EUROPEAN COMMISSION DG RTD

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1 EUROPEAN COMMISSION DG RTD SEVENTH FRAMEWORK PROGRAMME THEME 7 TRANSPORT - SST SST : Human physical and behavioral components GA No THORAX Thoracic injury assessment for improved vehicle safety Deliverable No. THORAX D4.2 Deliverable Title Dissemination level Written By Checked by Approved by Report with first preliminary dummy test experience Paul Lemmen (Humanetics), Steffi Wolf (Continental), Cecilia Sunnevang (Autoliv), Paul Lemmen (Humanetics) Cor van der Zweep (Uniresearch) Issue date December 18, 2012

2 Executive summary To get a first experience on the THORAX demonstrator dummy preliminary tests were done in two different labs. Testing included full scale vehicle tests as well as sled testing using a body in white set-up. For reference comparisons were made with the Hybrid-III 50 th dummy. In general it was found that the demonstrator dummy performs well. It was observed that the lower IRTRACC system is vulnerable upon rebound. Although this issue cannot be resolved in time for the sequel of the THORAX WP4 testing it is recommended to include means for protection of these devices in future dummy versions. Other recommendations for testing include a clear definition of the seating procedure, and a more efficient way of processing the dummy data. Page 2

3 Contents 1 Introduction Full scale tests Autoliv Test condition Dummy seating / positioning Vehicle measurements Dummy measurements Further remarks on dummy handling / performance Sled tests Autoliv Continental Body in White testsing THOR seating procedure workshop Conclusions and recommendations for dummy use in WP4 test program Risk Register APPENDIX I Dummy Seating Procedure for WP SAE Draft seating procedure with remarks from THORAX workshop Open issues Draft proposal for shoulder friction setting and positioning as proposed by Humanetics Page 3

4 1 Introduction In general the aim of THORAX Work Package 4 is to assess the demonstrator dummy in relevant load cases regarding its sensitivity against settings of modern vehicle safety systems. Also robustness, durability and repeatability need to be addressed. Based on results from WP1 and WP2 and experiences made in WP 3 relevant load cases for the evaluation were defined in Deliverable D4.1. Before starting to execute the related test matrix a first series of preliminary tests were planned to get a first experience of applying the demonstrator dummy. This report presents testing experiences and lessons learned as input to the execution of the broad scale test matrix in Task 4.2. Tests were conducted at the Autoliv facilities and the Continental facilities. Results and experiences on the use are reported in chapter 2 and 3 respectively. Page 4

5 2 Full scale tests Autoliv To gain insight in the dummy performance and handling three full scale tests with a small car were conducted. 2.1 Test condition Three tests were done using a small vehicle under the Euro NCAP ODB 64 km/h condition. Identical vehicles were used in all tests. In the first tests the Hybrid III 50% ile male was used (denoted Test 1 HIII). In the second test the driver was replaced by the TRL dummy with demonstrator thorax / shoulder complex (denoted Test 2 TRL Thor) and in the third test the Autoliv dummy with demonstrator kit was used (denoted Test 3 ALV Thor. The test condition was chosen as it concerns a real car test with all issues related to handling and dummy use appearing. Figure 1 Picture of HIII dummy (left) and THOR demonstrator (right) seated in test car. 2.2 Dummy seating / positioning For the HIII dummy the standard seating procedure was applied. The procedure for installing the THOR dummy is still under development by SAE. In these tests the Thor dummies were positioned with H-point aligned with the HIII H-point (+/- 10 mm), resulting seating position is depicted in figure 2. The seat adjustment was identical for HIII and THOR tests The THOR head C.o.G was found to be 35 mm more rearward and higher than the HIII CoG. As the THOR seating procedure is not fully defined yet it is recommended to have a seating workshop involving testing experts to define a clear positioning at the start of the test. This should reduce possible variation in testing due to initial positioning. Figure 2 Positioning of HIII (left) and THOR demonstrators (middle and right). 2.3 Vehicle measurements Page 5

