TRL s Child Seat Rating, (TCSR) Front Impact Testing Specification

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1 TRL s Child Seat Rating, (TCSR) Front Impact Testing Specification Revision 1 Prepared by TRL Limited July 2009

2 Foreword The UN-ECE Regulation provides a baseline level of safety for child restraint systems (CRSs) and all products must meet this before they can be sold in Europe. TRL Certification aims to provide industry with a mechanism to demonstrate where there are increased levels of safety of CRSs above that of the baseline level that seats need to achieve for approval. This information can be passed onto the consumer at point of sale to allow the consumer to distinguish between products and make an informed choice when purchasing a CRS. The testing is based on published work from two scientific research programmes. The first research programme (New Programme for the Assessment of Child restraint Systems (NPACS)) was carried out by a European consortium funded by the European Commission, the UK Department for Transport, the national governments of Catalunya and the Netherlands, the FIA Foundation (and members) and the German insurance industry (GdV). The research was carried out by a team of international experts in the field of child safety. The NPACS research comprised three broad strands; the first of these examined various accident databases in order to provide information to guide the severity of the test procedure and hence the crash pulse for the test. The second strand examined the environment within the vehicle. For the third strand, a sled based test programme examined the influence of variations in a number of the parameters identified in the first two strands, such as impact speed, pulse shape, impact angle and seat belt geometry. A second research programme was undertaken by the UK Department for Transport, who liaised with parties from the original NPACS project. This led to the UK validation of procedures that could be used for assessing and rating child restraint systems. The TCSR procedure is based largely on these research results and uses the protocols in the published TRL report, PR/VE/032/06 i, with amendments highlighted in this technical specification. TCSR i Revision 1

3 Contents 1 Impact test... 1 Description... 1 Test conditions Dummy and child restraint system... 2 Dummy selection and description of tests Data acquisition... 2 Photography Test specification... 3 Test checklist... 3 Post-test analysis... 3 Annex 1 Front impact test criteria... Test Bench... Carry cots... Child restraints attached with ISOFix... Test of rearward facing devices supported by the dash... 5 Annex 2 Test Matrix... 6 Glossary... 7 References... 7 TCSR ii Revision 1

4 Deceleration (g) 1 Impact test Description The impact test rig is detailed in the TRL report, Cheung G, Le Claire M, (2006) Additional Work to Deliver NPACS Protocols Final Report, Front Impact Protocol. Any differences in the test set-up or procedural changes are detailed in Annex 1. Test conditions The sled is calibrated to generate a sled deceleration as shown in Figure 1 prior to testing. The total velocity change of the sled is 65 (+0/-2) km/h. Acceleration prior to impact is less than 1g Time (s) Figure 1: Sled deceleration corridor TCSR 1 Revision 1

5 2 Dummy and child restraint system Dummy selection and description of tests The Q Series family of child dummies are used for the testing. Each child restraint is tested with the lightest and heaviest version of the Q dummy for which it is suitable. This is based on the mass groups in UN-ECE R: Group 0 device: Test using the Q0 and Q1 Group 0+ device: Test using the Q0 and Q1.5 Group 1 device: Test using the Q1 and Q3 Group 2 device: Test using the Q3 and Q6 Group 3 device 1 : Test using the Q6 and Q10 If the child restraint is suitable for two or more mass groups, the tests are carried out using the smallest and largest dummies for each group that the CRS covers. If the child restraint is equipped with a reclining mechanism, separate tests are carried out in both the fully upright position and the fully reclined position using the lightest and heaviest dummies. Child restraints that offer different attachment methods are treated as different products. The oblique impact tests for belt attached child restraints will not be conducted. A test matrix summarising how each child restraint shall be tested is provided in Annex 2. 3 Data acquisition Details of the instrumentation is listed in Cheung G, Le Claire M, (2006) Additional Work to Deliver NPACS Protocols Final Report, Front Impact Protocol. Photography Details of the photographs and videos to be recorded are listed in Cheung G, Le Claire M, (2006) Additional Work to Deliver NPACS Protocols Final Report, Front Impact Protocol. 1 Certification testing is not currently available for Group 3 CRSs. It will become available when the Q family includes a 10 yr dummy. TCSR 2 Revision 1

6 5 Test specification Test checklist A Test Procedure Checklist will be completed before each test to ensure that all actions are completed with the same sequence. These checklists can be found in Annexes -6 in Cheung G, Le Claire M, (2006) Additional Work to Deliver NPACS Protocols Final Report, Front Impact Protocol. Post-test analysis The following parameters are determined or recorded: Head excursion Head 3ms cumulative resultant acceleration Chest 3ms cumulative resultant acceleration Pelvis 3ms cumulative resultant acceleration Neck moment resultant Neck force resultant Loading to the abdomen, from speed photography: o o Acceptable loading High speed film shows that the adult belt or child harness system, loads the dummy low in the pelvic area during impact. Unacceptable loading The high speed film shows that the adult belt or child harness system, loads the abdominal area of the dummy during impact. An upward movement of the belts relative to the dummy is visible. Undesirable behaviour of the CRS during impact, from high speed photography: o No failure There is no visible damage to any parts of the CRS that are loaded by the belt and harness webbing during impact (eg. anchorage points, belt guides etc.). o o Collapsing system during impact: The adult belt or harness system fails to restrain the CRS or dummy. An anchorage point or belt guide (that is loaded by the adult belt or harness system) collapses, and are no longer able to function to transfer loading. Ejection During impact, the dummy is partially or fully ejected because the restraint is unable control the dummy. TCSR 3 Revision 1

