Rear Impact Dummies. Z. Jerry Wang, PhD, Chief Engineer Eric Jacuzzi, Project Engineer

Transcription

1 Rear Impact Dummies Z. Jerry Wang, PhD, Chief Engineer Eric Jacuzzi, Project Engineer GRSP International Informal Technical Group Meeting Washington DC November 6, 29 First Technology Safety Systems, Inc.

2 Contents RID3D Brief FTSS BioRID II + Development Page 2

3 RID3D Brief RID2 developed and evaluated in the EU program Whiplash RID3D update of RID2 in Whiplash2 Improvement of durability Maintaining RID2 rear performance Improvement of low severity frontal oblique impact head neck response (thus 3D) Rebound from rear impact Evaluation of RID3D and BIORID* Equally good rear impact performance RID3D wider range of application than BioRID Higher severity test conditions Rear impact and frontal impact Off axis loading Evaluation resulted in Recommendations for RID3D dummy updates 26 RID3D update according Whiplash2 recommendations EEVC WG12 rear impact dummy evaluation Evaluated against 5 selected rear impact biomechanical test conditions RID3D, BioRID and HIII Reports was summarized in EEVC report Dec 27 Page 3

4 Some Unique Features Positioning THOR thorax design Adjustable lower neck joint and lumbar joint for dummy positioning Tilt sensors available on 6 positions to allow accurate and repeatable seating position Output of rear impact dummies is highly sensitive to pre impact position Page 4

5 FTSS BioRID II + Development Why FTSS develop the BioRID II +? The customers requested FTSS to improve the BioRID II dummy Enable FTSS to provide full portfolio of dummies to the safety industry Goals A more repeatable and reproducible dummy Improved tolerance for better reproducibility Improve durability Improvement on dummy handling Critical user notes: Improve, but don t make a different dummy Page 5

6 BioRID II + Development FTSS Development and Improvements from Chalmers Design Calibration Fixture Development Current Fixture Review FTSS Calibration Fixture Calibration Data Summary Full Scale Sled Data Summary Durability and Repeatability Study FTSS Future Plan Page 6

7 Design Improvement Based on User s Feedback Task # Description Status 1 H-point feature (combine into one, aluminum to steel) implemented 2 Spring cable clearance to improve durability implemented 3 Harness for lifting legs implemented 4 Improved buffer locating feature implemented 5 Angled buffer for durability improvement not implemented 6 Move jacket split line away from the center implemented 7 Femur joint friction adjustment redesign no satisfactory solution yet 8 Head cable exit from side design completed, not implemented yet 9 Remove T1 load cell without disassembling the spine implemented 1 EuroNCAP T1 and L5 indicator improvement implemented 11 Calibration fixture improvement under development 12 ARS sensor to replace the rotary pot implemented 13 Head redesign to improve access to cable tension adjustment nuts Page 7 under development

8 Design Improvments muscle substitution cable sheath clearance. Jacket with side flap. Improved H-point locator design Vertebra bumper locating feature. Improved T1 design Page 8

9 Calibration Fixtures Current Calibration Fixture Review Too long for most labs to use on dummy tables Not enough constraint and allow lateral and vertical movement High friction with Teflon sheets Page 9

10 FTSS Calibration Fixture Matches weight of original sled with smaller package Track length reduced based on test duration Fits on a standard table and clamps Uses precision linear rails and ball bearings, reducing friction and constraining all motion to longitudinal axis only Tunable damper systems replaces the consumable foam Headrest ready Page 1

11 First Article Test Experience FTSS conducted over 25 tests on the first BioRID II + since June 29 The dummy was calibrated on monthly basis No replacement parts are needed after 25+ tests The cervical, thoracic, and lumbar bumpers and stops were never replaced. The original bumpers are still functioning properly. The dummy was completely disassembled 5 times, with load cells substituted etc. Page 11

12 Calibration Data Comparison Variation due to the foam blocks from different foam manufacturers Page 12

13 Calibration (cont d) Page 13

14 Validation and Comparison Tests Dual bucket rigid seat sled test FTSS dummy and Denton dummy for comparison IIHS procedure was used with some exceptions due to the rigid id seat Data channels EuroNCAP IIHS Additional Preliminary data review Planned tests in the coming months IIHS test protocol EuroNCAP test protocol Dummy reproducibility study Page 14

15 Sled Test Page 15

16 Sled Test Data Two tests overlay Red solid lines FTSS dummy Blue dotted lines Denton dummy Page 16

17 Head Acceleration Head Accelation Ax (g) HYH336 T L F DUMMY HEAD CG LONG CFC_1 HYH336 T R F DUMMY HEAD CG LONG CFC_1 HYH3361 T L F DUMMY HEAD CG LONG CFC_1 HYH3361 T R F DUMMY HEAD CG LONG CFC_ Head Accelation Az (g) Head Accelation Ay (g) HYH336 T L F DUMMY HEAD CG VERT CFC_1 HYH336 T R F DUMMY HEAD CG VERT CFC_1 HYH3361 T L F DUMMY HEAD CG VERT CFC_1 HYH3361 T R F DUMMY HEAD CG VERT CFC_ HYH3361T L F DUMMY HEAD CG LAT CFC_1 HYH3361 T R F DUMMY HEAD CG LAT CFC_ Page 17