6 Figure 3 gives accelerations and velocities at the tunnel for the three tests. It can be observed that all tests result in almost identical accelerations. Therefore these test provide a good basis for comparing the responses of the three dummies. Figure 3 Vehicle signals in terms of tunnel accelerations and velocities for the three tests. 2.4 Dummy measurements Figure 4 compares resultant head and chest accelerations of between the HIII dummy and one of the THOR dummies showing similar acceleration to head and chest. Unfortunately the TRL dummy was not equipped with accelerometers hence no comparison between both THOR dummies could be made for this signal Figure 4 Resultant head (left) and chest (right) accelerations for the HIII and the THOR dummy. Figure 5 shows chest deflections from all tests. Note that the HIII dummy only measures a single deflection at sternum location while the THORAX demonstrator has four IRTRACCs located at Upper Left, Upper Right, Lower Left and Lower Right thorax locations respectively. It can be observed that deflections measured for the THOR dummy are substantially larger than for the HIII dummy. Values up to 40 mm are observed whereas for the HIII peak values of about 23 mm occur. It is noted that in the test with the Autoliv THOR dummy the upper Right IRTRACC did not provide any output data. Therefore no full comparison between the TRL and Autoliv dummy could be made. However, comparison of the results for the other three locations shows that deflections correspond quite well. Page 6

7 Figure 5 Chest X-deflections. The THORAX demonstrators are equipped with 3D IRTRACCs. This device allows for calculation of the deflexion in three directions. Figures 6 and 7 show chest deflections in Y- and Z-directions for the TRL and the Autoliv dummy respectively. As noted the Upper Right IRTRACC in the Autoliv dummy failed, hence no data available at that location. A comparison between results in figures 6 and 7 shows that in general a good correlation is obtained. Differences observed might occur from differences in belt routing in between the two tests. This is confirmed by results of the strain gages as plotted in figure 8. Results for the TRL dummy in the upper right region are slightly higher compared to those of the Autoliv dummy. This might indicate a slightly different belt routing or slight difference in rotation of the vehicles between the tests. In the other regions a very good correlation between strains is found. Figure 6 Chest Y- and Z-deflections for TRL dummy Page 7

8 Figure 7 Chest Y- and Z-deflections for TRL dummy Figure 8 Strain gage results for TRL dummy (left) and Autoliv dummy (right). Results clustered per thorax region. Page 8

9 2.5 Further remarks on dummy handling / performance In addition to the remarks on the dummy positioning and performance as made in the previous sections the testing revealed the following remarks or lessons learned for future applications in Wp4: Good with the plug-and-play Onboard DAS quiet quick but could be more user friendly DAS activation warnings (ex light) needed Shoulder position indication and positioning procedure in general needed Post processing algorithms needed From the above items the post processing algorithms and the shoulder positioning procedure could be tackled in THORAX before the start of the WP4 testing. Other items remain open for future dummy updates / adjustments. Page 9

10 3 Sled tests Autoliv A further use case of the demonstrator dummies was considered by Autoliv repeating PMHS tests as previously conducted by Tornvall. As these tests are also used to judge the biomechanical performance evaluation of the dummy under task 3.3 results are included in deliverable report D3.3 which goes into more detail. Findings on dummy handling and use for these tests are identical to the ones mentioned in the previous section with the addition that the lower IRTRACC s seem to be unprotected from the rear side of the dummy. See photo in figure 9. This results in risk of failure under severe rebound as occurring in the Tornvall tests. For future dummy updates it is recommended to protect the device under rebound into the seat using a floating rib or other type of shield. Figure 9 Photo of IRTRACC assembly in lower rib region. Upon rebound into the seat this part is fairly unprotected and damage (e.g. cable break) might occur when hitting parts in the seat. Page 10

