.JIIIIIII"" Texas Transportation Institute SUMMARY OF TESTING ON 'l'he RENCO TRUCK MOUNTED ATTENUATOR by Wanda L. Menges Associate Research Specialist C. Eugene Buth, P.E. Senior Research Engineer and Sandra K. Schoeneman Research Associate Contract No. P2000463 Project No. 40000 1-RNC7F Sponsored by RENCO Supply Co. May2000 TEXAS TRANSPORTATION INSTITUTE THE TEXAS A & M UNIVERSITY SYSTEM COLLEGE STATION, TEXAS 77843
DISCLAIMER The contents of this report reflect the views of the authors who are solely responsible for the facts and accuracy of the data, and the opinions, findings and conclusions presented herein. The contents do not necessarily reflect the official views or policies of the RENCO Supply Company, The Texas A&M University System or Texas Transportation Institute. This report does not constitute a standard, specification, or regulation. In addition, the above listed agencies assume no liability for its contents or use thereof. The names of specific products or manufacturers listed herein does not imply endorsement of those products or manufacturers. KEYWORDS Truck Mounted Attenuators, TMA, work zone devices, crash cushion, crash testing, roadside safety
1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. Technical Report Documentation Pa2e 4. Title and Subtitle 5. Report Date SUMMARY OF TESTING ON THE RENCO TRUCK MOUNTED May2000 ATTENUATOR 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Wanda L. Menges, C. Eugene Buth, and Sandra K. Schoeneman 400001-RNC7F 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) Texas Transportation Institute The Texas A&M University System 11. ContractorGrantNo. College Station, Texas 77843-3135 P2000463 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered RENCO Supply Company Final Report P.O. Box 730 December 1998- May 2000 Pflugerville, Tx 78691 14. Sponsoring Agency Code 15. Supplementary Notes Research Study Title: NCHRP Report 350 testing of the RENCO RAM 1 OOk TMA Name of Contacting Representative: Ron Beyer 16. Abstract The RENCO Ren-Gard 815 TMA was designed to protect the occupants of errant vehicles who may impact the rear of a shadow vehicle (usually a dump truck). Vehicles tested may weigh up to 2000 kg and travel at speeds up to 70 kmlh. fu addition, the RENCO Ren-Gard 815 TMA was crash tested in accordance with and successfully met the evaluation criteria of National Cooperative Highway Research Program (NCHRP) Report 350 for a Test Level2 safety appurtenance. NCHRP Report 350 test 2-50 (820-kg passenger car at 70 kmlh with the support vehicle blocked to prevent movement) was performed June 29, 1998 on the RENCO Ren-Gard 815 TMA. The dimensions of the RENCO Ren-Gard 815 TMA were 2095 mm long by 2300 mm wide by 580 mm high. After attachment of the support frame, lights/harness, and rear jack, the TMA weighed 463 kg. RENCO Supply Company has recently developed a new TMA, designated the RENCO RAM look TMA. The RAM look was developed to meet or exceed NCHRP Report 350 Test Level 3 performance criteria. The dimensions oftherenco RAM look TMA are 3365 mmlong by 2145 mm wide by 580 mmhigh. The weight of the TMA without the mounting hardware was 427 kg (499 kg with mounting hardware). RENCO Supply Company, fuc. contracted with Texas Transportation fustitute (TTl) to crash test and evaluate the RENCO RAM look TMA to Test Level 3 (TL-3) of NCHRP Report 350. The objective of the tests reported herein.. is to evaluate and document the impact performance of the new RENCO RAM look TMA in accordance.with the guidelines presented in NCHRP Report 350 for Test Level 3 (TL-3) safety appurtenances. Crash test 400001-RNC2 reported herein is NCHRP Report 350 test 3-51 (2000-kg pick-up truck traveling 100 kmlh with the support vehicle parked free-standing, in second gear with the park brake set). fu addition, crash tests 400001-RNC6 and RNC7 reported herein correspond to the modified NCHRP Report 350 test 3-50 (820-kg passenger car traveling 100 kmlh with the support vehicle parked free-standing, in second gear with the park brake set). 17. Key Words 18. Distribution Statement Truck Mounted Attenuators, TMA, work zone devices, crash cushion, crash testing, roadside safety Copyrighted. Not to be copied or reprinted without consent from Sponsor. 19. Security Oassif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unclassified Form DOT F 1700.7 (8-72) Reproduction of completed page authorized
APPROXIMATE CONVERSIONS TO Sl UNITS APPROXIMATE CONVERSIONS FROM Sl UNITS Symbol When You Know Multiply by To Find Symbol Symbol When You Know Multiply by To Find Symbol LENGTH LENGTH In inches 25.4 millimeters mm mm millimeters 0.039 inches In It feet 0.305 meters m m meters 3.28 feet It yd yards 0.914 meters m m meters 1.09 yards yd ml miles 1.61 kilometers km km kilometers 0.621 miles ml AREA AREA In' square Inches 645.2 square millimeters mm' mm' square millimeters 0.0016 square inches In' II' square feet 0.093 square meters m' m' square meters 10.764 square feet II' yd' square yards 0.836 square meters m' m' square meters 1.195 square yards yd' ac acres 0.405 hectares ha ha hectares 2.47 acres ac ml' square miles 2.59 square kilometers km' km' square kilometers 0.386 square miles ml' VOLUME VOLUME fl oz fluid ounces 29.57 milliliters ml ml milliliters 0.034 fluid ounces fl oz gal gallons 3.785 liters L L liters 0.264 gallons gal II' cubic feet 0.028 cubic meters m' m' cubic meters 35.71 cubic feet It' yd' cubic yards 0.765 cubic meters m' m' cubic meters 1.307 cubic yards yd' ~ ~ NOTE: Volumes greater than 1000 I shall be-~jhown In m 3 MASS MASS oz ounces 28.35 grams g g grams 0.035 ounces oz lb pounds 0.454 kilograms kg kg kilograms 2.202 pounds lb T short tons 0.907 megagrams Mg Mg megagrams 1.103 short tons T {2000 lb) {or "metric ton") (or""!"") {or "t") {or "metric ton") {2000 lb) TEMPERATURE (exact) TEMPERATURE (exact) 'F Fahrenheit 5(F-32Y9 or Celclus 'C 'C Celcius 1.8C+32 Fahrenheit 'F temperature (F-32 1.8 temperature temperature temperature ILLUMINATION ILLUMINATION fc foot-candles 10.76 lux lx lx lux 0.0929 foot..candles fc II foot-lamberts 3.426 candela/nf cd/m 2 cdlrri' candela/m 2 0.2919 foot-lamberts fl FORCE and PRESSURE or STRESS FORCE and PRESSURE or STRESS lbf poundforce 4.45 newtons N N newtons 0.225 poundforce lbf lbf/ln' poundforce per 6.89 kilopascals kpa kpa kilopascals 0.145 poundforce per lbf/ln' square Inch square Inch E380.
