NVS321_Crash_Testing_Attachment_J6_Ex_Test_Report.doc

ATTACHMENT J.6

SAMPLE TEST REPORT

First three pages of the report shall be in accordance with “Laboratory Test Procedure for New Car Assessment Program (NCAP) Front Impact Testing”, dated December 2004.

TABLE OF CONTENTS

Purpose and Summary of tests

Occupant and Vehicle Information / Data Sheets

Appendix A - Photographs

Appendix B - Dummy, Vehicle, and Moving Deformable Barrier Load Cell Response Data Traces

Appendix C - Dummy Calibration

Appendix D - Test Equipment and Instrumentation Calibration

Appendix E - Procedure for Vehicle Interior Intrusion Measurements

Appendix F - INSIA Report

PURPOSE AND SUMMARY OF TEST

PURPOSE

SUMMARY

The occupant injury assessment values are summarized below.

HIC (15 ms)

Max Nij

Peak Upper Neck Tension (N)

Peak Upper Neck Compression (N)

3 ms Chest Acceleration (g’s)

Chest Deflection (mm)

Max Femur Compression (N)

Max Knee Displacement (mm)

Max Upper Tibia Index

Max Lower Tibia Index

Max Upper Tibia Compression (N)

Max Lower Tibia Compression (N)

Max Inversion/Eversion (degrees)

Max Dorsiflexion/Plantarflexion (degrees)

Max Internal/External Rotation

Electronic data anomalies are summarized below.

DATA SHEET NO. DESCRIPTION

1.

Crash Test Summary

2.

General Test and Vehicle Parameter Data

3.

Post Impact Data

4.

Test Vehicle Information

5.

Dummy Positioning in Vehicle

6.

Seat Belt Positioning Data

7.

Vehicle Accelerometer Location And Data Summary

8.

Dummy Injury Criteria Values

9.

Seat Belt Performance Data

10.

Summary of FMVSS 212 Data

11.

Windshield Zone Intrusion FMVSS 219 Data

12.

FMVSS 301 Fuel System Integrity Data

13.

FMVSS 301 Rollover Data

14.

Vehicle Measurements

15.

Camera Data

16.

Reference Photo Targets

17.

Post Test Air Bag Data

18. Accident Investigation Division Data

19. Offset Barrier and Vehicle Orientation

20. Deformable Barrier Honeycomb Crush

21. Deformable Barrier Load Cell Locations

DATA SHEET NO. 1

CRASH TEST SUMMARY

Vehicle NHTSA No.:

Test Mode:

Test Date:

Time:

Temperature:

oC

Vehicle Make/Model/Body Style:

Vehicle Test Weight:

Kg

Vehicle/Barrier Impact Angle:

o

Impact Velocity:

Kph

Maximum Static Crush:

Mm

Vehicle Rebound:

Mm

PASSENGER

Type:

Type Lower Leg / Serial Number

Restraint System:

Number of Data Channels:

Number of Cameras:

Real Time

High Speed

DOOR OPENING DATA:

- Left Front

- Right Front

PASSENGER

Seat Track Failure (mm of shift):

Seat Back Failure:

PASSENGER

Head:

Abdomen:

Chest:

Knees:

DATA SHEET NO. 2

GENERAL TEST AND VEHICLE PARAMETER DATA

TEST VEHICLE INFORMATION:

Year/Make/Model/Body Style:

NHTSA No.:

VIN:

Color:

Engine Data:

Cylinders

CID

Liters cc

Placement:

Longitudinal or In-line

Transverse or Lateral

Transmission Data:

Speeds

Manual

Automatic

Overdrive

Final Drive:

Rear Wheel

Front Wheel

Four Wheel

Major Options

A/C

Pwr. Steering

Pwr. Brakes

Pwr. Seats

Tilt Wheel

Pwr. Windows

Pwr. Locks

Cruise Control

Date Received:

Odometer Reading:

km

Selling Dealer:

& Address:

DATA FROM TIRE VEHICLE'S CERTIFICATION LABEL:

Vehicle Manufactured by:

Date of Manufacture

GVWR:

kg; GAWR:

kg FRONT;

kg REAR

DATA FROM TIRE OR TIRE PLACARD:

Tire Pressure with Maximum Capacity Vehicle Load:

kpa FRONT kpa REAR

Load Index & Speed Symbol:

Recommended Tire Size:

kpa FRONT;

kpa REAR

Tire Grades: ___________ Treadwear;

Size of Tires on Test Vehicle:

; Manufacturer:

Vehicle Capacity Data:

Type of Front Seats:

Bench;

Bucket;

Split Bench

Number of Occupants:

Front;

Vehicle Capacity Weight (VCW) = kg

No. of Occupants x 68 kg = kg

Rated Cargo/Luggage Weight (RCLW) = kg

*Tire pressure used for test

DATA SHEET NO. 2 (continued)

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

DATA RECORDED FROM ACTUAL TIRES ON TEST VEHICLE

Manufacturer

Brand Name

Tire Size (ex. P215/65R15)

Load Index & Speed Symbol

Tread wear

Traction

Temperature

DATA SHEET NO. 2 (continued)

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

WEIGHT OF TEST VEHICLE AS RECEIVED FROM DEALER (with maximum fluids) = UDW:

Right Front =

kg

Left Front =

kg

TOTAL FRONT =

kg

TOTAL DELIVERED WEIGHT =

Kg

% of Total Front of Vehicle Weight =

% of Total Rear Weight =

CALCULATION OF VEHICLE'S TARGET TEST WEIGHT :

Total Delivered Weight (UDW) = kg

Rated Cargo/Luggage Weight (RCLW) = kg

Weight of 2 p.572 Dummies @ 76 each = kg

TARGET TEST WEIGHT =

kg

WEIGHT OF TEST VEHICLE WITH TWO DUMMIES &

KG OF CARGO WEIGHT:

Right Front =

kg

Left Front =

kg

TOTAL FRONT =

kg

TOTAL TEST WEIGHT =

Kg

% of Total Front Weight =

% of Total Rear Weight =

Weight of Ballast Secured in Vehicle Trunk Area = kg

Vehicle Components Removed for Weight Reduction:

VEHICLE ATTITUDE (all dimension in millimeters):

LF

RR

LR

LF

RR

LR

LF

RR

LR

Vehicle's Wheel Base :

Mm

Location of Vehicle's C.G. :

mm rearward of front wheel center.

FUEL SYSTEM DATA :

Fuel System Capacity From Owner's Manual = liters

Usable Capacity Figure Furnished by COTR = liters

Test Volume Range (92 to 94% of Usable Capacity) = to liters

ACTUAL TEST VOLUME=

liters (with entire fuel system filled)

Test Fluid Type:

; Spec. Grav. =

Kinematic Viscosity =

Type of Fuel Pump: Electric-

; Mechanical-

No-

Details of Fuel System

DATA SHEET NO. 3

POST IMPACT DATA

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

TYPE OF TEST:

Type of Test:

Impact Angle:

Test Date:

Time:

Temperature:

oC

Vehicle NHTSA No. :

Required Impact Velocity Range:

to kph

BARRIER IMPACT VELOCITY: (Speed traps within 5 feet of impact plane.)

Trap No. 1 = kph; Trap No. 2 = kph

mm

(2) exiting trap = mm

VEHICLE STATIC CRUSH: (mm) (For frontal and rear impacts only.)

Vehicle Length:

; C/L =

; Left =

; C/L =

; Left =

; C/L =

; Left =

Mm

VEHICLE REBOUND: (From rigid barrier only.)

Distance from front of test vehicle to impact point:

Right =

; C/L =

; Left =

Mm

OFFSET DISTANCE FROM IMPACT POINT:

Lateral distance from impact point (mm):

Vertical distance from impact point (mm):

Desired Offset (mm)

Actual Offset (mm):

Note: Use SAE J211 vehicle and laboratory coordinate system to determine positive or negative distance from impact point.

DATA SHEET NO. 4

TEST VEHICLE INFORMATION

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

VEHICLE IDENTIFICATION:

Model Year:

Vehicle Model:

Body Style:

Nominal Design Riding Position for adjustable driver and passenger seat backs. Please describe how to position the inclinometer to measure the seat back angle. Include description of the location of the adjustment latch detent, if applicable.

Seat back angle for driver's seat:

Measurement instructions:

Seat back angle for passenger's seat:

Measurement instructions:

Positioning of the driver's seat:

Positioning of the passenger's seat:

liters

B. “Usable Capacity” of the optional equipment fuel tank is liters

C. “Usable Capacity” of the vehicle(s) used for certification testing to requirements of FMVSS 301 = liters

liters

; No-

If YES, explain the vehicle operating conditions under which the fuel pump will pump fuel.

Steering wheel and column adjustments are made so that the steering wheel hub is at the geometric center of the locus it describes when it is moved through its full range of driving positions. If the tested vehicle has any of these adjustments, does your company use any specific procedures to determine the geometric center?

Operational Instructions:

Nominal design riding position:

DATA SHEET NO. 5

FRONT SEAT DUMMY POSITIONING MEASUREMENTS IN VEHICLE

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

DATA SHEET NO. 5 (continued)

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

WAO

SWAO

SCAO

SAO

HZ

HH

HW

HR

NR

Angle

CD

CS

RA

KDL

Angle (KDA) deg.

KDR

Angle (KDA) deg.

PAO

deg.

deg.

TAO

deg.

deg.

KK

ST

Angle deg.

Angle deg.

SK

Angle deg.

Angle deg.

SH

Angle deg.

Angle deg.

SHY

HS

HD

AD

Dimensions in millimeters

FRONT SEAT DUMMY POSITIONING MEASUREMENTS IN VEHICLE

DESCRIPTIONS OF DUMMY MEASUREMENTS

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

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.

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

HH

Head to Header, taken from the point where the dummy's nose meets his forehead (between his eyes) to the furthest point forward on the header.

HW

Head to Windshield, taken from the point where the dummy's nose meets his forehead (between his eyes) to a point on the windshield. Use a level.

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.

CS

Steering Wheel to Chest, taken from the center of the steering wheel hub to the dummy's chest. Use a level.

CD

Chest to Dash, 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 dashboard, either between the upper part of the steering wheel between the hub and the rim, or measure to the dashboard placing the tape measure above the rim, whichever is a shorter measurement. See photograph.