7 Annex 1 Front impact test criteria Test Bench The test bench specifications are detailed in Cheung G, Le Claire M, (2006) NPACS (New Programme for the Assessment of Child restraint Systems) Phase 1 Final Report, Final TWG Front Impact Proposal. An alteration to the original location of the upper belt forward position has been made. The seat belt anchorages are positioned as shown in Table 1. The Cr point (x and z axes, or test seat centreline (y axis) are used as a reference for each coordinate. The coordinate system is based on ISO 678 and is outlined below: Positive x = Fore (towards the front of the sled) Positive y = Left to right (from the occupant s point of view) Positive z = Downwards Anchorage Upper (Mid Position) Table 1: Location of seatbelt anchorages Upper (Fwd Position) Lower inner (buckle) Lower outer Direction x y z x y z x y z x y z Distance (mm) A locked retractor is used instead of an inertia reel. Child restraints utilising the seat belt are tensioned so that there is 50N (±5N) in both the lap and shoulder sections of the belt and N (±3N) on the reel. Carry cots For carry cots in group 0, the points in Table 2 will be used and the carry cot installed as specified by the manufacturer of the child restraint system. Table 2: Anchor points for Group 0 carry cots Anchorage Upper right Upper Left Lower left Lower right Direction x y z x y z x y z x y z Distance (mm) Child restraints attached with ISOFix The dimensions of the seat cushions when the child restraint is attached with ISOFix are detailed in Cheung G, Le Claire M, (2006) Additional Work to Deliver NPACS Protocols Final Report, Front Impact Protocol. TCSR Revision 1

8 380 Test of rearward facing devices supported by the dash A simulated dash made from steel tube is fitted on the trolley in order to support the child restraint as shown in Figure 2. Steel tube 500 x Ø100 x Ø C r Dimensions in mm Figure 2: Set-up for rearward facing seats supported by the dash Larger, Group I and upwards, rearward facing seats that use lower forward tethers should be set-up as specified in UN-ECE R. TCSR 5 Revision 1

9 Annex 2 Test Matrix Group CRS Orientation ISOFix or Belted CRS Position Upper Belt Anchor Q0 Q1 Q1.5 Q3 Q6 Q10/12 Test type Number of Tests 0 RF Belted mid 1 1 baseline test 2 0 RF ISOFix baseline test 2 0+ RF Belted mid 1 1 baseline test 2 0+ RF ISOFix baseline test 2 upright mid 1 1 baseline test I FF Belted reclined mid 1 1 baseline test 5 upright forward 1 additional I FF ISOFix upright baseline test reclined baseline test I RF Belted upright mid 1 1 baseline test reclined mid 1 1 baseline test I RF ISOFix upright baseline test reclined baseline test upright mid 1 1 baseline test II FF Belted reclined mid 1 1 baseline test 5 upright forward 1 additional II FF ISOFix upright baseline test reclined baseline test II RF Belted upright mid 1 1 baseline test reclined mid 1 1 baseline test II RF ISOFix upright baseline test reclined baseline test upright mid 1 1 baseline test III FF Belted reclined mid 1 1 baseline test 5 upright forward 1 additional TCSR 6 Revision 1

10 References i Cheung G and Le Claire M (2006), Additional Work to Deliver NPACS Protocols Final Report, TRL Published Project Report, PPRO /012/015, for the United Kingdom Department for Transport, Published April, Glossary Pitcher M, Halewood C, Carroll J, Goodacre O, Fraser E, Gibson T, McGrath A, Le Claire M. Child Seat Consumer Information Project: Protocol Validation. TRL Published Project Report PPR339, for the United Kingdom Department for Transport. Published April, Cheung G and Le Claire M (2006). NPACS (New Programme for the Assessment of Child restraint Systems) Phase 1 Final Report. TRL final project report for the United Kingdom Department for Transport. Published May, 2006 Cheung G and Le Claire M. Progress on the Development of the Procedures for the Consumer Testing of Child Restraints NPACS. Conference Paper: "Protection of Children in Cars" International Conference, Cologne, Germany, September 200 Le Claire M and Bygrave, S. Aims of the New Programme for the Assessment of Child restraint Systems. Conference Paper "Protection of Children in Cars" International Conference, Cologne, Germany, July 2003 TCSR 7 Revision 1

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