11 4 Continental Body in White testsing The tests performed at Continental Safety Engineering International GmbH were done in a first step to gain some experience in dummy handling, respectively seating of the dummy, installation of the data management system and processing of data. The three tests were done with a THORAX dummy (Version IFFSTAR) in comparision to the regular 50% H III. A very basic test setup was used in a first step. The rigid steel seat (very similar to the ECE- R 16 seat) was fixed on a mounting plate. The instrument panel was also simulated by a rigid steel construction. The complete setup was used for testing with a 5% H III before, so that the distance between the seat and the contact area of the knee had to be modified to enable a positioning of the larger dummies. The height of the seat is too high in these tests for a 50% male-dummy, but as the goal of the tests was to get first experiences in dummy handling and all the tests were planned under the same conditions this was not an issue here. The setup simulated the passenger area of a car. To simplify the setup a preinflated passenger airbag was installed with a coated webbing. A rigid steel B- Pillar was mounted close by the seat. The attached belt was not fired; the belt was only used to keep the dummy in place during the test. The general test setup is shown in the following picture. The pulse used for all tests is shown below: Figure 10 Setup Figure 11 Sledpulse Test 08705S002F and 08705S003F were done with a 50% H III. The tests were done as a baseline. The only difference was that the first test was done without the double sided Teflon plates under hip and upper legs of the dummy. There were no major differences between those two tests, the movement of the dummy and the biomechanical values were nearly the same. The difference between Teflon coated surface and steel surface can be neglected. Page 11

12 The third test was done with the THORAX dummy. The IFFSTAR dummy was used with the following equipment: updated SD-2 shoulder, a Thorax upgrade kit, 4 IRTRACCs and an internal Messring M=Bus 36ch DAS. The following pages give an overview above measured test results. Only head and pelvis can be compared directly, the rib data of the THORAX are shown separately below. Figure. 12 Head Acceleration H III and THORAX Figure 13 Pelvis Accelerations H III and THORAX Figure 14 Upper Rib Displacements THORAX Page 12

13 Figure 15 Lower Rib Displacements THORAX Figure 16 Rib displacements THORAX The general handling of the THORAX dummy was comparable to the handling of a H III. The tests were done on a rigid seat so that the seating position as known from the H III cannot be applied even for the H III. One problem with the THORAX dummy was to achieve a good neck position. The H III neck can be adjusted by changing the neck angle. The THORAX neck angle also can be adjusted with a screw on the top of the head adjusting a string through the neck of the dummy. Positioning the dummy on the steel seat it was not possible to achieve a neck angle of 0 measured on the cap of the head; the angle remained at 7 because further adjustment by the screw was not possible. The positioning on a rigid seat it not a common way to test; usually seats with foam and seat adjustment are used. But it would make sense to keep an eye on that issue to make sure that the adjustment range of the head/neck is sufficient. Page 13

14 5 THOR seating procedure workshop Based on the observation from the full scale testing at Autoliv on the need for an adequate seating procedure a workshop was organised between WP3 and WP4 members to review the draft procedures as defined by SAE. The workshop was held October at BMW. Three different vehicles (classes) were available for exercises with one of the demonstrator dummies. The workshop was participated in person by THORAX partners and representatives from EU OEM s. In addition members from the Technical Advisory group participated via WebEx sessions. This included representatives from UVa, VRTC, NHTSA, JAMA and JARI. Attendees in person: Phillip Wernicke, Andre Eggers, Benny Tholin, Cecilia Sunnevang, Bernard Been. Attendees via WebEx: Aloke Prasad VRTC, Hohmann VW, Dhynd TRL, L.Martinez INSIA, Greg UVA, many more, Dan Parent, NHSTA. The workshop started with a short introduction to the dummy providing info on all available means in the dummy to adjust the seating. This was then followed by some hands on experience and first positioning jointly dome all participants. The procedure as drafted by SAE in June 2011 was used as basis. Next experiences were shared between participants and another positioning exercise was run. This in turn was followed by a WebEx with participants from other regions to collect feedback / experience from the US and Japan. On the second day another iteration step in terms of review, positioning exercises and WebEx with other regions was repeated. The workshop resulted in several recommendations for updating the SAE draft seating procedure. For usage in WP4 a complete package of information is included in Appendix I consisting of three sections: 1) SAE Draft seating procedure with remarks from the THORAX workshop included 2) Overview of open issues 3) First draft proposal for shoulder positioning. Page 14