RA

Steering Wheel Rim to Abdomen, taken from the bottommost point of the steering wheel rim horizontally rearward to the dummy. Use a level.

NR

Nose to Rim, taken from the tip of the dummy's nose to the closest point on the top of the steering wheel rim. Also indicate the angle this line makes with respect to the horizontal (NA).

*1

KDL, KDR

Left and Right Knees to Dashboard, taken from the center of the knee pivot bolt's outer surface to the closest point forward acquired by swinging the tape measure in continually larger arcs until it contacts the dashboard. Also reference the angle of this measurement with respect to the horizontal for the outboard knee (KDA). See photograph.

SH, SK, ST

Striker to Hip, Knee, and Head, these measurements are to betaken in the X‑Z plane measured from the forward most center point on the striker to the center of the H‑point, outer knee bolt, and head target. When taking this measurement a firm device that can be rigidly connected to the striker should be used. Use a level. The angles of these measurements with respect to the horizontal should also be recorded. The measurement in the Y (transverse) direction from the striker to the H‑point should also be taken (SHY). See photograph.

NOTE:

Measurement used in Data Tape Reference Guide

Only outboard measurement is referenced in Data Tape Reference Guide

DATA SHEET NO. 5 (continued)

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

REAR SEAT DUMMY POSITIONING MEASUREMENTS IN VEHICLE

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

REAR PASSENGER (Serial #)

SA

HZ

HR

HS

HB

CB

KB

PAO

Deg.

TAO

Deg.

KK

ST

Angle deg.

SK

Angle deg.

SH

Angle deg.

SHY

HS

HD

AD

Dimensions in millimeters

REAR SEAT DUMMY POSITIONING MEASUREMENTS IN VEHICLE

DESCRIPTIONS OF DUMMY MEASUREMENTS

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

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.

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

HW

Head to seatback, taken from the point where the dummy's nose meets his forehead (between his eyes) to the seatback. Use a level.

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.

CB

Chest to seatback, 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 seatback.

KB

Knee to seatback, taken from the center of the knee pivot bolt's outer surface to the seatback.

SH, SK, ST

Striker to Hip, Knee, and Head, these measurements are to betaken in the X‑Z plane measured from the forward most center point on the striker to the center of the H‑point, outer knee bolt, and head target. When taking this measurement a firm device that can be rigidly connected to the striker should be used. Use a level. The angles of these measurements with respect to the horizontal should also be recorded. The measurement in the Y (transverse) direction from the striker to the H‑point should also be taken (SHY). See photograph.

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, roll the window down to the exact height, which allows a level measurement. Use a level. See photograph.

AD

Arm to Door, taken from the outer biceps on a Hybrid III dummy to the first point it hits on the door. When a SID is used make the measurement from the center of the bottom of the arm segment where it meets the dummy's torso.

HD

H‑point to Door, taken from the H‑point on the dummy to the closest point on the door. Use a level.

HR

Head to Side Header, measure the shortest distance from the point where the dummy's nose meets his forehead (between his eyes) to the side edge of the header just above the window frame, directly adjacent to the dummy.

SHY

Striker to H‑point, taken from a rod rigidly connected to the forward most center point on the striker to the H‑point. Use a level. See photograph.

KK

Knee to Knee, for Hybrid III dummies measure the distance between the outboard knee clevis flange surfaces. (This measurement may not be exactly transverse.)

Angles

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.

PA

Pelvic or Femur Angle, taken by inserting the pelvic angle gauge into the H‑point gauging hole on the SID or the Hybrid III dummies and taking this angle with respect to the horizontal.

TA

Tibial Angle, use a straight edge to connect the dummy's knee and ankle bolts. Then place an inclinometer on the straightedge and measure the angle with respect to the horizontal.

DATA SHEET NO. 6

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

DRIVER DUMMY

(mm)

PASSENGER DUMMY

(mm)

REAR PASSENGER DUMMY

(mm)

PBU — Top surface of aluminum plate to belt upper edge

PBL — Top surface of aluminum plate to belt lower edge

LAP BELT TENSION

SHOULDER BELT TENSION

DATA SHEET NO. 7

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

DATA SHEET NO. 7 (continued)

VEHICLE ACCELEROMETER LOCATIONS AND DATA SUMMARY

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

PRE-TEST VALUES

A Left Rear Seat Cross member Y

B Right Rear Seat Cross member Y

C Top of Engine X

D Bottom of Engine X

E Right Disc Brake Calipers X

F Left Disc Brake Calipers X

G Instrument Panel X

H Left Rear Seat Cross Member X

I Right Rear Seat Cross Member X

J Vehicle Center of Gravity X

K Driver Side Mid Seat Track X

L Accelerator Pedal X

M Break Pedal X

N Foot Rest X

LOCATION

NUMBER

DATA SHEET NO. 7 (continued)

VEHICLE ACCELEROMETER LOCATIONS AND DATA SUMMARY

DATA SHEET NO. 8

DUMMY MAX/MIN VALUES

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

MAXIMUM VALUE

15.