TABLE OF CONTENTS Section INTRODUCTION... 1 PROBLEM... 1 BACKGROUND... 1 OBJECTIVES... 2 TECHNICAL DISCUSSION... 3 TEST PARAMETERS... 3 Test Facility... 3 Test Article - Design and Construction... 3 Test Conditions... 7 Evaluation Criteria... 8 CRASH TEST 400001-RNC6 (NCHRP REPORT 350 TEST MODIFIED 3-50)... 11 Test Vehicle... 11 Weather Conditions... 11 Impact Description... 11 Damage to Test Article... 15 Vehicle Damage... 15 Occupant Risk Factors... 15 CRASH TEST 400001-RNC7 (NCHRP REPORT 350 TEST MODlFIED 3-50)... 21 Test Vehicle... 21 Weather Conditions... 21 Impact Description... 21 Damage to Test Article... 25 Vehicle Damage... 25 Occupant Risk Factors... 30 CRASH TEST 400001-RNC2 (NCHRP REPORT 350 TEST 3-51)... 33 Test Vehicle... 33 Weather Conditions... 33 Impact Description... 33 Damage to Test Article... 37 Vehicle Damage... 37 Occupant Risk Factors... 37 SUMMARY AND CONCLUSIONS... 43 ASSESSMENT OF TEST RESULTS... 43 CONCLUSIONS... 48 iii
TABLE OF CONTENTS (continued) APPENDIX A. CRASH TEST PROCEDURES AND DATA ANALYSIS o o o o 0 o 0 0 0 0 0 0 0 57 ELECTRONIC INSTRUMENTATION AND DATA PROCESSING o o 0 0 0 0 0 0 0 0 57 ANTHROPOMORPHIC DUMMY INSTRUMENTATION o o o o o o o o 0 0 0 0 0 0 0 0 0 0 58 PHOTOGRAPHIC INSTRUMENTATION AND DATA PROCESSING 0 0 0 0 0 0 0 58 TEST VEHICLE PROPULSION AND GUIDANCE o 0 0 o o o o o o 0 o o o 0 0 0 0 0 0 0 0 0 0 0 59 APPENDIX B. TEST VEHICLE PROPERTIES AND INFORMATION 0 0 0 0 0 0 0 0 0 0 0 0 0 61 APPENDIX C. SEQUENTIAL PHOTOGRAPHS 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o o o o o o o o o o 0 0 o 0 0 0 0 0 71 APPENDIX D. VEHICLE ANGULAR DISPLACEMENTS AND ACCELERATIONS o 0 o o o 0 o o o o o o o 0 0 0.. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 77 REFERENCES o o o o o o o o o 0 0 o 0 o o 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o o o o o o o o o o 0 0 0 0 0 0 0 0 0 0 99 iv
LIST OF FIGURES Figure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Details of the RENCO RAM 1 OOk TMA... 4 RENCO RAM look TMA prior to test 400001-RNC6... 12 VehicletrMA geometries for test 400001-RNC6... 13 hnpacting vehicle before test 400001-RNC6... 14 Vehicle trajectory after test 400001-RNC6... 16 TMAaftertest400001-RNC6... 17 hnpacting vehicle after test 400001-RNC6... 18 Interior of impacting vehicle for test 400001-RNC6... 19 Summary of Results for test 400001-RNC6, NCHRP Report 350 test 3-50... 20 RENCO RAM look TMA prior to test 400001-RNC7... 22 VehiclefTMA geometries for test 400001-RNC7... 23 hnpacting vehicle before test 400001-RNC7... 24 Vehicle trajectory after test 400001-RNC7... 26 TMAaftertest400001-RNC7... 27 hnpacting vehicle after test 400001-RN C7....................... 28 Interior of impacting vehicle for test 400001-RNC7... 29 Summary of Results for test400001-rnc7, NCHRP Report 350 test 3-50... 31 RENCO RAM look TMA prior to test 400001-RNC2... 34 VehiclefTMA geometries for test 400001-RNC2... 35 hnpacting vehicle before test 400001-RNC2... 36 Vehicle trajectory after test 400001-RNC2... 38 TMA after test400001-rnc2... 39 hnpacting vehicle after test 400001-RNC2... 40 Interior of impacting vehicle for test 400001-RNC2... 41 Summary of Results for test 400001-RNC2, NCHRP Report 350 test 3-51... 42 Comparison of TMA damage... 49 Vehicle properties fortest400001-rnc6... 61 vehicle propl':rties for test400001.~rnc7... 64 Vehicle properties for test 400001-RNC2... 67 Sequential photographs for test 400001-RNC6 (overhead and frontal views).................................. 71 Sequential photographs for test 400001-RNC7 (overhead and frontal views)... 73 Sequential photographs for test 400001-RNC2 (overhead and frontal views)... 75 Vehicular angular displacements for test 400001-RNC6... 77 Vehicle longitudinal accelerometer trace for test 400001-RN C6 (accelerometer located at center of gravity)... 78 Vehicle lateral accelerometer trace for test 400001-RNC6 (accelerometer located at center of gravity)... 79 v
LIST OF FIGURES (continued) Figure 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Vehicle vertical accelerometer trace for test 400001-RNC6 (accelerometerlocated at center of gravity)... 80 Vehicle longitudinal accelerometer trace for test 400001-RNC6 (accelerometer located over rear axle)... 81 Vehicle lateral accelerometer trace for test 400001-RN C6 (accelerometer located over rear axle)... 82 Vehicle longitudinal accelerometer trace for test 400001-RNC6 (accelerometer located at center of gravity on support vehicle)... 83 Vehicular angular displacements for test 400001-RNC7... 84 Vehicle longitudinal accelerometer trace for test 400001-RNC7 (accelerometer located at center of gravity)... 85 Vehicle lateral accelerometer trace for test 400001-RNC7 (accelerometer located at center of gravity)... 86 Vehicle vertical accelerometer trace for test 400001-RNC7 (accelerometer located at center of gravity)... 87 Vehicle longitudinal accelerometer trace for test 400001-RNC7 (accelerometer located over rear axle)... 88 Vehicle lateral accelerometer trace for test 400001-RNC7 ( accelerometerlocated over rear axle)... 89 Vehicle longitudinal accelerometer trace for test 400001-RN C7 (accelerometer located at center of gravity on support vehicle)... 90 Vehicular angular displacements for test 400001-RNCZ... 91 Vehicle longitudinal accelerometer trace for test 400001-RNCZ (accelerometerlocated at center of gravity)... 92 Vehicle lateral accelerometer trace for test 400001-RNC2 (accelerometer located at center of gravity)... 93 Vehicle vertical accelerometer trace for test 400001-RNC2 (accelerometer located at center of gravity)... 94 Vehicle longitudinalaccelerometer trace for test 400001-RNCZ ( accelerometerlocated over rear axle)... 95 Vehicle lateral accelerometer trace for test 400001-RN C2 (accelerometer located over rear axle)... 96 Vehicle longitudinal accelerometer trace for test 400001-RNCZ (accelerometer located at center of gravity on support vehicle)... 97 vi
LIST OF TABLES Table No. Page 1 Performance evaluation summary for impacting vehicle during test 400001-RNC6, NCHRP Report 350 Test 3-50... 50 2 Performance evaluation summary for support vehicle during test 400001-RNC6, NCHRP Report 350 Test 3-50... 51 3 Performance evaluation summary for impacting vehicle during test 400001-RNC7, NCHRP Report 350 Test 3-50... 52 4 Performance evaluation summary for support vehicle during test400001-rnc7, NCHRP Report 350 Test 3-50... 53 5 Performance evaluation summary for impacting vehicle during test400001-rnc2, NCHRP Report 350 Test 3-51... 54 6 Performance evaluation summary for support vehicle during test400001-rnc2, NCHRP Report 350 Test 3-51... 55 7 Exterior crush measurements for test 400001-RNC6... 62 8 Occupant compartment measurements for test 400001-RNC6... 63 9 Exterior crush measurements for test 400001-RNC7... 65 10 Occupant compartment measurements for test 400001-RNC7... 66 11 Exterior crush measurements for test 400001-RNC2... 68 12 Occupant compartment measurements for test 400001-RNC2... 69 vii