15 6 Conclusions and recommendations for dummy use in WP4 test program To get a first experience on the THORAX demonstrator dummy preliminary tests were done in two different labs. Testing included full scale vehicle tests as well as sled testing using a body in white set-up. For reference comparisons were made with the Hybrid-III 50 th dummy. In general it was found that the demonstrator dummy performs well. It was observed that the lower IRTRACC system is vulnerable upon rebound. Although this issue cannot be resolved in time for the sequel of the THORAX WP4 testing it is recommended to include means for protection of these devices in future dummy versions. Other recommendations for testing include a clear definition of the seating procedure, and a more efficient way of processing the dummy data. For the latter two items actions were defined in terms of a dummy seating workshop and in terms of software (matlab) development for WP4 data processing. The dummy seating workshop was held early October. Appendix I of this report includes a procedure for application in Task 4.3 testing. Page 15

16 7 Risk Register Risk No. WP4.3 What is the risk The highest risk is the tight timeplan. There is not much time left for testing and analysis. THORAX parts could be damaged and spare parts are difficult to get. Level Solutions to overcome the risk of risk 1 2 Testing in Task 4.2 has shown that the demonstrator is quite durable. Apart from IRTRACC s no serious damages were observed. As a contingency to possible damage Task 4.3 will use the two dummies that are instrumented with strain gages. The third demonstrator dummy will be used to take parts from in case needed (cannibalize) 1 Risk level: 1 = high risk, 2 = medium risk, 3 = Low risk Page 16

17 8 APPENDIX I Dummy Seating Procedure for WP4 This appendix presents the outcome of a seating workshop which was organised to define a seating procedure for the THOR dummy to be applied in Wp4 testing. The activities were based on the draft seating procedure as defined by the SAE in June This appendix consists of three sections: 4) SAE Draft seating procedure with remarks from the THORAX workshop included 5) Overview of open issues 6) First draft proposal for shoulder positioning. 8.1 SAE Draft seating procedure with remarks from THORAX workshop The procedure as defined by SAE is included below. Updates / remarks from the THORAX workshop are included in red bold text. 1 VEHICLE PREPARATION 1.1. Adjustments Position the test seat s adjustable lumbar supports so that the lumbar supports are in the lowest, retracted or deflated adjustment positions Position any adjustable parts of the seat that provide additional support so that they are in the lowest or most open adjustment position Position an adjustable seat cushion length to the retracted position Position an adjustable leg support system in its rearmost position If there is a retractable center armrest, put it in the lower position as when it is used as an arm rest Place adjustable pedals in the full forward position (towards the front of the vehicle.) Set the steering wheel hub at the geometric center of the full range of driving positions including any telescoping positions Set the head restraint vertical position to the vehicle manufacturer s nominal design position for a 50th percentile adult male occupant (Or if testing without manufacturer s provided information, position the head restraint in the full up position.) Set the head restraint longitudinal position to the vehicle manufacturer s nominal design position for a 50th percentile adult male occupant (Or if testing without manufacturer s provided information, position the head restraint in the full rearward position.) Place any adjustable seat belt anchorages at the vehicle manufacturer s nominal design position for a 50th percentile adult male occupant. (Or if testing without manufacturer s provided information, position any adjustable seat belt anchorages to their full up or full outboard positions.) No comments 1.2. Seat Markings Define seat cushion reference points Identify one seat cushion reference point at the front and one at the rear on the side of the seat bottom. These points should be on the rigid seat trim if available, if not on the flexible seat cushion itself. Draw a line through these two seat side reference points. Do we need this line? Or specify to use angle tool for measurement of pitch (and adjust to mid) Define seat centerline reference Bucket seats: Locate and mark the longitudinal centerline of the seat cushion. The intersection of the vertical longitudinal plane that passes through the SRP and the seat cushion upper surface determines the longitudinal centerline of a bucket seat cushion. Adjust wording to include measurement independent of SRP, to define seat centerline. Ex, measure seat width. Note centerline measurement for LHP. Page 17

