NVS321_Crash_Testing_Attachment_J5_Hypothetical_Task.doc

Attachment J.5

Hypothetical Task Order

40 PERCENT FRONTAL OFFSET VEHICLE-TO-DEFORMABLE BARRIER CRASH TESTS IN SUPPORT OF NHTSA’S OFFSET FRONTAL PROGRAM

1.0 Objective

The objective is to perform 5 paired comparisons test of two different offset frontal test procedures to evaluate and compare vehicle and occupant responses in support of the NHTSA Offset Frontal Program (Total 10 tests).

2.0 Introduction

Over the past several years, NHTSA has conducted testing to evaluate the feasibility of adopting a high-speed fixed offset deformable barrier crash test in Federal Motor Vehicle Safety Standard (FMVSS) No. 208, ``Occupant crash protection.'' It was preliminarily determined that the benefits from such a crash test could lead to an annual reduction in approximately 1,300 to 8,000 MAIS 2+ lower extremity injuries. During this time the Directorate for Road Traffic and Safety (DSCR) of France has developed and proposed the Progressive Deformable Barrier (PDB) to replace the current offset deformable barrier in the UNECE R.94 regulation. Therefore, NHTSA is performing a paired comparison to the two offset frontal test procedures.

3.0 Referenced Documents

The following documents are required:

A. “Laboratory Test Procedure for FMVSS No. 208, Occupant Crash Protection”, TP208‑13, July 27, 2005.

B. “Laboratory Test Procedure for New Car Assessment Program (NCAP) Front Impact Testing”, dated July 2005.

C. INSIA report, “Structural Survey of Cars, Methodology of the Main Resistant Elements in the Car Body,” March 1999

Information on the NHSTA EV5 and Intrusion data format as specified in the Version 5 Test Reference Guide, Volume 1: Vehicle Tests (VTRG), may be downloaded, along with supporting data entry software, Entree for Windows, Version 5, from http://www-nrd.nhtsa.dot.gov/software/entree/index.htm All tests shall be conducted as specified in Reference B above, unless otherwise specified in this TO and according to Attachment J.6.

5. Task Description

Section 5.1 -- Task 1. Submit test plan Section 5.2 -- Task 2. Perform Frontal 40 percent Offset Deformable Barrier Crash Tests

The following sections outline the required procedures and standards for performance of the frontal 10 offset deformable barrier crash tests.

5.2.1 Mounting of Load Cell Mounting Plate and Load Cells

The Contractor shall mount the load cell mounting plate (GFE) to the barrier extension. The Government will not provide the barrier extension. The mounting plate and extension shall be rigidly attached to the concrete wall. The Contractor shall mount the load cells (GFE) to the mounting plate. Information on the load cell mounting plate and instructions for mounting the load cells to the plate will be provided upon request.

5.2.2 Pre- and Post-Test Static Measurements

Pre and post-test measurements of the test vehicles and honeycomb are listed in Attachment J.6 and shall be obtained for each vehicle and honeycomb barrier. Measurements shall be made prior to the crash test and repeated after the crash test. All linear measurements shall be in millimeters. The pre- and post-crash test measurements shall be documented in the test report. A sample test report is shown in Attachment J.6.

5.2.3 Crash Tests

5.2.3.1 Offset Deformable Barrier Test Procedure

Five crash tests are to be performed in accordance with FMVSS 208 Occupant Crash Protection procedure for offset frontal tests (Code of Federal Regulations, 571.208 S18, dated October 1, 2002), except the impact speed shall be increased to 56. The vehicles will be furnished by government as GFE.

5.2.3.2 Progressive Deformable Barrier Test Procedure

Five crash tests are to be performed in accordance with FMVSS 208 Occupant Crash Protection procedure for offset frontal tests (Code of Federal Regulations, 571.208 S18, dated October 1, 2002), except the impact speed shall be increased to 60 kph, overlap is increased to 50 percent and the honeycomb barrier is replaced with the Progressive Deformable Barrier . The vehicles will be furnished by government as GFE.

5.2.3.3 Test Specifications

For each test, the test speed and offset distance should be controlled as closely as possible, keeping test speed within a maximum tolerance of ( 1.5 kmph and the offset distance within a maximum tolerance of 20 mm, for both lateral and vertical offset. The Contractor shall provide the deformable honeycomb face for each test.