INTRODUCTION PROBLEM Construction and maintenance operations on the Nation's highways pose hazards to both workers and motorists. Various measures are employed to route traffic around work zones, including channelizing devices (cones, barrels, etc.), signs, flaggers, and flashing arrow boards. However, these measures alone do not adequately protect the workers from errant vehicles. Inattentive drivers may not follow the detour, or for some reason may be forced into the work zone. A measure commonly used to protect maintenance workers from errant vehicles is to place a shadow truck behind the construction or maintenance operation. Shadow trucks, or barrier vehicles, are also used in slow moving operations. Shadow trucks are used to protect workers performing striping, patching, sanding, snow plowing, pavement resurfacing, bridge deck repair, guardrail and attenuator repair, and other operations. While the shadow truck is effective in protecting work crews, it does not always protect riders in vehicles which strike the shadow truck. Because of this problem, several impact attenuation devices have been developed to decrease the severity of collisions. Several truck mounted attenuators (TMAs) have been developed and tested, and are being used by various states. A TMA is a compact crash cushion which is attached to the rear of a shadow truck and is intended to reduce the accelerations felt by occupants in a vehicle striking a shadow truck. BACKGROUND The history of the development of the TMA in the United States can be traced to the early 1970's when Texas Transportation Institute (TTl) designed and tested a "crash cushion trailer."c') The TTl crash cushion trailer was 6.9 m long and 1.8 m wide creating maneuverability problems. In late 1975, the Connecticut Department of Transportation contracted with the University of Connecticut to develop a TMA which could be suspended or cantilevered off the rear of a dump truck, rather than trailered.c 2 ) Since 1975, many cantilevered TMAs have been developed. Federal Highway Administration (FHW A) has formally adopted National Cooperative Highway Research Program (NCHRP) Report 350 as the official guidelines for safety performance of evaluation of roadside features (including TMAs).C3J FHW A has further required that most roadside features to be used on the National Highway System (NHS) be crash tested in accordance with the NCHRP Report 350 guidelines by October 1998. Therefore, it is necessary for all new roadside features, including TMAs, to be evaluated to NCHRP Report 350. The RENCO Ren-Gard 815 TMA was designed to protect the occupants of errant vehicles that may impact the rear of a shadow vehicle (usually a dump truck). Vehicles tested may weigh up to 2000 kg and travel at speeds up to 70 kmlh. In addition, the RENCO Ren-Gard 815 TMA was crash tested in accordance with and successfully met the evaluation criteria of NCHRP Report 350 for a Test Level2 safety appurtenance.c 4 ) NCHRP Report 350 test 2-50 (820-kg 1
passenger car at 70 km/h with the support vehicle blocked to prevent movement) was performed June 29, 1998 on the RENCO Ren-Gard 815 TMA The dimensions of the RENCO Ren-Gard 815 TMA were 2095 mm long by 2300 mm wide by 580 mm high. After attachment ofthe support frame, lights/harness, and rear jack, the TMA weighed 463 kg. RENCO Supply Company has recently developed a new TMA, designated the RENCO RAM 1 OOk TMA. The RAM 1 OOk was developed to meet or exceed NCHRP Report 350 Test Level 3 performance criteria. The dimensions of the RENCO RAM look TMA are 3365 mm long by 2145 mm wide by580 mm high. The weight of the TMA without the mounting hardware was 427 kg (499 kg with mounting hardware) RENCO Supply Company, Inc. contracted with TTl to crash test and evaluate the RENCO RAM look TMA to Test Level 3 (TL-3) of NCHRP Report 350. OBJECTIVES The objective of the tests reported herein is to evaluate and document the impact performance of the new RENCO RAM 1 OOk TMA in accordance with the guidelines presented in NCHRP Report 350 for Test Level 3 (TL-3) safety appurtenances. Crash test 400001-RNC2 reported herein is NCHRP Report 350 test 3-51 (2000-kg pickup truck traveling 100 km/h with the support vehicle parked free-standing, in second gear with the park brake set). In addition, crash test 400001-RNC6 and RNC7 reported herein correspond to the modified NCHRP Report 350 test 3-50 (820-kg passenger car traveling 100 km/h with the support vehicle parked free-standing, in second gear with the park brake set). 2
TECHNICAL DISCUSSION TEST PARAMETERS Test Facility The test facilities at the Texas Transportation Institute's Proving Ground consist of an 809-hectare complex of research and training facilities situated 16 Ian northwest of the main campus of Texas A&M University. The site, formerly an Air Force Base, has large expanses of concrete runways and parking aprons well suited for experimental research and testing in the areas of vehicle performance and handling, vehicle-roadway interaction, durability and efficacy of highway pavements, and safety evaluation of roadside safety hardware. The site selected for placing of the RENCO TMAs is on the surface of a wide expanse of concrete aprons which were originally used as parking aprons for military aircraft. These aprons consist of unreinforced jointed concrete pavement in 3.8 m by 4.6 m blocks (as shown in the adjacent photo) nominally 203-305 mm deep. The aprons and runways are about 50 years old and the joints have some displacement, but are otherwise flat and level. Test Article - Design and Construction RENCO's TMA absorbs energy by the use of cardboard honeycomb sections. The TMAs are constructed using a shoe box style aluminum container divided into several sections to hold combinations of "soft" and "heavy" cardboard material. The TMAs were assembled, wired, and painted before delivery to TTL The dimensions of the RENCO RAM look TMAs used in tests RNC2, RNC6 and RNC7 were3365 mm long by 2145 mm wide by 580 mm high. In tests 400001~RNC6 and RNC7, the weight of the TMA without the mounting hardware was 427 kg ( 499 kg with mounting hardware). In test 400001-RNC2, the weight of the TMA without the mounting hardware was 499 kg (544 kg with mounting hardware). Changes in the TMA were made between tests RNC2 and RNC6. They were reported by Mr. Beyer ofrenco to be: 1) A double row of rivets was added in the rear 457 mm of center seam of lid, and 2) A 1219 mm "heavy" honeycomb section was glued to the 610 mm "soft" section. Details of the RENCO RAM 1 OOk TMA are shown in figure 1. The RENCO RAM look TMA was then attached to a 1981 Ford F600 11,000 kg (GVWR) dump truck. The truck was ballasted to 8849 kg, which brought the total weight for the 3