18 Suggested change: In case SRP is not specified, use the half width of the seat cushion to identify center line Bench seats: Locate and mark the longitudinal line on the seat cushion that marks the intersection of the vertical longitudinal plane through the centerline of the steering wheel and the seat cushion upper surface Starting Seat Position Use the seat control that primarily moves the seat fore-aft to adjust the rearmost seat reference point defined in section to the rear most location Use the seat control that primarily moves the seat vertically to adjust the rearmost seat reference point defined in section to the lowest vertical location. If there are two controls, one that moves the front of the seat vertically and another that moves the rear of the seat vertically; activate both to lower the front and rear to their lowest positions simultaneously Seat Test Position Use the seat control that primarily moves the seat fore-aft to adjust the rearmost seat reference point defined in section to the rear most location; Record the X position Use the seat control that primarily moves the seat fore-aft to adjust the rearmost seat reference point defined in section to the forward most location; Record the X position Measure and mark an X position 15mm rearward of the midpoint between the positions defined in sections and (MP +15mm). Comment: History of -15? Why not -20 mm as for WSID since they are both based on UMTRI anthropometry? (comment also from Japan) Use the seat control that primarily moves the seat fore-aft to adjust the rearmost seat reference point defined in section to the X position marked in section If the seat cannot be placed at exactly 15 mm rearward of the midpoint select next closest available rearward setting Use the seat control that primarily moves the seat vertically to adjust the rearmost seat reference point defined in section to the lowest vertical location Determine and record the range of angles of the seat cushion pitch and using only the control(s) that primarily adjust(s) the cushion pitch, set cushion pitch to the mid-angle. (Or if the controls that move the front and rear of the seat are the only controls that change the seat pitch, then use those to identify the maximum and minimum seat pitch. Then use these two controls to set the seat in mid pitch.) The vertical position of the seat should remain in its lowest position as much as possible while achieving the mid pitch position. Comment: Clarify that pitch will influence the reference point, but not the seat center vertical height. (comment also from Japan) Record seat test position co-ordinates Pedal and Floorpan Markings Locate and mark the Right Heel Point (RHP) on the carpet Flat accelerator pedals: Extend a line on the surface of the pedal and through the axis of symmetry (when viewed from the rear. The RHP is the intersection of that line with the floorpan Curved accelerator pedals: Construct a line in the side view tangent to the accelerator pedal such that the distance from the contact point on the pedal to the floorpan, along the tangent line, is 200 mm. This line is also through the axis of symmetry of the pedal. The RHP is at the intersection of this tangent line and the floorpan. Comment: How to define the line for hanging pedals? Locate a longitudinal line L1 and a transverse line T1 on the floorpan through the RHP. Locate a Left Heel Point (LHP) point on the line T1 that is to the left of the seat centerline at the same distance from the seat centerline as the RHP. Locate a longitudinal line L2 through the LHP SAE H-point Measurement Page 18