5.2.3.4 Dummies

Each subject vehicle shall include three fully instrumented belted Hybrid III dummies. The driver and front passenger shall be the HIII 50th percentile male dummy retrofitted with Thor lower legs (Thor-Lx). The left rear seat occupant shall be the HIII 10 year old dummy in booster seat. The Contractor shall use dummy instrumentation as described in Table 1 and Table 1a. The dummies will be furnished by government as GFE.

Table 1. HIII 50th Percentile Dummy Instrumentation

Data Channels

Nine Accelerometer Array 6 (Redundant)

- Forces, Fx, Fy, Fz

- Moments, Mx, My, Mz

Lower Neck Load Cell

- Forces, Fx, Fy, Fz

- Moments, Mx, My, Mz

Sternal Deflection Potentiometer 6 (Redundant)

Lower Legs

(Thor Lx/FLx)

Upper Tibia Load Cell

- Forces, Fx, Fz

- Moments, Mx, My

Lower Tibia Load Cell

- Forces, Fx, Fy,Fz

- Moments, Mx, My

Tibia mid-shaft Ax, Ay

Mid-Foot Ax, Ay, Az

Foot Rotations

(dorsiflexion/plantar flexion, inversion/eversion, internal/external rotation)

Table 1a. 10 year old Dummy Instrumentation

Data Channels

- Forces, Fx, Fy, Fz

- Moments, Mx, My, Mz

Lower Neck Load Cell

- Forces, Fx, Fy, Fz

- Moments, Mx, My, Mz

Right Shoulder – Fx, Fz

Deflection Potentiometer

Anterior Superior Iliac Spine

Left upper – Fx, Right upper – Fx

Left lower – Fx, Right lower - Fx

Lumbar Spine

Lumbar Spine Load Cell

- Forces, Fx, Fy, Fz

- Moments, Mx, My, Mz

2.

The Hybrid III dummies and Thor lower legs used in the TO shall be certified before commencement of crash testing and after every three tests (including after final test) or sooner if any injury criterion in an individual test exceeds its Injury Assessment Reference Value (IARV) by more than 15%. The Thor-Lx will be sent back to the government for certification.

3.

Dummy injury data and lower leg injury data shall be computed and reported.

4.

Instrumented lower legs (Thor-LX/FLX) will be provided by the Government/ NHTSA and shall be used by the Contractor in all tests. On-site technical assistance for the use of Thor-LX/FLX instrumentation will be provided to the Contractor on or before the first day of testing, if desired (at Contractors expense). In addition, a copy of the Thor-LX/FLX Hybrid III Retrofit Version User’s Manual, together with an Addendum (Attachment 3 for the Thor-LX and Attachment 4 for the Thor-FLX) specifying measurement procedures for use with Thor-LX/FLX ankle rotary potentiometers, will be provided to the Contractor. With regard to integration of Thor-LX/FLX instrumentation into the Contractor’s data acquisition system, the Contractor shall:

a. Ensure and document that all leg instrument polarities are correct and in accordance with a Thor-LX/FLX manipulation/polarity table, to be provided to the Contractor by the COTR;

b. Ensure that all foot/ankle rotation angles are reported in absolute units, with respect to Thor-LX/FLX foot/ankle mechanical zero positions (defined with the foot in neutral position) established by the lower leg manufacturer and supplied with Thor-LX/FLX instrument calibration data. That is, the Government specifically does not wish to utilize initial (pre-test) foot angular positions in the vehicle as zero rotation references. Further details are provided in the Addendum referenced above.

5.

The Contractor shall place a white t-shirt on the driver dummy.

6.

The COTR reserves the right to change the number of tests between the certification tests for the Thor-LX/FLX and dummies.

5.2.3.5 Vehicle Instrumentation

The Contractor shall mount the vehicle instrumentation and report their data for each vehicle as listed in Table 3. The location of the vehicle instrumentation as well as the output versus time into the event shall be recorded and included in the final test report and CD/diskette.

Table 3. Vehicle Instrumentation

* The Contractor shall place these accelerometers where the midfoot of the dummy is going to be placed.

**For vehicles with dual stage air bag systems, the Contractor shall monitor both squibs for each dual stage air bag system. Monitoring of the air bags squib circuits (voltage vs. time) shall be achieved in a noninvasive manner as to not interfere with the normal operation of the air bag system.

5.2.3.6 Load Cell Barrier

a. The Contractor shall obtain data from 36 individual load cells.