DATA SHEETS... Continued

DATA SHEET NO. 8 (continued)

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

MAXIMUM VALUE

DATA SHEETS... Continued DATA SHEET NO. 8 (continued)

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

MAXIMUM VALUE

DATA SHEET NO. 8 (continued)

DUMMY INJURY CRITERIA VALUES

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

HEAD INJURY CRITERIA

t1 to t2

Position #1 - Driver

Position #2 - Passenger

** HIC is as defined in FMVSS 208. The maximum time interval from t1 to t2 is 0.015 seconds.

CLIP SUMMARY*

Position #1 - Driver

Position #2 - Passenger

* The maximum chest resultant acceleration is defined as the maximum acceleration that exceeds 0.003 seconds in duration.

DATA SHEETS... Continued DATA SHEET NO. 8 (continued)

DUMMY INJURY CRITERIA VALUES

REDUNDANT DATA

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

HEAD INJURY CRITERIA (HIC) — REDUNDANT

t1 to t2

Position #1 - Driver

Position #2 - Passenger

** HIC is as defined in FMVSS 208. The maximum time interval from t1 to t2 is 0.015 seconds.

CLIP SUMMARY* — REDUNDANT

Position #1 - Driver

Position #2 - Passenger

* The maximum chest resultant acceleration is defined as the maximum acceleration that exceeds 0.003 seconds in duration.

DATA SHEET NO. 9

SEAT BELT PERFORMANCE ASSESSMENT TEST DATA

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

Passenger *

Belt length from trim panel exit to bolt hole anchor point for continuous webbing systems.

Shoulder belt length as measured on Part 572 Dummy.

Lap belt length as measured on Part 572 Dummy.

SHOULDER BELT SPOOL-OFF DATA:

As determined by film analysis.

As determined mechanically.

As determined electronically.

BELT STRETCH DATA:

Measured electronically between shoulder belt load cell and the “D” ring.

Measured mechanically.

NOTE:

* All Dimensions in millimeters.

† Safety belt trim exit was located at the upper D-ring. There was no available mounting location for the mechanical or electronic spool-off measurement.

DATA SHEET NO. 10

SUMMARY OF FMVSS 212 DATA

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

FMVSS NO. 212 - “WINDSHIELD MOUNTING” DATA

DETAILS OF WINDSHIELD MOUNTING SUCH AS RETENTION METHOD, TRIM TYPE, ETC.

FMVSS 212 REQUIREMENTS

The Post-Test periphery retention amount must be at least 75% of the Pre-Test periphery measurement for vehicles NOT equipped with automatic restraints, and 50% for each side of the windshield for vehicles equipped with automatic restraint systems for front occupants, FMVSS 212 TEST DATA

WINDSHIELD PERIPHERY

RIGHT SIDE

LEFT SIDE

TOTAL

AREA OF RETENTION FAILURE

DIMENSIONS (mm)

A

B

C

D

FAILURE DETAILS

DATA SHEET NO. 11

FMVSS NO. 219 (PARTIAL) - “WINDSHIELD ZONE INTRUSION” DATA

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

PROTECTED ZONE LOWER EDGE REQUIREMENT

The lower edge of the protected zone is determined by placing a 165mm diameter rigid sphere weighing 6.8 kg in a position such that it simultaneously contacts the inner surface of the windshield and the top surface of the instrument panel including padding. The locus of points is drawn on the inner surface of the windshield contacted by the sphere across the width of the instrument panel. From the outermost contactable points extend the locus line horizontally to the edges of the windshield; then draw a line on the inner surface of the windshield below and 13mm distant from the locus line. The LOWER EDGE OF THE PROTECTED ZONE is the longitudinal projection of this line onto the outer surface of the windshield.

FMVSS 219 TEST DATA

(Dimensions in mm)

DIMENSIONS

A

B

C

D

E

F

DETAILS OF WINDSHIELD

GLASS PENETRATION

GREATER THAN 6 mm: None

(Show location of penetration on the above sketch)

COORDINATES

1.

2.

3.

4.

DATA SHEET NO. 12

FMVSS NO. 301-75 “FUEL SYSTEM INTEGRITY” POST IMPACT TEST DATA

NHTSA TEST No.:

TEST DATE:

VEHICLE MAKE/MODEL:

The test vehicle was filled from 92% to 94% of the manufacturer's “usable” capacity. The electric fuel pump was operating if it will operate without engine operation. Two Part 572 anthropomorphic test devices were located at each of the front designated seating positions.

TEST VEHICLE IMPACT TYPE

Frontal (56 kph)

Oblique (48 kph) with _________ deg. barrier face first contacting _______________________________ side

(driver / passenger)

Rear Moving Barrier (48 kph)

Lateral Moving Barrier (32 kph)

FUEL SPILLAGE MEASUREMENT

ALLOWED

1. From impact until vehicle motion ceases

28 g

2. For 5 minute period after vehicle motion ceases

141 g

3. For next 25 minutes

28 g/min.

SOLVENT SPILLAGE DETAILS

DATA SHEET NO. 13

FMVSS 301 STATIC ROLLOVER DATA SHEET tc "FMVSS 301 STATIC ROLLOVER DATA SHEET " \l 5 Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

0° TO 90°

90° TO 180°

180° TO 270°

270° TO 360°

1. The specified fixture rollover rate for each 90° of rotation is 60 to 120 seconds.

2. The position hold time at each position is 300 seconds (minimum).

Details of Stoddard Solvent spillage locations

(oz.)