19 1.6.1 Using only the controls that move the seat fore-aft return the test seat to the rearmost position to facilitate placement of the SAE J826 H-point machine Place the H-point machine in the seat and position the seat to the test position as defined by the coordinates recorded in section Follow the SAE J826 procedure except that the length of the lower leg and thigh segments of the H-point machine shall be adjusted to the 50th percentile (418 mm) and 10th percentile (408 mm) positions, respectively Set the seat back angle to the angle specified by the manufacturer (design angle). If the seat back design angle is not specified by the manufacturer set the seat back angle to 23º or as close to 23 º as possible (as measured by the SAE J826 H-Point machine) Record the SAE H-point X, Y and Z coordinates The THOR H-point is set to 10 mm forward of SAE H-point X coordinate; Y and Z coordinates of the SAE H-point are not adjusted. Comment: Why 10 mm? Thor and WSID based on UMTRI anthropometry. As synergy with WSID should be 20 mm? 2 THOR DUMMY PLACEMENT 2.1. THOR installation Adjust the THOR lumbar to the standard seating position (one of four distinct lumbar / spine adjustment positions.) Comment: Specify what lumbar position. Slouched or 9 is nominal? If different position more suitable for different type of vehicle, it should be specified how to decide and who will make such a decision If necessary to facilitate placement of THOR into the seat, move the seat fore-aft to the rearmost position Place the THOR dummy in the seat such that the mid-saggital plane is coincident with the centerline markings and the upper torso resting against the seat back Apply a for-aft and lateral rocking motion (approximately +/- 5 degrees) to settle the pelvis rearward in the seat Move the seat together with the THOR to the test seat position defined in section Position the H-point of the dummy to match the THOR H-point coordinates recorded in section to within ± 10 mm in both the X and Z directions Adjust the head until the tilt sensors read 0º ± 1º. If necessary, adjust the lower neck bracket to achieve a level head. Comment: Difficult to adjust neck adjustment in vehicle. Adjustment will have slight affect to overall position. After adjustment all tilt sensors should be checked again. Page 19

20 THORAX D4.2 Report with first preliminary dummy test experience Head/neck assembly can be adjusted at upper neck, or in the head. Head angle should however be specified in certification tests (see open issues in end). (comment also from Japan) To the left: Lower neck adjustment (difficult to access when dummy in vehicle) To the right: Head angle should be kept as adjusted in certification tests [include in certification tests] White to white or white to red definition? Adjust the THOR until the thorax tilt sensor coincides with the angle specified by the manufacturer. If neither the seat back angle nor the thorax tilt sensor angle is specified by the manufacturer adjust the dummy until the thorax tilt sensor reads TBD ± 2º. Comment: Add reference plane for tilt sensors (as backup if no sensors or non-reliable results (0 straight). 23 for the spine => read out in tilt sensor. Possible also to measure on shoulder rigid surface. Page 20

21 How adjustable is pelvis angle? Is it defined with H-point measurement and then only angle recorded? (comment also from Japan) 2.2. Leg Placement Extend the right leg without displacing the thigh from the seat cushion. Allow the sole of the foot to settle on the accelerator pedal (if it reaches the pedal); the heel of the shoe should be in contact with the floor pan. Comment: What it does not reach the pedal? Extend the left leg, without lifting the thigh from the seat cushion and allow the sole of the foot to settle on the footrest (if applicable). The heel of the shoe should be in contact with the floorpan. In case of tibia contact slide the foot rearward, toward the seat until a 5 mm clearance between the tibia and vehicle structure is obtained Set the left and right feet in the neutral position (longitudinal centerline of foot in the same plane as the lower leg/thigh, foot Y angle at -15 degrees +/- 2 degrees to lower leg), as determined by the output of the potentiometers at the ankle. Comment: How to determine without ankle potentiometers Without moving the seat, and while keeping the right thigh and leg in the same vertical plane, set the right foot heel on Line L1. If the vehicle interior prevents the heel from reaching L1, place the heel as close to L1 as possible, while maintaining a clearance of 0.25 from the vehicle interior Without moving the seat, and while keeping the left thigh and leg in the same vertical plane, move the left foot laterally to the left as follows: If there is a foot rest move the left foot until it is longitudinally in line with the center of the foot rest, or until the edge of the foot is 0.25 from the vehicle structure, whichever occurs first. If there is no foot rest, move the left foot until the left edge of the foot is 0.25 from the vehicle structure or until the center of the foot is TBD mm from the center of the right foot, whichever occurs first If sections through can be accomplished with both the left and right foots remaining in a neutral position (as described in section 2.8.3) then no further fore aft adjustment of the seat is necessary; skip to section 2.9. (The right foot can be in contact with Page 21