5.2.3.7 Additional Requirements

b. The lower half of the steering wheel rim shall be painted with contact paint (prior to the start of the crash test) to denote dummy abdomen-to-rim contact.

c. For all dummies, the Contractor shall paint the tibias with contact paint different from each other and different from the knees.

d. For all dummies, the Contractor shall paint the head with contact paint. With the head divided at the mid-saggital plane, the contractor shall paint the left hemisphere of the head a different color than the right hemisphere.

e. The Contractor shall paint the foot pedals (top, sides, and bottom) with contact paint different from each other to denote lower leg-to-pedal contact.

f. The Contractor shall add the Actual Vehicle Offset after Maximum Static Crush in the crash test summary section of the report.

g. The Contractor shall add a row called Lower Legs in the Dummy section of the final report and include serial numbers for the dummy and Thor-LX/FLX legs

h. The Contractor shall measure the vertical and longitudinal distance from the target point (desired impact point). The method for measuring this distance must be approved by the COTR before testing is to begin.

i. In addition, three contact switches will be added between the left foot and toepan, the right foot and accelerator pedal, and between the knee and knee bolster. If the right foot is resting on the pedal, then there is no need for a contact switch.

i. The summary table in Attachment J.6 shall include injury values for the 6 and 10 year old dummies. The injury values to be included include HIC, max Nij, peak neck tension and compression, 3ms chest clip, and chest deflection.

j.

Data sheet No. 8 shall be updated with the HIC and peak chest 3ms clip for both the 6 year old and 10 year old dummies.

5.2.3.7 Additional Still Photos (Pre- and Post-Crash)

j. The Contractor shall provide still photos of driver foot/leg close-up with door open.

k. The Contractor shall provide still photos of passenger foot/leg close-up with door open.

l. The Contractor shall provide still photos of driver dummy abdomen (close-up view with door open and air bag pushed away as to not obstruct the view of the dummy abdomen).

m. The Contractor shall provide still photos of driver toe pan pre- and post-test from same camera position and angle with dummy removed.

n. The Contractor shall provide still photos of passenger toe pan pre- and post-test from same camera position and angle with dummy removed.

o. The Contractor shall provide still photos of passenger toe pan / floor pan (close-up view with door open and dummy removed). Note the pre- and post-test pictures should be taken from the same perspective.

p. The Contractor shall provide close-up still photos of the deformation of the A, B, and C Pillars and sill with the door open.

q. The Contractor shall provide close-up still photos of any deformation on the rocker.

r. The Contractor shall provide close-up still photos of any interior dummy-to-vehicle contacts.

s. The Contractor shall remove the wheel/tire and provide still photos of the rail from the side and close-up still photos of the wheel well area. If possible, a photo of the shotgun would be helpful.

t. The Contractor shall provide close-up still photos of the steering rack and/or sway bar (including connections and any cracking).

u. The Contractor shall provide close-up still photos of bumper to rail attachments, and any crush initiators.

v. The Contractor shall provide close-up still photos of wheel/tire deformation.

w. The Contractor shall provide close-up still photos of any area where the tire/wheel hit the rocker/hinge pillar

x. The Contractor shall provide still photos of deformed front sub-frame by itself, if possible.

y. The Contractor shall provide still close-up photos of the underbody of the front structure, taken perpendicular with front of car on left side of the picture.

z. The Contractor shall provide still photos of the underbody overall – same as above

aa. The COTR reserves the right to add additional photos.

ab. The Contractor shall provide still photos of all dummies with the door open.

ac. The Contractor shall follow the following procedure to obtain toepan/floorboard photos (driver and passenger sides):

1) Overall toepan/floorpan from the right of the seat, left of the seat, and the center of the seat. When the photo is taken from the side with the door, the door should be opened. One set of these photos shall be taken from the height of the seat cushion and another set shall be taken from the height of the sill.

2) Photo of the accelerometer pedal taken from the left side of the seat at seat cushion height. The left edge of the photo shall be at the center of the brake pedal. The left edge of the brake pedal shall not be shown in this picture. This picture shall include the whole accelerometer pedal. The same picture shall be taken from the sill height.

3) From behind the brake pedal or clutch pedal if equipped a photo shall be taken of the accelerometer pedal. The photo shall include the whole accelerometer pedal and the area behind the accelerometer pedal. The same photo shall be taken from the front of the brake pedal. If camera does not fit behind the pedals, then the photo shall be taken from the front of the brake pedal.

