linear or if pre- and post-test calibration results in a ―drift,‖ the load cell shall be returned to the manufacturer for check-out and calibration. Notify the COTR whenever calibration problems arise.

NOTE: Load cells are prone to corrosion when exposed to damp environments.

Therefore, extra precautions shall be taken to prevent moisture entering the cells.

CAUTION: Weep holes are provided for equalization of barometric pressure and must be directed downward. If cells are found with the hole pointing upward, the cell must be removed and calibrated by compression testing. If they are found to be non-linear, they must be returned to the manufacturer. The load cell barrier shall be covered between tests. When the load cell barrier will not be used for a period of time, it shall be removed from the barrier area and placed in a dry storage area. The plywood blocks shall be intact and completely bonded to the backup support. If these blocks receive significant damage during crash testing, they shall be replaced or repaired such that a full surface is present.

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

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9. PHOTOGRAPHIC DOCUMENTATION

9.1 CAMERAS

High-Speed Digital Cameras

A. The Contractor shall document the frontal crash event with high-speed digital cameras, arranged as shown in Figure 2, that operate at 1000 frames-per-second (fps) for 5 ms before the vehicle contacts the barrier and for 300 ms after vehicle contacts the barrier.

B. The minimum resolution for these cameras shall be 1536 CMOS sensors per every two rows of pixels, with 80% of the horizontal distance of the two rows covered by effective light sensors. There shall be a minimum of 1024 rows of sensors.

C. 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 video analysis.

D. A time zero mark must be registered in a frame to indicate when contact with the barrier occurs. Each frame shall contain the camera speed and the frame number beginning with the time zero frames labeled as ―Frame 0.‖ The frame numbers prior to time zero shall be negative numbers.

E. If hard copies are needed, digital video files shall be transferred to a compact disc (CD) or DVD as AVI or MPEG format with standard or generally available ―codec‖. These are also the acceptable formats for video files being transferred to the FTP site. Other types of files can be used if approved by the COTR.

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

Real Time Camera

The Contractor shall use a ―real time‖ color digital video camera that operates at 24-30 frames per second to document the views indicated below. The video shall be transferred to the FTP site, compact disc (CD) or DVD as .AVI, .MPEG, or .WMV files with standard or generally available ―codec‖.

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Figure 2 - Camera Positions for Frontal Impacts

Camera 1 Filename: Camera No. 1 – REAL-TIME LEFT OVERALL

Real-time (24-30 fps) left side view camera to follow the test vehicle down the tow road, across the photographic pit, and into the barrier face.

Camera 2 Filename: Camera No. 2 - DRIVER CLOSE-UP

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

Camera 3 Filename: Camera No. 3 – LEFT FRONT HALF

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

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Camera 4 Filename: Camera No. 4 – LEFT ANGLE

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

Camera 5 Filename: Camera No. 5 – STEERING COLUMN – TOP*

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

Camera 6 Filename: Camera No. 6 – STEERING COLUMN –

BOTTOM*

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

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

Camera 7 Filename: Camera No. 7 – RIGHT OVERALL

High speed right side view camera to cover the entire right side of the test vehicle during the impact event. The centerline of the camera shall be perpendicular to the longitudinal centerline of the vehicle.

Camera 8 Filename: Camera No. 8 – PASSENGER CLOSE-UP

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

Camera 9 Filename: Camera No. 9 – RIGHT FRONT HALF vehicle’s B post or center post at an angle to document the movement of the passenger dummy during the impact event.

Camera 10 Filename: Camera No. 10 – RIGHT ANGLE vehicle's right front door to document the movement of the

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passenger dummy during the impact event.

Camera 11 Filename: Camera No. 11 – WINDSHIELD

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

Camera 12 Filename: Camera No. 12 – DRIVER WINDSHIELD

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

Camera 13 Filename: Camera No. 13 – PASSENGER WINDSHIELD

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

Camera 14 Filename: Camera No. 14 – PIT FRONT*

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

Camera 15 Filename: Camera No. 15 – PIT REAR*

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

NOTE: Cameras 16 and 17 (see Figure 2) are optional views that may be installed in any feasible location in any NCAP test at the COTR's request. It is suggested that if no special request is made by the COTR, the contractor install cameras 16 and 17 regardless. They can be positioned inside the test vehicle over each dummy’s inboard shoulder such that they may capture frontal airbag deployment. In addition, the outside rearview mirrors may be removed to eliminate any camera view obstructions in any NCAP test.

*Camera view may be recorded at 500 fps if necessary.

9.2 COLORING REQUIREMENTS FOR PHOTOGRAPHIC PURPOSES

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

B. Vehicle underbody components such as the floor pan, frame rail members, steering

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mechanism, suspension components, engine oil pan, and all fuel system components shall be painted with different colored paint (pink, green, blue, orange, etc.).