0° TO 90°

90° TO 180°

180° TO 270°

270° TO 360°

DATA SHEET NO. 14

TEST VEHICLE MEASUREMENTS (cont.)

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

DATA SHEET NO.14 (continued)

VEHICLE MEASUREMENTS

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

All Dimensions in mm

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

DOOR OPENING WIDTH AND WHEELBASE

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

STATIC FOOTWELL DEFORMATION

DRIVER

A

B

C

D

All units in millimeters

PASSENGER

A

B

C

D

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

STATIC PASSENGER COMPARTMENT INTRUSION

I

J

K

L

M

N

O

P = K (PASS.)

Q = M (PASS.)

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

FLOORBOARD DEFORMATION

A

B

C

D

E

F

G

H

DATA SHEET NO. 14 (continued)

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

Test Vehicle Frontal Profile Data

Pre-Test Profile

Y

Z

Y

Z

Y

Z

Y

Z

Post-Test Profile

Y

Z

Y

Z

Y

Z

Y

Z

Change

Y

Z

Y

Z

Y

Z

Y

Z

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

VEHICLE STRUCTURAL MEASUREMENTS

*All distance measurements are in millimeters. The numbers in () denote the measurement numbers in the INSIA report.

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

ADDITIONAL TOE PAN FLOORBOARD INTRUSION

Driver Side Toe Pan and Floorboard Measurements

A1

B1

C1

D1

A2

B2

C2

D2

A3

B3

C3

D3

A4

B4

C4

D4

A5

B5

C5

D5

BP

LB

RB

SW

AB

BP=Brake Pedal, LB=Left side of bolster, RB=Right side of bolster, SW=Steering wheel center, AB=Front outboard seat anchor bolt

Procedure for measuring interior points is located in Appendix E

DATA SHEET NO.14 (continued)

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

Passenger Side Toe Pan and Floorboard Measurements

A1

B1

C1

D1

A2

B2

C2

D2

A3

B3

C3

D3

A4

B4

C4

D4

A5

B5

C5

D5

LB

RB

AB

LB=Left side of bolster, RB=Right side of bolster, AB=Front outboard seat anchor bolt

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

Driver Side Contour Measurements

Additional points to be identified by COTR

DATA SHEET NO. 15

CAMERA POSITIONS FOR FRONTAL IMPACTS

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

NOTE: Camera information shown in Table 3 of Attachment 1.

DATA SHEET NO.15 (continued)

HIGH-SPEED CAMERA LOCATIONS

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

X Y Z

ANGLE

(deg)**

(mm)

SPEED

(fps)

DATA SHEET NO.15 (continued) Additional Requirements

High Speed Film Coverage of the Vehicle Crash Tests

1. Provide rooftop targets in the plane of the steering column.

2. Provide overhead stationary reference targets over each vehicle by means of stanchions anchored to the ground.

3. To correctly position the cameras before the test, line the cars up at the impact area and position each camera to cover its portion of the vehicles and targets throughout the duration of the impact.

4. Ensure each camera is accurately focused on its subject.

5. Provide exact lighting of the vehicle interior, not too bright such that the interior is washed out.

6. Provide two targets fastened to the centerline of each steering column.

7. After the face chamois has been applied to the dummies, paint the center of the dummies face with a line of chalk in a contrasting color to the steering assembly and instrument panel.

8. Remove outside rear view mirrors from each vehicle before the test.

9. Choose the color of the inch tapes on the car exterior to contrast sharply with the color of the car.

10. Place targets at the centers of all wheels such that they will not come off during impact.

11. A table titled “High Speed Camera Locations” shall appear in the Test Report and shall include, for each camera:

a. camera number,

b. description of the view of the camera,

c. camera position in x, y, and z directions in inches from stated reference points,

d. camera angles in degrees from a stated reference plane,

e. camera lens size in millimeters, and

f. exact film speed.

The same reference points/plane (mentioned in c. and d. above) shall be used for all camera positions. The movie shall be spliced such that the films appear in the order the cameras are numbered in the above table.

DATA SHEET NO. 16

VEHICLE REFERENCE PHOTO TARGET LOCATIONS

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

DATA SHEET NO. 17

POST TEST AIR BAG DATA

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

NHTSA No.:

Test Date:

Technician:

Vehicle Model Year/Make/Model:

A.

No. of vent holes:

-Driver

-Passenger

B.

-Driver

-Passenger

C.

-Driver

-Passenger

D.

Deflated air bag length and width dimensions or, if round, diameter. (mm)

Driver:

-Length;

-Width;

-Diameter

Passenger:

-Height;

-Width;

-Depth

E.

Is the air bag tethered?

Driver:

-Yes;

Passenger:

-Yes;

Sketch the air bag showing the location of the vent holes, how the bag is tethered, and where the bag is tethered. Also describe how the tethers are attached to the bag and the steering wheel.

(Note: Not to scale; Vn = Vent holen , Tn = Tethern ).

F.

Record part numbers and manufacturer name of the air bag and gas generator.