4) Photo of the footrest taken from the right side of the seat at seat cushion height. The right edge of the photo shall be at the center of the brake pedal and the whole footrest shall be in picture. The right edge of the brake pedal shall not be shown in this picture. Take the same picture from the right side of the seat at sill height.

5.2.3.8 Toepan Measurements

The Contractor shall measure interior points of the vehicle pre and post test. Attachment J.6 provides the procedure for measuring these points.

5.2.3.9 Data Plots

Plots of all data channels and tables showing the maximum value, minimum value, and times that these values occurred for each channel shall be included in the test report. The plot should also indicate the CFC filter used.

5.2.3.10 Reporting Data Anomalies

1.

Within 48 hours after each test the Contractor shall review the data from each channel recorded. The Contractor is responsible for finding any anomalies in the data or the behavior of the instrumentation and reporting it to the COTR. Anomalies include, but are not limited to:

a.

A transducer that transmits no signal or stops transmitting during the test b.

A recorded signal in which the peak (at 1650 Hz) is greater than the capacity of the instrumentation

c. A recorded signal which contains more than one “spike” unexplainable by the physics of the impact

d. Bias errors

e. Zero drifts

The Contractor shall attempt to find the cause of any anomalies and no further tests shall be conducted until the Contractor and the COTR are assured of the quality of the data transmitted by the instrumentation and the procedure for the next test.

2. The Contractor shall insert a table in the test report directly following “Summary of Test” which lists each problem, the channel number, the instrumentation involved and its location on the vehicle or dummy including mounting axis if applicable, and the known or suspected cause of the problem.

Section 5.3 - Deliverables

5.3.1 Test Plan

The Contractor shall submit a Test Plan that describes the method for conducting the tests to the COTR within three (3) weeks of the date of the TO award. If major changes occur within the duration of the TO to the crash test plan, the changes must be submitted to the COTR in an addendum to the Test Plan. The Contractor shall not begin testing until receiving approval of the Test Plan by the COTR. The Test Plan shall include a schedule for completion of the tests, instrumentation, measurements, camera/lens identification, camera position (approximate x, y and z coordinates), camera layout and test procedure.

5.3.2 Reports

Reports shall be submitted by the Contractor to the COTR as specified in sections C.3.3 and C.3.4 of the contract. Metric units are required. The Contractor shall deliver two PDF formatted copies of the draft final report and two PDF copies of the final report. Example of report format is in Attachment J.6.

Monthly Progress and Cost Summary reports as described in Section C.5 of the contract will be required and shall be submitted to the COTR and the Contracting Officer (2 copies each).

5.3.3 Film and Video

For photographic documentation (photos and video), the Contractor shall follow the procedures in Chapter 9 of the “Laboratory Test Procedure for New Car Assessment Program (NCAP) Front Impact Testing”, dated December 2004. The Contractor shall use one real time camera and 16 high-speed cameras to document the crash. The camera coverage requirements are described in Table 3. The camera used to document the movement of the driver’s seat belt in the NCAP procedure shall be moved to provide an overhead view of the top of the vehicle (perpendicular to the top of the vehicle). This camera shall cover 50 percent of the top of the vehicle when the vehicle impacts the barrier. In addition, the Contractor shall use in each camera view (where practical) the specific reference targets, and impact event markers as specified in the above referenced document and additional targets on top of the vehicle. The COTR will provide the location of these additional targets. The Contractor shall use camera numbers 17 and 18 to capture the motion of the driver and passenger lower limbs and feet respectively interacting with the toeboard. The Contractor shall meet the additional requirements for high-speed film/video coverage of the vehicle crash test specified on data sheet 15 of Attachment J.6. The COTR reserves the right to modify the locations of these cameras. A copy of the NCAP document will be available upon request from the COTR. Placards and any other information that references the title of the test should use the make/model/year of the vehicle and the crash test speed and configuration (instead of the NCAP notations).

The Contractor shall deliver an AVI file for each camera.

Table 3. Camera Coverage Requirements

(fps)

DIGITAL

IMAGE

RESOLUTION*

1024x1024

* The resolution specified is the minimum nominal requirement except as defined below. If an alternative means for achieving this resolution is proposed, it must be discussed with the COTR.

** The Contractor shall place the camera under the seat and the carpet. The Contractor shall ensure that the carpet is glued down on the toepan and floorboard regions and that the cables do not block the camera during the test.