OTY ITEM 1 2 1 3 2 4 5 1 2 ' 7 2 8 1 9 4 DESCRIPTION HYDRAULIC CYLINDER CONTROL UNIT TRUCK MOUNT ( 1 /2" PLATE W/BRACKETS) SUPPORT BRACKET BATTERY & HYDRAULIC PUMP HYDRAULIC CYLINDER ADJUSTMENT TURN SCREW TELSPAR JACKSTAND REPLACEABLE CRASH PAD TAIL LIGHTS NOTES 1. TRUCK FRAME IS HIGH CARDON STEEL. TO AVOID CRACKING DO NOT WELD OR APPLY EXCESSIVE HEAT TO BOTTOM FLANGE. 2. DO NOT CUT FRAME CROSS MEMBER WHICH TIES INTO OUTROAD LEAF SPRING HANGERS. 3. DIMENSION (XX.XX) ARE CENTIMETERS. PIVOT POINTS (3 POINTS) TO RAISE PAD 75" TO VERTICAL POSITION FOR TRANSPORTING. RAISED BY HYDRAULIC CYLINDER. HOLE FOR LOCKPINS- -------------- 1.32 Lg X 84 W,----------------1.--'~n~r~L_9 ~1"l7t~~jP=1:Jy:4-~~"Q"~2~="~=;,~,;===================- i_jda (_"_' 2_a_x_2_"_ "_1 1,L' ~: :~/~ 7 (S ~i1 ~5:1 FUL~ENGTH PAD 9 "'~GLE DETERMINE~ AT \\ eb (33.02±2.54) ~ INSTALLATION (45. MIN) ~ _/ GROUND LINE--- "" TWO ADJUSTABLE STANDS~ FRONT CORNERS (NOT SHOWN) Figure 1. Details of the RENCO RAM 1 OOk TMA.
1. HYDRAULIC CYLINDER, PUMP, CONTROLS AND ADJUSTMENT TURN SCREWS ARE NOT SHOWN. PAD RAISES 75" FOR WHEN NOT IN USE TWO ADJUSTABLE JACK STANDS IN FRONT OF PAD CCAG HOLDERS ADDITIONAL TAIL LIGHTS ARE ON THE UNDERSIDE FOR WHEN CUSHION IS IN RAISED POSITION ITEM ' 4 5 6 QlY DESCRIPTION MECHANICAL SUPPORT MECHANISM CRASH CUSHION TELSPAR JACKSTANDS TAIL LIGHTS RUNNING LIGHT BACK PLATE EXTERIOR WIRING HARNESS Figure 1. Details of the RENCO RAM look TMA (continued).
1. DIMENSION (XX.XX) ARE CENTIMETERS. 132" r--------(335.")----------j~ 84"... """~............................... Figure 1. Details of the RENCO RAM look TMA (continued).
dump truck and TMA to 9348 kg. In all three tests, the support truck was parked freestanding in second gear with the park brake set. Nominal height from the bottom of the TMA to the pavement surface was 305 mm. Photographs of the TMAs as tested are shown with each test. Test Conditions According to NCHRP Report 350, the following tests are required to evaluate truck mounted attenuators to test level three (TL-3): NCHRP Report 350 test designation 3-50: An 820-kg vehicle impacting the truck mounted attenuator at 100 km/h and 0 degree with the centerline of the vehicle aligned with the centerline of the TMA. The support vehicle is to be parked against a rigid wall. The test is intended to evaluate the risks to occupants of a small car when impacting the TMA. NCHRP Report 350 test designation 3-51: A 2000-kg pickup truck impacting the truck mounted attenuator at 100 km/h and 0 degree with the centerline of the vehicle aligned with the centerline of the TMA. The support vehicle is to be free-standing, parked in second gear with the park brake on. The test is intended to evaluate structural adequacy of the TMA, risks to occupants, and the roll-ahead distance of the supporting truck for impacts with a heavy passenger vehicle. In a memo from FHW A, dated July 25, 1997, titled "Action: Identifying Acceptable Highway Safety Features," the following exception was made to the above testing: The guidelines in Report 350 for assessing the crashworthiness of truck mounted attenuators (TMAs) are to be followed except that, until state-of-the-art developments indicate that practical and economic TMAs can fully meet the guidelines in Report 350 under test 3-50, the FHWA will accept a modified test 3-50, provided an unmodified test 2-50 (70 km/h, small car test with the host vehicle blocked to prevent movement) is run and passed. The modified 3-50 test the FHWA will accept for qualifying a test level] TMA is a 100 km/h small car test where the host vehicle only has its brakes set and is in second gear. This assumes all other Report 350 test level 3 requirements are met. Crash test 400001-RNC6 and RNC7 reported herein correspond to the modified NCHRP Report 350 test 3-50 (820-kg passenger car at 100 kmlh with the support vehicle free-standing, park brake set, in second gear). Crash test 400001-RNC2 corresponds to NCHRP Report 350 test 3-51 with the 2000-kg pickup truck. The crash test and data analysis procedures were in accordance with guidelines presented in NCHRP Report 350. Brief descriptions of these procedures are presented in appendix A. 7
Evaluation Criteria Structural adequacy of the TMA, risks to occupants of both the impacting and the support vehicle, and the roll-ahead distance of the support vehicle are the relevant factors in evaluating the safety performance of the TMA. The crash tests performed were evaluated in accordance with the criteria presented in NCHRP Report 350. As stated in NCHRP Report 350, "Safety performance of a highway appurtenance cannot be measured directly but can be judged on the basis of three factors: structural adequacy, occupant risk, and vehicle trajectory after collision." Accordingly, the following safety evaluation criteria from table 5.1 of NCHRP Report 350 were used to evaluate the crash tests reported herein. The following evaluation criteria apply to the impacting vehicle: Occupant Risk D. Detached elements, fragments or other debris from the test article should not penetrate or show potential for penetrating the occupant compartment, or present an undue hazard to other traffic, pedestrians, or personnel in a work zone. Deformation of, or intrusions into, the occupant compartment that could cause serious injuries should not be permitted. F. The vehicle should remain upright during and after collision although moderate roll, pitching and yawing are acceptable. H. Occupant impact velocities should satisfy the following: Longitudinal and Lateral Occupant Impact Velocitv - mls Preferred Maximum 9 12 I. Occupant ridedown accelerations should satisfy the following: Vehicle Trajectory Longitudinal and Lateral Occupant Ridedown Accelerations - g 's Preferred Maximum 15 20 K. After collision it is preferable that the vehicle's trajectory not intrude into adjacent traffic lanes. In a memo entitled: Action: Identifying Acceptable Highway Safety Features, FHW A suggests the following supplemental evaluation factors and terminology be used for visual assessment of test results: 8