Driver:

Passenger:

DATA SHEET NO. 18

ACCIDENT INVESTIGATION DIVISION DATA

Vehicle Year/Make/Model/Body Style:

NHTSA Test No.:

Test Date:

FOR FRONTAL BARRIER IMPACT

Vehicle Make/Model/Body Style:

NHTSA Test No.:

VIN:

Model Year:

Build Date:

Test Date:

Vehicle Size Category:

Test Weight:

kg

Vehicle Wheelbase:

mm; Front Overhang:

mm; Overall Width:

mm

Collision Deformation Classification (CDC) Code:

Crush Depth Dimensions

C1 =

Mm

C2 =

Mm

C3 =

Mm

C4 =

Mm

C5 =

Mm

C6 =

Mm

mm

L2= mm

L3= mm

REMARKS:

DATA SHEET NO. 19

OFFSET BARRIER AND VEHICLE ORIENTATION

NHTSA Test No.:

Test Date:

DATA SHEET NO. 20

DEFORMABLE BARRIER HONEYCOMB CRUSH

NHTSA Test No.:

Test Date:

Similar to example below:

Include table of pre and post measurements. Also, include change in measurements. The Contractor shall take measurements every 100mm in the lateral direction.

DATA SHEET NO. 21

DEFORMABLE BARRIER LOAD CELL LOCATIONS

NHTSA Test No.:

Test Date:

Front view of load cell plate with overall dimensions and gap distance between load cells and load cell dimensions. Label each load cell.

APPENDIX A

PHOTOGRAPHS

A.

Pre-test and post-test frontal view of test vehicle

B.

Pre-test and post-test left side view of test vehicle

C.

Pre-test and post-test right side view of test vehicle

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

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

F. Pre-test and post-test windshield view

G.

Pre-test and post-test engine compartment view

H.

Pre-test and post-test fuel filler cap view

I. Pre-test and post-test front underbody view1 J. Pre-test and post-test rear underbody view1

K.

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

L.

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

M.

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

N.

Frontal pre-test and post-test passenger dummy position view with the camera in the same plane as the longitudinal centerline of the dummy

O.

Pre-test and post-test driver dummy and vehicle interior view with the door open

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

Q.

Dummy contact point(s) vehicle and dummy

R.

Pre-test and post-test view of the knee bolsters

S.

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

T.

Pre-test and post-test view of the steering shaft and steering box (located under the hood). Take the best photograph possible without removing any parts.

U.

Pre-test and post-test view of the steering column intersecting the firewall from the inside of the vehicle. Take the best photograph possible without removing any parts.

V.

Pre-test and post-test under hood view of the steering column intersecting the firewall. Take the best photograph possible without removing any parts.

W. Photograph of ballast installed in vehicle

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

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

Z. Photograph of certification label

AA. Photograph of tire placard

AB. Photograph of the impact

Note: 1 – The underbody views will include the following vehicle components: fuel pump, fuel lines, sender unit, fuel tank filler pipe and any other visible fuel system components.

APPENDIX B

DUMMY, VEHICLE AND LOAD CELL BARRIER RESPONSE DATA TRACES (filtered)

APPENDIX C

PART 572B/E DUMMY CONFIGURATION

AND PERFORMANCE VERIFICATION DATA SHEETS

[Data sheets from “Laboratory Test Procedure for New Car Assessment Program (NCAP) Front Impact Testing”, dated December 2004 shall be used to document dummy calibration in the final test report. Also, include Thor-LX/ FLx verification information]

APPENDIX D

TEST EQUIPMENT AND INSTRUMENTATION CALIBRATION

[Data sheets from “Laboratory Test Procedure for New Car Assessment Program (NCAP) Front Impact Testing”, dated December 2004 shall be used to document the test equipment and instrumentation calibration — Temperature traces should be included]

NOTE: This section should include the pre- and post-test zero and shunt calibration values as described in section 11.13 if applicable.

APPENDIX E

PROCEDURE FOR VEHICLE INTERIOR INTRUSION MEASUREMENTS

The interior intrusion measurement locations are marked on both the driver and passenger side of the vehicle and are to be recorded using a coordinate measuring machine (CMM). The coordinate system for intrusion measurements is based on SAE J211 vehicle and laboratory coordinates. The X-direction is positive from the back of the vehicle to the front of the vehicle. The Y-direction is positive from the left of the vehicle to the right of the vehicle. The Z-direction is positive from the top of the vehicle to the ground. The frame of reference for the vehicle coordinate system is the non-deforming part of the vehicle.

The Contractor shall level the vehicle (Note: do not use suspension) and locate the vehicle coordinate system on a rigid surface of the vehicle’s bumper at centerline of the vehicle. The post-test intrusion measurement points shall be measured using the same reference coordinate system by leveling the vehicle to the same pretest condition. The before and after impact measurements are in millimeters in the range -10,000 to 10,000 millimeters. A unique intrusion point number (IPNO) further identifies an intrusion point within each possible intrusion point location. The unique IPNO codes are identified in Table E1. The locations of the toe pan intrusion points are depicted in Figure E1. The Contractor shall record the intrusion measurements described in Figure E1. The COTR reserves the right to modify these measurements and the procedure.