22 the accelerator pedal or not, as long as the neutral position is maintained and the right heel is on Line L1 or as close as possible as described in section 2.8.4) Readjustment of seat position If contact between the pedals (or vehicle) and either foot prohibits the maintenance of the neutral position, then the seat should be moved rearward as follows: Power seat adjusters: The seat should be moved an additional 10 mm rearward using the controls that primarily move the seat fore aft. After this readjustment of the seat, sections 2.6 through need to be repeated. If after an initial adjustment of 10 mm rearward, the feet cannot be positioned in their neutral position then the seat should be adjusted one more time 10 mm rearward (for a total of 20 mm rearward adjustment resulting in a seat position of 35 mm rearward of mid track). If after this final adjustment of 10 mm rearward (for a total of 20 mm rearward adjustment) the feet cannot be placed in a neutral position, then the right foot should be placed in contact with the accelerator pedal and with the heel on line L1 or as close as possible to L1 as described in section and the left foot positioned as described in section In this case only the feet can be positioned in a non neutral position Manual seat adjusters: The seat should be moved rearward one notch. After this readjustment of the seat, sections 2.6 through need to be repeated. If after an initial adjustment of one notch rearward, the feet cannot be positioned in their neutral position then the seat should be adjusted rearward another notch. This can be continued until the feet can be positioned in their neutral position, but the total adjustment of the seat cannot be more than 20 mm. If the feet cannot be positioned in their neutral axis after the seat readjustments, then the seat should be positioned in the most rearward notch that is 20mm or less from the original position. The right foot should be placed in contact with the accelerator pedal and with the heel on line L1 or as close as possible to L1 as described in section and the left foot positioned as described in section In this case only the feet can be positioned in a non neutral position If the seat is repositioned 10 mm rearward or 20 mm rearward as described in section , then the target H point, relative to vehicle coordinates should be adjusted accordingly in the X direction (also in the Z direction, if the fore aft adjustment of the seat causes changes in the Z position of the seat) Confirm that the THOR H-point is still on within 10 mm of the target (as described in sections and/or ) in the X and Z directions. Comment: How flexible is pelvis angle? Confirm that the head is still at 0º ± 1º Arm and Hand Placement Comment: This whole section needs to be updated due to the SD3 shoulders. Shoulder adjustments. Adjust shoulder bracket hole to match indent showing nominal position. Difficult to reach SW with nominal shoulder position => Elbows more lifted => Hand position 10 to 2 o clock to will be contradicted. Measure point on arm to have as reference for last check. Shoulder friction? What if hands do not reach steering wheel? Page 22