+ PASSENGER COMPARTMENT INTRUSION 1. Windshield Intrusion a. No windshield contact b. Windshield contact, no damage c. Windshield contact, no intrusion d. Device embedded in windshield, no significant intrusion e. Complete intrusion into passenger compartment f. Partial intrusion into passenger compartment 2. Body Panel Intrusion + LOSS OF VEHICLE CONTROL 1. Physical loss of control 3. Perceived threat to other vehicles 2. Loss of windshield visibility 4. Debris on pavement + PHYSICAL THREAT TO WORKERS OR OTHER VEHICLES 1. Harmful debris that could injure workers or others in the area 2. Harmful debris that could injure occupants in other vehicles VEHICLE AND DEVICE CONDITION 1. Vehicle Damage 2. 3. a. None b. Minor scrapes, scratches or dents c. Significant cosmetic dents Windshield Damage a. None b. Minor chip or crack c. Broken, no interference with visibility d. Broken and shattered, visibility restricted but remained intact Device Damage d. Major dents to grill and body panels e. Major structural damage e. Shattered, remained intact but partially dislodged f. Large portion removed g. Completely removed a. b. c. None Superficial Substantial, but can be straightened d. e. Substantial, replacement parts needed for repair Cannot be repaired 9
The following evaluation criteria apply to the support vehicle: Structural Adequacy C. Acceptable test article performance may be by redirection, controlled penetration, or controlled stopping of the vehicle. OccupantEUsk D. Detached elements, fragments or other debris from the test article should not penetrate or show potential for penetrating the occupant compartment, or present an undue hazard to other traffic, pedestrians, or personnel in a work zone. Deformation of, or intrusions into, the occupant compartment that could cause serious injuries should not be permitted. F. The vehicle should remain upright during and after collision although moderate roll, pitching and yawing are acceptable. I. Occupant ridedown accelerations should satisfy the following: Vehicle Trajectory Longitudinal and Lateral Occupant Ridedown Accelerations - g 's Preferred Maximum 15 20 K. After collision it is preferable that the vehicle's trajectory not intrude into adjacent traffic lanes. 10
CRASH TEST 400001-RNC6 (NCHRP REPORT 350 TEST MODIFIED 3-50) The RENCO RAM look TMA was tested and evaluated in test 400001-RNC6. The dimensions of the RENCO RAM look TMA was 3365 mm long by 2145 mm wide by 580 mm high. The weight of the TMA without the mounting hardware was 427 kg (499 kg with mounting hardware). Details of the TMA are given in figure 1. Test Vehicle The RENCO RAM look TMA was installed for this test as shown in figures 1 and 2. A 1994 Geo Metro, shown in figures 3 and 4, was used for the crash test. Test inertia weight of the vehicle was 820 kg, and its gross static weight was 896 kg. The height to the lower edge of the vehicle front bumper was 370 mm and to the upper edge of the front bumper was 455 mm. Additional dimensions and information on the vehicle are given in appendix B, figure 27. The vehicle was directed into the installation using the cable reverse tow and guidance system, and was released to be free-wheeling and unrestrained just prior to impact. Information on the support vehicle is given in Technical Discussion under Test Article. Weather Conditions The crash test was performed the morning of November 11, 1999. No rainfall was recorded for the ten days prior to the test. Weather conditions at the time of testing were as follows: Temperature: l5 C; Relative Humidity: 30 percent. hnpact Description The vehicle, traveling at 94.9 kmlh, impacted the RENCO RAM look at 0 degrees with the centerline of the impacting vehicle aligned with the centerline of the TMA. Shortly after impact, the TMA moved. At 0.033 s, the rear wheels of the support vehicle moved. The impacting vehicle began to underride the TMA at 0.036 s. The top edges on the side of the TMA folded in and the front of the TMA moved forward at 0.045 s. :By!tb64 s, tlie hood of tlie vehicle deformed and folded toward the windshield. The hood contacted the windshield, and shattered the glass. At 0.098 s, the back-up plate on the TMA deformed upward. At 0.103 s, the bottom rear edge of the TMA contacted the windshield, and at 0.124 s, the driver's side window shattered. The dummy's head was fully extended forward at 0.131 s, and at 0.160 s, the rear of the TMA extended up and over the windshield of the impacting vehicle. By 0.181 s, the undercarriage of the vehicle contacted the ground surface, and by 0.253 s, the impacting vehicle stopped moving forward. At 0.265 s, the support vehicle and TMA moved forward slightly and then the TMA slid backward. At 1.671 s, the support vehicle stopped moving forward. Brakes on the impacting vehicle were not applied, and the vehicle subsequently came to rest under the TMA. Maximum roll-ahead distance of the support vehicle was 1055 mm. Sequential photographs of the test period are shown in appendix C, figure 30. 11
Figure 2. RENCO RAM look TMA prior to test 400001-RNC6. 12
Figure 3. Vehicle/TMA geometries for test 400001-RNC6. 13
Figure 4. Impacting vehicle before test 40000 1-RNC6. 14
Damage to Test Article The damage sustained by the RENCO RAM -1 OOk TMA is shown in figures 5 and 6. The TMA buckled on the top surface 460 mm from the front, 530 mm folded under on the rear, 496 mm rolled downward, and the bottom of the TMA folded up in front of the vehicle. The backup/support structure on the left side deformed 5 mm. Maximum dynamic crush of the RENCO RAM-lOOk TMA during the test was not attainable, but the maximum residual deformation was 2.6 m. Vehicle Damage The vehicle sustained extensive damage to the front as shown in figure 7. Structural damage was imparted to the right and left A-posts and the front strut mounts. Also damaged were the front bumper, hood, radiator and support, left and right head lights, right door, left door and window. The right and left quarter panels and the roof of the vehicle were deformed. The windshield was broken and deformed inward with significant damage, penetration of the windshield (small hole near the edge on the passenger side), and the windshield was separated from the frame on the passenger side as well (Case 2 of the FHW A windshield classification which states: Any impact that destroys or deforms the windshield to the extent that it separates from the frame). Maximum exterior crush was 190 mm at the front bumper. Maximum occupant compartment deformation was 130 mm (18 percent reduction in space) in the firewall area. The interior of the vehicle is shown in fignre 8. Exterior vehicle crush and occupant compartment measurements are shown in appendix B, tables 7 and 8. Occupant Risk Factors Data from the accelerometer located at the vehicle center of gravity (e.g.) were digitized for evaluation of occupant risk and were computed as follows. Also note that the impacting speed of the vehicle was 4.9 km/h under the target speed of 100 kmlh. For the impacting vehicle: In the longitudinal direction, the occupant impact velocity was ll.5 rn!s at 0.109 s, the highest 0.010-s occupant ridedown acceleration was -16.6 g' s from 0.223 to 0.233 s, and the maximum 0.050-s average acceleration was -14.3 g's between 0.201 and 0.251 s. In the lateral direction, the occupant impact velocity was 0.8 rn!s at 0.109 s, the highest 0.010-s occupant ridedown acceleration was -1.5 g's from 0.213 to 0.223 s, and the maximum 0.050-s average was -1.4 g's between 0.048 and 0.098 s. For the support vehicle: The highest 0.010-s longitudinal ridedown acceleration was 2.6 g' s at 0.108 s. These data and other pertinent information from the test are summarized in figure 9. Vehicle angular displacements and accelerations versus time traces are presented in appendix D, figures 33 through 39. 15