18 Upper Neck Data Up pper Neck Fx (N) HYH336 T L F DUMMY NECK UPPER FX LOAD CFC_ 1 HYH336 T R F DUMMY NECK UPPER FX LOAD CFC_1 HYH3361 T L F DUMMY NECK UPPER FX LOAD CFC_1 HYH3361 T R F DUMMY NECK UPPER FX LOAD CFC_1 Upp per Neck My (Nm) HYH336 T L F DUMMY NECK UPPER MY LOAD CFC_6 HYH336 T R F DUMMY NECK UPPER MY LOAD CFC_6 HYH3361 T L F DUMMY NECK UPPER MY LOAD CFC_6 HYH3361 T R F DUMMY NECK UPPER MY LOAD CFC_ Page 18

19 T1 Acceleration 2 2 g) T1 Acceleraton Ax ( 15 HYH336 T L F DUMMY T1 LONG CFC_6 HYH336 T R F DUMMY T1 LONG CFC_6 HYH3361 T L F DUMMY T1 LONG CFC_6 1 HYH3361 T R F DUMMY T1 LONG CFC_ T1 acceleration right sid de (g) 15 HYH336 T L F DUMMY T1 AUX R LONG CFC_6 HYH336 T R F DUMMY T1 AUX R LONG CFC_6 HYH3361 T L F DUMMY T1 AUX R LONG CFC_6 HYH3361TRF DUMMYT1 AUXRLONG CFC_ Page 19

20 T1 Load Cell 25 2 T1 Load Cel l Fx (N) 2 HYH336 T L F DUMMY T1 FX LOAD CFC_1 15 HYH336 T R F DUMMY T1 FX LOAD CFC_1 HYH3361 T L F DUMMY T1 FX LOAD CFC_1 1 HYH3361 T R F DUMMY T1 FX LOAD CFC_ T1 Load Cel l Fz (N) HYH336 T L F DUMMY T1 FZ LOAD CFC_1 HYH336 T R F DUMMY T1 FZ LOAD CFC_1 3 HYH3361 T L F DUMMY T1 FZ LOAD CFC_1 HYH3361 T R F DUMMY T1 FZ LOAD CFC_ Page 2

21 L1 Acceleration HYH336 T L F DUMMY L1 LONG CFC_18 1 HYH336 T L F DUMMY L1 VERT CFC_18 HYH336 T R F DUMMY L1 VERT CFC_18 HYH3361 T L F DUMMY L1 VERT CFC_18 L1 Acceleratio on Ax (g) HYH336 T R F DUMMY L1 LONG CFC_18 HYH3361 T L F DUMMY L1 LONG CFC_18 HYH3361 T R F DUMMY L1 LONG CFC_18 L1 Acceleratio on Az (g) HYH3361 T R F DUMMY L1 VERT CFC_ Page 21

22 Pelvis Acceleration 25 6 Acceleration Noise: Hip joint found not as tight as it should be (1g set) after the test 15 5 HYH336 T L F DUMMY PELVIS LONG CFC_1 HYH336 T R F DUMMY PELVIS LONG CFC_1 HYH3361 T L F DUMMY PELVIS LONG CFC_1 1 HYH336 T L F DUMMY PELVIS VERT CFC_1 HYH336 T R F DUMMY PELVIS VERT CFC_1 Pelvis Acceleration P n Az(g) Pellvis Acceleration A Ax (g) 2 HYH3361 T R F DUMMY PELVIS LONG CFC_1 5 HYH3361 T L F DUMMY PELVIS VERT CFC_1 4 HYH3361 T R F DUMMY PELVIS VERT CFC_ () Page

23 Summary All design improvements are based on users experience and comments Calibration and sled testing were conducted Good durability and repeatability in calibration test and sled test Good comparison to Denton dummy performance in sled test Mini-sled design show good handling and will continue the development and refinement work Page 23

24 Status and Future Work 2 nd and 3 rd dummy are ready for testing in December 29 Dummies for customer orders are in process Participation of Global BioRID Users Group Meeting (GBUM) and GRSP whiplash group to support the activities toward rear impact regulation and harmonization Further improvements Friction reduction in muscle substitution system to improve the repeatability in testing Further refinement of tunable damper system for mini-sled Improve the accessibility to the head cavity for the cable tension adjustment Page 24

25 Manufacturing Clarification FTSS is committed to manufacture both RID3D and BioRID + II and continue to provide support to the industry. Page 25