23 2.3.1 Place the upper arms adjacent to the torso with the centerline as close to the coronal plane as possible Maintaining the head alignment as determined above, place the right hand with the palm in contact with the steering wheel at the rim s horizontal centerline and with the thumb over the steering wheel Maintaining the head alignment as determined above place the left hand with the palm in contact with the steering wheel at the rim s horizontal centerline and with the thumb over the steering wheel If the hands don t reach the steering wheel at the horizontal centerline, maintaining the head alignment place them at symmetric location on the wheel, below the horizontal centerline Tape the thumb of each hand to the steering wheel by using masking tape with a width of 0.25 inch. The length of the tape shall only be enough to go around the thumb and steering wheel one time Verify that the feet are in the neutral position (+/- 2 deg) (unless the seat was readjusted the full 20 mm as described in section , in which case the neutral position does not need to be met), and in their proper lateral locations as described in sections (right foot) and (left foot) Verify that the head is level (0 +/- 1 deg.) 8.2 Open issues The following open issues and actions were identified during the workshop Reference points for tilt sensors (and hardware structure to control angles on) BB to calibrate (and check) tilt sensors for Autoliv dummy (w42) BB to switch abdomen measurement from LH to RH Head angle w.r.t. specification tests (should be included in certification procedure) How to make priority between neck and head? Define shoulder position and update arm positioning => Possibility to use pin for positioning in nominal position. Specification of shoulder friction 8.3 Draft proposal for shoulder friction setting and positioning as proposed by Humanetics Draft procedure for SD3 shoulder and arm friction adjustment Prepared: Bernard Been, Humanetics Europe GmbH, 21 Oct. 2012, v0. Introduction Page 23

24 The current procedure was written to achieve a starting point and reference for adjustment of the SD3 shoulder and arm joint friction for use during prototype evaluations. It was intended to have a suitable friction for stable positioning of the dummy in a test environment, and aimed at intermediate friction level (i.e. lower than the current 1G settings of HIII). This is achieved by specifying adjustment to slowly sinking of the body segment being adjusted and by bending back the lower arm and hand. Step by step procedure 1. Place the dummy in a stable upright position, with shoulders and clavicles in a more or less horizontal plane and the jacket removed (or unzipped at the sides and shoulders). 2. Shoulder z-axis friction. Lift the arm up for access. With a 13mm open box spanner adjust the friction on the lower end of the shaft. The nut is on the side of the spine in the arm pit area, access is between the 2 nd and 3 rd rib. Adjust the friction for smooth forward and backward motion of the shoulder. The shoulder spring should be able to bring the shoulder back close to its zero position (alignment hole and mark are visible below the shoulder moulding). Figure 1: Shoulder z-axis adjustment 3. Wrist. Adjust the wrist joint in two directions (3/8 and 3/16 hexagon wrench) to a practical friction for a stable hand. 4. Elbow pin joint: hold upper arm shaft hanging vertical; hold lower arm horizontal and bend back the hand; adjust the elbow joint (1/4 hexagon wrench) such that fore arm goes down slowly after release. For easy access to the screw rotate the lower arm about the vertical axis side ways. With the lower arm held horizontal, the joint can be adjusted in this position. Page 24

25 Figure 2: Elbow pin joint adjustment 5. Humerus (upper arm) Y-axis joint: start from upper arm hanging vertical; rotate upper arm up-forward about y-axis until horizontal; bend back the lower arm and hand and hold by the elbow; adjust the friction in arm pit with a 19mm (or 3/4 ) ring spanner, such that the arm goes down slowly after release. Figure 3: Upper arm y-axis adjustment 6. Humerus (upper arm) X-axis joint: start from upper arm hanging down vertically and lower arm forward horizontally; rotate the lower arm about the upper arm shaft (zaxis) laterally to the side; then rotate the upper and lower arm up laterally to horizontal and bend the hand back to the head (this is the typical posture of a body builder showing his biceps); adjust the friction on shoulder bolt with 5mm hex wrench. Please note that the shoulder may also lift. Check by pushing down on the shoulder that the shoulder is on the stop. The friction is properly adjusted when arm goes down slowly from horizontal after release. Page 25

26 Figure 4: Upper arm x-axis adjustment 7. Lower arm z-axis friction (moment along upper arm shaft); start from upper arm hanging down vertically and lower arm and hand horizontally forward (~90 angle), rotate upper and lower arm up laterally to horizontal and hold the upper arm by the elbow in that position; adjust z-axis friction with 4mm hex wrench through a hole in the upper arm flesh; adjust the friction such that the lower arm and hand go down slowly after release. Figure 5: Lower arm z-axis adjustment 8. Repeat all steps for the opposite side shoulder and arm joints.. Page 26