Figure 5. Vehicle trajectory after test 400001-RNC6. 16
Figure 6. TMA after test 400001-RNC6. 17
Figure 7. Impacting vehicle after test 400001-RNC6. 18
Before test After test Figure 8. Interior of impacting vehicle for test 400001-RNC6. 19
General Information ~ Test Agency... Texas Transportation Institute Test No................. 400001-RNC6 Date................... 11/30/99 Test Article Type... Truck Mounted Attenuator Name.................. RENCO RAM-1 OOk TMA Installation Length (m)..... 2.1 Material or Key Elements... Cardboard Honeycomb Covered with Aluminum Sh~eting Soil Type and Condition.... Concrete Pavement, Dry Test Vehicle Type................... Production Designation............. 820C Model.................. 1994 Geo Metro Mass (kg) Curb... 766 Test Inertial........... 820 Dummy.............. 76 Gross Static........... 896 Impact Conditions Speed (km/h).... Angle (deg).... Exit Conditions Speed (km/h).... Angle (deg).... Occupant Risk Values Impact Velocity (m/s) x-direction.... y-direction.... THIV (km/h).... Ridedown Accelerations (g's) x-dlrection.... y-direction...,,..,..,.. PHD (g's).... ASI.... Max. 0.050-s Average (g's) x-direction...,..,.. y-direction.... z-direction.... 95.13 0 Stopped N/A 11.5 0.8 41.5-16.6-1.5 16.6 1.20-14.3-1.4 2.8 Test Article Deflections (m) Dynamic.,............... N!A Permanent............... 2.6 Vehicle Damage Exterior VDS... 12FD7 CDC... 12FDEW6 Maximum Exterior Vehicle Crush (mm)...... 190 Interior OCDI................. FS0021 000 Max. Occ. Compart. Defonmation (mm)... 130 Post-Impact Behavior (during 1.0 s after impact) Max. Yaw Angle (deg)...... 1 Max. Pitch Angle (deg)...... -3 Max. Roll Angle (deg)....... 1 Figure 9. Summary of Results for test 400001-RNC6, NCHRP Report 350 test 3-50.
CRASH TEST 400001-RNC7 (NCHRP REPORT 350 TEST MODIFIED 3-50) The RENCO RAM look TMA was tested and evaluated in test 400001-RNC7. The dimensions of the RENCO RAM look TMA were 3365 mm long by 2145 mm wide by 580 mm high. The weight of the TMA without the mounting hardware was 427 kg ( 499 kg with mounting hardware). Details of the TMA are given in figure 1 and 11. Test Vehicle The RENCO RAM look TMA was installed on the support vehicle as shown in figure 10. A 1991 Ford Festiva, shown in figures 11 and 12, was used for the crash test. Note that the vehicle was older than allowed in NCHRP Report 350; however, prior permission was given by FHW A allowing use of this vehicle. Test inertia weight of the vehicle was 820 kg, and its gross static weight was 895 kg. The height to the lower edge of the vehicle front bumper was 380 mm and to the upper edge of the front bumper was 1530 mm. Additional dimensions and information on the vehicle are given in appendix B, figure 28. The vehicle was directed into the installation using the cable reverse tow and guidance system, and was released to be freewheeling and unrestrained just prior to impact. Information on the support vehicle is given in Technical Discussion under Test Article. Weather Conditions The crash test was performed the morning of March 23, 2000. A total of 48 mm of rainfall was recorded beginning nine days prior to the date. No rainfall was recorded for the remaining eight days prior to the test. This rainfall would have no effect on the test as the test was conducted on the concrete The refe~ence for I [EB; i wind direction is 90" vehicle fixed as surface. Weather conditions at the time of testing were as howo. follows: Wind Speed: 24 kmlh; Wind Direction: 180 degrees _ " 00 it(]h '""!Bo' with respect to the vehicle (vehicle was traveling in a northerly direction); Temperature: 24 oc; Relative Humidity: 67 percent. 1270. Impact Description The vehicle, traveling at a speed of 100.2 kmlh, impacted the RAM-lOOk TMA at 0 degrees with the centerline of the vehicle aligned with the centerline of the TMA. Shortly after impact the TMA moved. The bottom seam at the rear of the TMA began to tear and move toward the ground at 0.012 s. At 0.017 s, the dummy's head moved forward. By 0.019 s, the bottom of the TMA contacted the ground surface, and by 0.024 s, the bottom side seam had ruptured 0.51 m and the backup/support structure plate rotated downward. The TMA slid closer to the impacting vehicle at 0.028 s, and at 0.034 s, the support vehicle rolled forward. At 0.036 s, the front tires of the impacting vehicle rode up on the bottom shell of the TMA, and at 0.039 s, the top of the shell of the TMA split at the seam. By 0.044 s, the impacting vehicle moved downward 21
Figure 10. RENCORAM 100kTMApriortotest400001-RNC7. 22
Figure 11. VehicleffMA geometries for test 400001-RNC?. 23
Figure 12. hnpacting vehicle before test 400001-RNC?. 24
toward the ground surface, and by 0.051 s, the hood of the vehicle deformed toward the windshield. At 0.058 s the bottom comer seam had ruptured 0.84 m and a rupture was visible in the bottom middle seam. By 0.064 s the top middle seam had opened 1.06 m. The bottom center of the TMA contacted the ground surface at 0.075 s, and at 0.080 s, the front of the impacting vehicle lost contact with the ground. A secondary rupture began opening on the bottom comer seam at 0.090 s. By 0.104 s the bottom comer seam had ruptured a total of 3.13 m. The dummy's head contacted the steering wheel and instrument panel at 0.102 sand 0.109 s, respectively. By 0.173 s, the left and right front tires lost contact with the ground, and by 0.268 s, the impacting vehicle stopped moving forward. The left and right front tires contacted the ground surface at 0.654 s, and at 0.781 s, the support vehicle stopped moving forward. The support vehicle and impacting vehicle stopped moving at 2.919 s. Brakes on the impacting vehicle were not applied and the vehicle subsequently came to rest within the TMA. The vehicle was slowed over 3.07 m until a common velocity with the support vehicle of 12.1 kmlh was attained. During this time the support vehicle was pushed forward 0.23 m. Maximum roll-ahead distance of the support vehicle was 730 mm. Sequential photographs of the test period are shown in appendix C, figure 31. Damage to Test Article The damage sustained by the RENCO RAM-lOOk TMA is shown in figures 13 and 14. The TMA was crushed somewhat evenly from left to right