C. Parts of the 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.

CHALK COLORS TO BE USED ON TEST DUMMIES

DUMMY PART

DRIVER

PASSENGER

Nose

Red

Yellow

Lips

Face

Blue Red

Top of Head

Blue

Back of Head

Left Knee

Right Knee

Blue

Blue (FMVSS 208 uses

Red)

Lower Steering Wheel

Rim

N/A

NOTE: Face chalk should extend below the chin.

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

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

9.3 VEHICLE AND DUMMY PHOTOGRAPHIC COVERAGE (REAL-TIME)

A. A real-time camera (24-30 fps) shall be used to document the pre-test and post-test condition of the test vehicle in addition to the pre-test and post-test positions of the test dummies, including, but not limited to, the placement of the lap and shoulder belts. The positions of the belt load cells shall be documented along with the tape supports for the shoulder belt load cells. Particular attention must be exercised to fully document the proper closing of all vehicle doors, including any rear hatchback or tailgate.

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

The real-time camera (24-30 fps) shall be used to record any Stoddard solvent spillage from the test vehicle after the impact event or during the static rollover test.

9.4 IMPACT EVENT MARKERS

Strobe lights or taped photoflash bulbs (cloth tape on bulb exterior to form small slit for light passage) shall be placed in the field-of-view of all cameras to mark the beginning

(time zero) of the crash test. Light from the impact detectors SHOULD NOT COVER

MORE THAN 3 FRAMES OF HIGH-SPEED VIDEO. Suggested locations for impact detectors or ―time zero‖ markers are as follows:

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

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

C. Adjacent to engine oil pan

D. Adjacent to vehicle's fuel tank

9.5 PHOTOGRAPHIC TARGETS AND TAPE FOR TEST VEHICLE

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Figure 5

Figure 3 - Reference Photo Targets

Figure 4 - Reference Photo Targets, Cont'd

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A. Reference photographic targets shall be rigidly mounted on the test vehicle and attached to the barrier assembly as shown in Figures 3 and 4 The primary moving reference targets Al and A2 MUST BE mounted 24 inches (609.6mm) apart on a flat rectangular panel, and be firmly fixed to a structure of the vehicle that remains undisturbed by the crash, such as the vehicle roof. The panel must be in the same plane as the plane of motion. The setup rotation of the panel within the motion plane is unimportant. To ensure against unexpected displacements of the car top, the backup moving reference targets C1 and C2 should also be attached to undisturbed portions of the vehicle, such as the vehicle door or body, and must also be 24 inches (609.6mm) apart.

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

C. Photographic targets should be placed at 12‖ intervals along the side of the vehicle along the 1-inch tape. Target placement should be documented.

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

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

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

9.6 TARGET VEHICLE INFORMATION PLACARDS

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

Vehicle's NHTSA Number

The words ―NCAP 35 MPH FRONTAL‖

Date of crash test

Vehicle year, make and model

NOTE: The name of the test laboratory should not be present on any vehicle placards used in photos and videos submitted to NHTSA.

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9.7 DOCUMENTATION VIDEO TITLE AND SEQUENCE

The pre-and post-test real-time documentation video shall include the following title frames:

A. ―The following 35 mph frontal barrier impact test was conducted under contract with the

National Highway Traffic Safety Administration by (name and location of test laboratory)‖

35 MPH FRONTAL BARRIER IMPACT TEST

TEST VEHICLE MODEL YEAR, MAKE AND MODEL

NHTSA No. CXXXXX

DATE OF IMPACT EVENT

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

B. The ending frame shall state ―THE END‖

9.8 DOCUMENTATION VIDEO RECORDING AND EDITING

The video shall be recorded and edited in the following sequence:

A. Title

B. Pre-test Coverage (at barrier)

a. Left side of vehicle (pan from front to rear of vehicle)

b. Right side of vehicle (pan from front to rear of vehicle)

c. View of gas cap being removed and correctly replaced

d. Left side view of vehicle interior and driver dummy (with vehicle door open)

e. Right side view of vehicle interior and passenger dummy (with vehicle door open)

f. Frontal view looking through windshield at both dummies

g. Cycling of airbag indicator light

h. Door closings

C. Real-Time Pan Coverage

D. Post test Coverage

a. Left side of vehicle (pan from front to rear of vehicle, including footage of vehicle’s front end damage)

b. Driver dummy post-test positioning (close up with door closed)

c. Right side of vehicle (pan from front to rear of vehicle, including footage of vehicle’s front end damage)

d. Passenger dummy post-test positioning (close up with door closed)

e. Frontal view looking through windshield at both dummies

f. Left side view of vehicle interior and driver dummy (as technician opens vehicle door)

g. Right side view of vehicle interior and passenger dummy (as technician opens vehicle door)

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E. Rotating Fixture Coverage (a minimum 10 seconds ―burst‖ during 0 to 90 degree roll)

a. View of Rollover – 0 degrees

b. View of Rollover – 90 degrees

c. View of Rollover – 180 degrees

d. View of Rollover – 270 degrees

e. View of Rollover – 360 degrees

F. If applicable, any fuel system, windshield, seat back, or other vehicle failures or testing anomalies. If the contractor has concerns about whether a test issue should be included, please contact the COTR.