*** The camera is to be perpendicular to the vehicle. The field of view shall be from the load cell plate to the top of the vehicle back to the b-pillar

Any digital high-speed video view having greater than 1500 mm in the horizontal plane, shall be high resolution with a lens of 50 mm or longer. High resolution is defined as having a minimum of 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 also be a minimum of 1024 rows of sensors.

Any digital high-speed video view having less than 1500 mm in the horizontal plane, shall be at least medium resolution, having a minimum actual pixel resolution of 512 x 512 and a lens of 25 mm or greater. Medium resolution is defined as having a minimum of 512 CMOS sensors per every row of pixels, with 80% of the horizontal distance of the row covered by effective light sensors.

Close-up digital video views are allowed with low resolution (less than 512 x 512) or medium resolution video cameras with any lens combination, if approved by the COTR. These close-up digital cameras are typically reserved for visual observation and timing only, but not for film analysis purposes.

The Contractor shall provide a minimum four high-resolution digitally formatted (e.g., AVI) movie files of the crash test. Digital images may be stored on more than one CD. Footage for each camera shall be stored as a separate file.

The digital movie files shall record from at least 10 ms before barrier contact to at least 310 ms after barrier contact. A time zero light must be registered in a frame to indicate when contact with the barrier is made in a crash test. The views may originate from high-speed digital cameras or may be scanned from the 16 mm negative film. The views that will be provided in digital format shall be approved by the COTR.

Digitally formatted movie files scanned from 16 mm film shall include the timing information from outside the frame. The resolution shall be at least the resolution specified in Table 3. Transferring the film to a digital format shall conform to these specifications:

· The digital video output shall record at least 10 ms before barrier contact to at least 310 ms after barrier contact. A time zero light must be registered in a frame to indicate when contact with the barrier is made in a crash test.

· The digital video output should be in AVI or MPEG format.

· Each image should able to be viewed by software such as Real player or Windows Media player.

· Real timing marks must be transferred to the digital image.

· Transferred video output should not jump around the screen when viewing frame-by-frame.

· The quality of the image transferred from film to digital video must be pre-approved by the COTR.

The Contractor shall deliver one set of still photos in digital (JPEG) format. The JPEG files shall have the same naming convention as used on the photos in the final report.

5.3.4 Electronic Test Data

The Contractor shall submit data CD's/diskettes in the NHSTA EV5 and Intrusion data format as specified in the Version 5 Test Reference Guide, Volume 1: Vehicle Tests (VTRG), which may be downloaded, along with supporting data entry software, Entree for Windows, Version 5, from http://www-nrd.nhtsa.dot.gov/software/entree/index.htm.

The initial electronic data submission post-test will contain specification and measurement data in this EV5 and intrusion format. Subsequent submission of the digital photos (JPEG), AVI files, and the PDF copies of the final report shall also be prepared in accordance with the specifications for submission of these deliverables as defined in the Guide (VTRG).

6.0 Government Furnished Equipment (GFE)

All dummies including special instrumentation (not including standard FMVSS 208 requirements) will be furnished by the Government. In addition, the Government will furnish the load cell mounting plate and the load cells. The Contractor will firmly affix the load cells to the mounting plate and the mounting plate to the barrier extension. .

7.0 Contractor Acquired Property

The Contractor shall purchase 5 honey comb barriers as specified in Code of Federal Regulations, 571.208 S18, dated October 1, 2002 and 5 PDBs. Assume the cost of the barriers is $40,000.

7.0 Schedule

Deliverables Date Test plan

No later than three weeks after award of TO vehicle acquisition

Begin Testing

Upon COTR'S approval of Test Plan or when

COTR authorizes commencement

Injury Summary Table Submitted two days after each test

Data CD/diskette One week after each test

High Speed Video or Film Two days after each test

Draft Final Report and Still Photos Submitted to COTR two weeks after each test

Final Report Submitted to COTR one week after receiving comments on the respective draft report

Progress and Cost Summary Reports Submitted monthly to the COTR and Contracting Officer

Additionally, the Contractor shall notify the TOCOTR and the ACO; when 75% of the total authorized TO has been expended; when the level of effort that the Contractor expects to incur under any TO in the next 30 days, when added to the level of effort previously expended in the performance of the TO, will exceed 90% of the level established for that TO; or the level of effort required to perform a particular TO will be greater than the level of effort established for that TO.