and top to bottom. The top seam split stopped at 400 mm from the front of the TMA. Both bottom comer seams were almost entirely ruptured leaving the bottom sheath of the TMA to remain under the vehicle. The backup/support structure on the right side deformed 2 mm. Maximum dynamic crush of the RENCO RAM-lOOk TMA during the test was not attainable. The maximum residual deformation was 2.1 m and the maximum impacting vehicle displacement relative to the support vehicle, when common velocity was attained, was 2.82 m as measured on the high speed film. It was noted that the seams on the TMA in test RNC7 ruptured more rapidly and more significantly than in test RNC2. Vehicle Damage The vehicle sustained extensive damage to the front as shown in figure 15. Structural damage was imparted to the left and right front struts. Also damaged were the bumper, hood, fan and radiator, right and left doors, and the floor pan area. The right and left front quarter panels were deformed. The windshield was broken and deformed inward with significant damage but did not separate from the frame (Case 3 of the FHW A windshield classification which states: Any impact where the windshield is cracked overall to such a degree that the driver cannot readily see to navigate). Maximum exterior crush of the vehicle was 150 mm at the front bumper. Maximum occupant compartment deformation was 42 mm (6 percent reduction in space) in the firewall area. The interior of the vehicle is shown in fignre 16. Exterior vehicle crush and occupant compartment measurements are shown in appendix B, tables 9 and 10. 25
Figure 13. Vehicle trajectory after test 400001-RNC?. 26
Figure 14. TMA after test 400001-RNC7. 27
Figure 15. Impacting vehicle after test 400001-RNC7. 28
Before test After test Figure 16. Interior of impacting vehicle for test 400001-RNC?. 29
Occupant Risk Factors Data from the accelerometer located at the vehicle e.g. were digitized for evaluation of occupant risk and were computed as follows. For the impacting vehicle: In the longitudinal direction, the occupant impact velocity was 12.3 m/s at 0.100 s, the highest 0.010-s occupant ridedown acceleration was -13.7 g's from 0.192 to 0.202 s, and the maximum 0.050-s average acceleration was -14.2 g's between 0.029 and 0.079 s. In the lateral direction, there was no contact, the highest 0.010-s occupant ridedown acceleration was 3.2 g's from 0.162 to 0.172 s, and the maximum 0.050-s average was 1.0 g's between 0.085 and 0.135 s. For the support vehicle: The highest 0.01 0-s longitudinal ridedown acceleration was -1.6 g' s at 0.100 s. These data and other pertinent information from the test are summarized in figure 17. Vehicle angular displacements and accelerations versus time traces are presented in appendix D, figures 40 through46. 30
~Dilll~ I~ c::j c::j c::j c::j s Oil ~~~" _i1?'i:)"'.~:.o.:.j., w General Information ~-'- Test Agency.... Test No..... Date.... Test Article Type.... Name.... Installation Length (m).... Material or Key Elements... Soil Type and Condition... Test Vehicle Type.... Designation.... Model.... Mass (kg) Curb.... Test Inertial.... Dummy.... Gross Static.... Texas Transportation Institute 400001-RNC? 03/23/00 Truck Mounted Attenuator RENCO RAM-1 OOk TMA 2.1 Cardboard Honeycomb Covered with Aluminum Sheeting Concrete Pavement, Dry Production 820C 1991 Ford Festiva 854 820 75 895 Impact Conditions Speed (km/h)... 100.2 Angle (deg)... 0 Exit Conditions Speed (km/h)................ Stopped Angle (deg)................. N/A Occupant Risk Values Impact Velocity (m/s) x~direction... 12.3 y-direction................ 0 THIV (km/h)............. 44.4 Ridedown Accelerations (g's) x-direction... -13.7 y-direction................ 3.2 PHD (g's)................... 13.8 ASI....................... 1.18 Max. 0.050-s Average (g's) x-direction... -14.2 y-direction................ 1.0 z-direction................ 2.4 Test Article Deflections (m) Dynamic................. N/A Permanent............... 2.1 Vehicle Damage Exterior VDS... 12FD4 CDC................ 12FDEW5 Maximum Exterior Vehicle Crush (mm).... 150 Interior OCDI............... FS0010000 Max. Occ. Compart. Deformation (mm)... 42 Post-Impact Behavior {during 1.0 s after impact) Max. Yaw Angle (deg)...... 3 Max. Pitch Angle (deg)...... 7 Max. Roll Angle (deg)....... -5 Figure 17. Summary of Results for test 400001-RNC7, NCHRP Report 350 test 3-50.
CRASH TEST 400001-RNC2 (NCHRP REPORT 350 TEST 3-51) TheRENCO RAM look TMA was tested and evaluated in test400001-rnc2. The dimensions of the RENCO RAM look TMA were 3365 mm long by 2145 mm wide by 580 mm high. The weight of the TMA without the mounting hardware was 427 kg ( 499 kg with mounting hardware). Details of the TMA are given in figure 1. Test Vehicle The RENCO RAM look TMA was attached to the support vehicle as shown in figure 18. A 1994 Ford F-250 pickup truck, shown in figures 19 and 20, was used for the crash test. Test inertia weight of the vehicle was 2000 kg, and its gross static weight was 2000 kg. The height to the lower edge of the vehicle front bumper was 435 mm and to the upper edge of the front bumper was 710 mm. Additional dimensions and information on the vehicle are given in appendix B, figure 29. The vehicle was directed into the installation using the cable reverse tow and guidance system, and was released to be free-wheeling and unrestrained just prior to impact. Information on the support vehicle is given in Technical Discussion under Test Article. Weather Conditions The crash test was performed the morning of Aprill5, 1999. A total of 1 mm of rainfall was recorded nine days prior to the test and 20 mm was recorded the day before the test. This rainfall would have no effect on the test as the test was conducted on the concrete surface. Weather conditions at the time of testing were as follows: Wind Speed: 27 kmlh; Wind Direction: 340 degrees with respect to the vehicle (vehicle was traveling northerly direction); Temperature: 14 C; Relative Humidity: 36 percent. The reference for j wind dlrecl!on Is 90 vehicle fixed as.howotjr~ ~ if(lj. ~lso' 1270 Impact Description The vehicle, traveling at 100.3 kmlh, impacted the RENCO RAM-lOOk TMA at 0 degrees with the centerline of the impacting vehicle aligned with the centerline of the TMA. Shortly after impact, the rear wheels of the support vehicle began to roll. By 0.017 s the comer seam had ruptured 0.44 m. The bottom rear section of the TMA contacted the ground surface at 0.079 s. By 0.106 s the bottom comer seam had ruptured 1.91 m. The support vehicle had moved 0.20 m by 0.159 s. The front and rear tires of the impacting vehicle lost contact with the ground at 0.159 sand 0.187 s, respectively. A common velocity of 12.6 kmlh was attained at approximately 0.225 s. Total pickup CG displacement at common velocity was 3.23 m. The front and rear tires returned to the ground surface at 0.613 s, 0.619 s, 0.665 s, and 0.707 s, respectively. The impacting vehicle stopped moving forward at 1.977 s. The support truck rolled 33