Driver Side

Passenger Side

Figure E1. Toe Pan Intrusion Points Table E1: Intrusion Point Numbers (IPNO) Codes Intrusion Point Number (IPNO)

Format: Integer Description

Procedure for Marking Toe Pan and Floorboard

1. Locate and mark point D1 (column D row 1): Project a line 45 degrees (from the horizontal) down and forward from the center of the top accelerometer pedal in the x-z plane until the line intersects the interior of the vehicle. Mark this point by cutting a small “v” in the carpet and underlying padding and peeling back and exposing the floor. The carpet and padding are then refitted prior to crash.

2. ST plane: The ST plane is a y-z plane that passes through the front edge of the right seat track.

3. AP1 plane: The AP1 plane is a y-z plane that passes through point D1.

4. AP2 plane: The AP2 plane is an x-z plane that passes through point D1.

5. AP3 plane: The AP3 plane is an x-y plane that passes through point D1.

6. MP plane: The MP plane is a y-z plane located halfway between the ST plane and AP1 plane.

7. CF plane: The CF plane is an x-z plane that passes through the center of the footrest. If there is no visible footrest, locate the x-z plane to pass through a point located 64 mm measured along the MP plane in the y-direction from the intersection of the door sill and floorboard.

8. BP plane: The BP plane is an x-z plane that passes through the center of the brake pedal.

9. TP plane: The TP plane is a y-z plane at the intersection of the BP plane and the intersection of the toe pan and floorboard.

10. Column A is at the intersection of the vehicle and the CF plane.

11. Column D is at the intersection of the vehicle and the AP2 plane.

12. Row 1 is at the intersection of the vehicle and the AP3 plane.

13. Row 3 is at the intersection of the vehicle and the TP plane.

14. Row 5 is at the intersection of the vehicle and MP plane.

15. Columns B and C are evenly spaced between Columns A and D.

16. Row 2 is evenly spaced between Row 1 and Row 3.

17. Row 4 is evenly spaced between Row 3 and Row 5.

18. Map and mark additional driver points:

a. Mark the center of the brake pedal.

b. Mark the left upper IP located above where dummy’s knees contact the dash.

c. Mark the right upper IP located above where dummy’s knees contact the dash.

d. Mark the center of the steering wheel.

e. Mark the front outboard seat attachment point.

19. Map all driver side toe pan and floorboard points to the passenger side from the center line of the vehicle

20. Map and mark additional driver points:

a. Mark the left upper IP located above where dummy’s knees contact dash.

b. Mark the right upper IP located above where dummy’s knees contact dash.

c. Mark the front outboard seat attachment point.

Data Submission

For each intrusion point, six measurements may be taken. The Contractor shall submit a table that describes the data for three pre-test and three post-test measurements in the test report. The data shall be submitted in ENTRÉE format:

Notes: (1) If no data is taken for one of the coordinate systems please leave blank - do not put a zero.

(2) VEHNO denotes Vehicle Number

(3) TSTREF denotes Test Reference Number

(4) Table E2 defines IPLOC.

(5) Table E3 defines measurement format.

Table E2: Intrusion Point Location Format

Intrusion Point Locations (IPLOC)

Format: Text Description

Table E3: Intrusion Measurement Format

Intrusion Measurements (Millimeters)

Format: Integer Description

APPENDIX F

INSIA REPORT

APARICIO IZQUIERDO, FRANCISCO

PÁEZ AYUSO, FRANCISCO JAVIER

INSIA

Carretera de Valencia, km. 7

Campus Sur de la Universidad Politécnica de Madrid

28031 – MADRID – (SPAIN)

March, 1999

REPORT DOCUMENTATION PAGE

Title:

STRUCTURAL SURVEY OF CARS. MEASUREMENT METHODOLOGY OF THE MAIN RESISTANT ELEMENTS IN THE CAR BODY

Author(s):

Aparicio Izquierdo, Francisco

Páez Ayuso, Francisco Javier

Performing Organisation name and address:

INSIA – University Institute for Automobile Research

Carretera de Valencia, Km. 7 – Campus Sur de la Universidad Politécnica de Madrid

28031 – Madrid – Spain

Supplementary notes:

Under contract to:

THE EUROPEAN COMMUNITY

Project: “Improvement of Crash Compatibility between Cars”

Contract Nº: RO – 97 – SC.1064

Abstract:

The main aim of this working package -Structural Survey of Cars- is the reduction of incompatibilities, both structural and geometric, between passenger vehicles and their potential collision partners. The understanding of these incompatibilities needs a previous step for the knowledge of the existing car fleet.

Firstly, it is necessary to select the main resistant elements in the car body. These elements have to be chosen from the point of view of the sort of collision that we want to study, that is to say, frontal and side impacts.

Detailed measurements have been taken from exterior and interior elements, spread to a total number of 74 models selected from the main vehicle manufacturers at Spain. All of them are being sold this year. Using the information available from the previous measurements in vehicles, the geometric characteristics of the main resistant elements involved in the geometric compatibility between cars will be defined.

This report shows the methodology followed to get these measurements.

Subject terms:

Crash compatibility, geometric compatibility, resistant elements, measure methodology

Date:

March, 1999

METHODOLOGY.