G. ―The End‖

9.9 STILL PHOTOGRAPHS

Clear and properly focused digital still photographs in .jpg format with a minimum dots-per-inch (DPI) of 180 shall be taken to document the test. A target vehicle information placard, identifying the test vehicle model as well as the pole and NHTSA number, along with an indication of whether the photo was taken pre-test or post-test, shall appear in each photograph and be legible A time/date stamp on each photo is also highly recommended. Each photograph shall also be labeled when transferred to the FTP site as part of the QuickLook data. In addition, the photos should be labeled in Appendix A of the final test report and on the final CD provided to NCAP. A list of photographs with their labeling convention can be found in Section 3 of Appendix N.

10. DEFINITIONS

The contractor shall check the Code of Federal Regulations for the most recent definitions.

A citation is provided after each definition not specified in Standard 208.

A. Automatic-locking retractor: A retractor incorporating adjustment hardware by means of a positive self-locking mechanism which is capable when locked of withstanding restraint forces. (571.209, S3)

B. Designated seating capacity: The number of designated seating positions provided.

(571.3)

C. Designated seating positions: Any plan view location capable of accommodating a person at least as large as a 5th percentile adult female, if the overall seat configuration and design and vehicle design is such that the position is likely to be used as a seating position while the vehicle is in motion, except for auxiliary seating accommodations such as temporary or folding jump seats. Any bench or split-bench seat in a passenger car, truck or multipurpose passenger vehicle with a GVWR less than 4,586 kilograms

(10,000 pounds), having greater than 127 centimeters (50 inches) of hip room

(measured in accordance with SAE Standard J1100(a)) shall nave not less than three seat designated seating positions, unless the set design or vehicle design is such that the center position cannot be used for seating. For the sole purpose of determining the classification of any vehicle sold or introduced into interstate commerce for purposes that include carrying students to and from school or related events, any location in such

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vehicle intended for securement of an occupied wheelchair during vehicle operation shall be regarded as four designated seating positions. (571.3)

D. Emergency-locking retractor: A retractor incorporating adjustment hardware by means of a locking mechanism that is activated by vehicle acceleration, webbing movement relative to the vehicle, or other automatic action during an emergency and is capable when locked of withstanding restraint forces. (571.209, S3)

E. Fixed Collision Barrier: A flat, vertical, unyielding surface with the following characteristics:

1. The surface is sufficiently large that when struck be a tested vehicle, no portion of the vehicle projects or passes beyond the surface,

2. The approach is horizontal surface that is large enough for the vehicle to attain a stable attitude during its approach to the barrier, and that does not restrict vehicle motion during impact,

3. When struck by a vehicle, the surface and its supporting structure absorb no significant portion of the vehicle’s kinetic energy, so that a performance requirement described in terms of impact with a fixed collision barrier must be met no matter how small an amount of energy is absorbed by the barrier. (571.3)

F. Fuel Spillage: The fall, flow, or run of fuel from the vehicle but does not include wetness resulting from capillary action (571.301, S3)

G. Gross axle weight rating or GAWR: The value specified by the vehicle manufacturer as the load-carrying capacity of a single axle system as measured at the tire-ground interfaces (571.3)

H. Gross vehicle weight rating or GVWR: The value specified by the manufacturer as the loaded weight of a single vehicle. (571.3)

I. H Point: The mechanically hinged hip point of a manikin which simulates the actual pivot center of the human torso and thigh, described in SAE Recommended Practice

J826, ―Manikins for Use in Defining Vehicle Seating Accommodations,‖ November

1962 (571.3)

J. Longitudinal or longitudinally: Parallel to the longitudinal centerline of the vehicle.

(571.3)

K. Outboard designated seating position: A designated seating position where a longitudinal vertical plane tangent to the outboard side of the seat cushion is less than

12 inches from the innermost point on the inside surface of the vehicle at a height between the design H-point and the shoulder reference point (as shown in fig. 1 of

Federal Motor Vehicle Safety Standard No. 210) and longitudinally between the front and rear edges of the seat cushion. (571.3)

L. Overall vehicle width: The nominal design dimension of the widest part of the vehicle, exclusive of signal lamps, marker lamps, outside rearview mirrors, flexible fender extensions, and mud flaps, determined with doors and windows closed and the wheels in the straight-ahead position. (571.3)

M. Rated cargo and luggage capacity weight (RCLW): RCLW = vehicle capacity weight – (68 kg x designated seating capacity) Maximum RCLW used in testing a truck, MPV, or bus is 136 kg.

N. Seating reference point (SgRP): The unique design H-point, as defined in SAE J1100

(June 1984), which:

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1. Establishes the rearmost normal design driving or riding position of each designated seating position, which includes consideration of…