Detailed measurements have been taken from exterior and interior elements. Using the information available from the previous measurements in vehicles, the geometric characteristics of the main resistant elements involved in the geometric compatibility between cars have been defined. These elements are presented in the following figures, and have been divided in two main groups according to the vehicle zones studied in this project.

Figure 1.- Definition of the main resistant elements. General dimensions.

Figure 2.- Definition of the main resistant elements. Side elements.

Figure 3.- Measurements of the side resistant elements (outer).

Figure 4.- Measurements of the side resistant elements (inner).

Figure 5.- Definition of the main resistant elements. Front elements.

Figure 6.- Measurements of the main resistant elements. Front elements 1.

Figure 7.-

Measurements of the main resistant elements. Front elements 2.

Figure 8.- Measurements of the main resistant elements. Front elements 3.

Figure 9.- Definition of the main resistant elements. Front elements (Longitudinal engine).

FRONT ELEMENTS

• Total Length –(1)- (Side & Front Sheets - C column): distance between the point in the front bumper further on and the point in the rear bumper further back.

• Weight (Side & Front Sheets - D column): mass, including an average driver weight (70 kg), and the fuel tank mass (at half-capacity).

• Total Width –(2)- (Side & Front Sheets - E column): distance between the outer side points in a transverse plane of the vehicle (middle plane between the front and rear axles).

• Bumper bottom height –(4)- (Front Sheet G column): distance between the ground and the lowest point on the front bumper, being a resistant member (aerodynamic elements under the front bumper are not considered).

• Bumper top height –(3)- (Front Sheet H column): distance between the ground and the highest point on the front bumper, being a resistant member (aerodynamic elements are not considered).

• Longitudinal member top height –(5)- (Front Sheet I column): distance between the ground and the highest point on the longitudinal members, measured approximately in the front bumper‑longitudinal member joint (when accessible).

• Longitudinal member bottom height –(6)- (Front Sheet J column): distance between the ground and the lowest point on the longitudinal members, measured approximately in the front bumper‑longitudinal member joint.

• Distance between longitudinal members (Front Sheet K column): transverse distance between extreme points in longitudinal members, measured approximately in the front bumper‑longitudinal member joint.

Depending on the accessibility of these members, the extreme points are the inner points (I) or the outer points (O).

• Longitudinal member width -7’- (Front Sheet L column): width of one of the longitudinal members, measured approximately in the front bumper-longitudinal member joint.

• Engine top height (8) (Front Sheet N column): distance between the ground and the highest point on the engine that can be a resistant member in case of accident (usually, the highest point on the head, or the highest point of the inlet or exhaust manifolds).

• Engine bottom height (9) (Front Sheet M column): distance between the ground and the lowest point on the engine (usually, the lowest point on the crankcase).

• Engine and Gearbox width (10) (Front Sheet O & P columns):

· Transverse configuration engine: distance between extreme points in the gearbox‑cylinder block unit or others resistant members attached to the cylinder block unit, i.e. fan belts (from a front point of view).

· Longitudinal configuration engine: distance between extreme points in the cylinder block unit (from a front point of view).

• Front bumper - Engine distance (11) (Front Sheet Q column): distance between the point in the front bumper further on and the point in the engine further on that is a resistant element, i.e. the further on point of the exhaust manifold placed in the front of the engine.

• Front shock absorber fixing width (14) (Front Sheet R column): transverse distance between the front shock absorber ‑ body car joints.

• Front shock absorber fixing height (12) (Front Sheet S column): distance between the ground and the front shock absorber‑body car joint.

• Bonnet leading edge height (Front Sheet T column): distance between the ground and the bonnet edge further on.

SIDE ELEMENTS

• Front bumper - Front axle distance (15) (Side Sheet G column): distance between the point in the front bumper further on and the middle point in the front tyre‑road contact patch.

• Front axle - A Pillar distance (16) (Side Sheet H column): distance between the middle point in the front tyre‑road contact patch and the point in the A‑pillar further back.

• A Pillar - B Pillar distance (17) (Side Sheet I column): distance between the point in the A‑pillar further back and the middle point in the B‑pillar.

• B Pillar - C Pillar distance (19) (Side Sheet J column): distance between the middle point in the B‑pillar and the point in the C‑pillar further back (only 4/5-door vehicles).

• B Pillar - Rear axle distance (18) (Side Sheet K column): distance between the middle point in the B‑pillar and the middle point in the rear tyre‑road contact patch.

• Roof sill bottom height (20) (Side Sheet L column): distance between the ground and the lowest point on the roof sill, measured in the front door middle point.

• Roof sill top height (21) (Side Sheet M column): distance between the ground and the highest point on the roof sill (usually located in the sill-roof joint), measured in the front door middle point.

• Floor sill bottom height (22) (Side Sheet N column): distance between the ground and the lowest point on the floor sill, measured in the front door middle point.

• Floor sill top height (23) (Side Sheet O column): distance between the ground and the highest point on the floor sill, measured in the front door middle point.

NOTE

· N/A: dimension not available.

ATTACHMENT 6

RFP TASK ORDER REQUEST NO. 2

SEQ CHAPTER \h \r 1Addendum to Thor-Lx (Mid Male) Hybrid III Retrofit

Versio…