Figure 18. RENCO RAM look TMA prior to test 400001-RNC2. 34
Figure 19. V ehicle/tma geometries for test 400001-RNC2. 35
Figure 20. Impacting vehicle before test 400001-RNC2. 36
forward 4.3 m. Brakes on the vehicle were not applied. Sequential photographs of the test period are shown in appendix C, figure 32. Damage to Test Article The damage sustained by the RENCO RAM-lOOk TMA is shown in figures 21 and 22. The TMA was crushed somewhat evenly from left to right and top to bottom. The middle seam split stopped at 460 mm from the front of the TMA and the bottom lower seam split stopped 1730 mm on the left side and 305 mm on the right side. There was a 16 mm tear on the top right comer 470 mm from the front of the TMA. The backup/support structure on the right side deformed 10 mm. Maximum dynamic crush of the RENCO RAM-lOOK TMA during the test was not attainable, but the maximum residual deformation was 1.7 m. Vehicle Damage The vehicle sustained damage to the front as shown in figure 23. The front bumper, hood, grill, left and right front tires, radiator and fan were damaged. The right and left front quarter panels were deformed. No deformation or intrusion into the occupant compartment occurred during the test. The interior of the vehicle is shown in figure 24. Exterior vehicle crush and occupant compartment measurements are shown in appendix B, tables 11 and 12. Occupant Risk Factors Data from the accelerometer located at the vehicle e.g. were digitized for evaluation of occupant risk and were computed as follows. For the impacting vehicle: In the longitudinal direction, the occupant impact velocity was 11.7 m/s at 0.104 s, the highest 0.010-s occupant ridedown acceleration was -18.3 g's from 0.134 to 0.144 s, and the maximum 0.050-s average acceleration was -14.7 g's between 0.113 and 0.163 s. In the lateral direction, the occupant impact velocity was 0.9 m/s at 0.104 s, the highest 0.010-s occupant ridedown acceleration was 2.6 g' s from 0.222 to 0.232 s, and the maximum 0.050-s average was -1.6 g' s between 0.062 and... '. 0.112 s. For the support vehicle: The highest 0.010-s longitudinal ridedown acceleration was -3.2 g's at 0.105 s. These data and other pertinent information from the test are summarized in figure 25. Vehicle angnlar displacements and accelerations versus time traces are presented in appendix D, figures 47 through 53. 37
Figure 21. Vehicle trajectory after test 400001-RNC2. 38
Figure 22. TMA after test 400001-RNC2. 39
Figure 23. Impacting vehicle after test 400001-RNC2. 40
Before test After test Figure 24. Interior of impacting vehicle for test 400001-RNCZ. 41
'"""';~= General Information tj Test Agency.... Test No..... Date.... Test Article Type.... Name.... Installation Length (m).... Material or Key Elements... Soil Type and Condition... Test Vehicle Type.... Designation.... Model.... Mass (kg) Curb.... Test Inertial.... Dummy.... Gross Static.... Texas Transportation Institute 400001-RNC2 04/15/99 Truck Mounted Attenuator RENCO RAM-1 00 k TMA 2.1 Cardboard Honeycomb Covered with Aluminum Sheeting Concrete Pavement, Dry Production 2000P 1994 Ford F-250 Pickup Truck 2090 2000 No dummy 2000 Impact Conditions Speed (km/h).... Angle (deg).... Exit ConditiOns Speed (km/h).... Angle (deg).... Occupant Risk Values Impact Velocity (m/s) x-direction.... y-direction.... THIV (kmlh).... Ridedown Accelerations (g's) x-direction.... y-direction.... PHD (g's).... ASI.... Max. 0.050-s Average (g's) x-direction.... y-direction.... z-direction.... 100.3 0 Stopped N/A 11.7 0.9 42.2-18.3 2.6 18.5 1.26-14.7-1.6 5.1 Test Article Deflections (m) Dynamic................. N/A Pennanent... 1.7 Vehicle Damage Exterior VDS... 12FD1 CDC... 12FDEW1 Maximum Exterior Vehicle Crush (mm)...... 250 Interior OCDI................. FSOOOOOOO Max. Occ. Compart. Defonnation (mm)....... nil Post-Impact Behavior (during 1.0 s after impact) Max. Yaw Angle (deg)...... 4 Max. Pitch Angle (deg)...... -4 Max. Roll Angle (deg)....... 7 Figure 25. Summary of Results for test 400001-RNC2, NCHRP Report 350 test 3-51.
SUMMARY AND CONCLUSIONS ASSESSMENT OF TEST RESULTS As stated previously, the following NCHRP Report 350 safety evaluation criteria were used to evaluate this crash test: The following evaluation criteria apply to the impacting vehicle: OccupantFtisk D. Detached elements, fragments or other debris from the test article should not penetrate or show potential for penetrating the occupant compartment, or present an undue hazard to other traffic, pedestrians, or personnel in a work zone. Deformation of, or intrusions into, the occupant compartment that could cause serious injuries should not be permitted. No detached elements, fragments or other debris were present from any of the TMAs to penetrate or show potential for penetrating the occupant compartment, or to present undue hazard to others in the area. In crash test RNC6 (NCHRP Report 350 mod. test 3-50 with the RAM look), the impacting vehicle underrode the TMA which allowed the lower rear edge of the TMA to contact the windshield area of the impacting vehicle, deformed the windshield inward causing the inner layer of glass to shatter into the occupant compartment, causing a small hole near the edge of the windshield on the passenger side, and some separation of the windshield from the frame on the passenger side. In test RNC7 (repeat of mod. test 3-50), the TMA pushed the hood into the windshield which caused the windshield to crack, the inner layer of glass to shatter slightly and the windshield deform inward. The windshield was not damaged and no deformation nor intrusion of the occupant compartment occurred in test RNC2 (the test with the pickup truck, NCHRP Report 350 test 3-51). F. The vehicle should remain upright during and after collision although moderate roll, pitching and yawing are acceptable. The impacting vehicles in all tests remained upright during and after the collision period. 43
H. Occupant impact velocities should satisfy the following: Longitudinal and Lateral Occupant Impact Velocity - mls Preferred Maximum 9 12 For test RNC6 (NCHRP Report 350 mod. test 3-50): Longitudinal OIV was 11.5 rn!s and lateral OIV was 0.8 rn!s.. (Also note that the impact speed was 95.1 km!h which was 4.9 km!h lower than target speed of 100 km!h. NCHRP Report 350 allows ±4 km!h.) For test RNC7 (NCHRP Report 350 mod. test 3-50): Longitudinal OIV was 12.3 m/s and there was no contact in the lateral direction. For test RNC2 (NCHRP Report 350 test 3-51): Longitudinal OIV was 11.7 m/s and lateral OIV was 0.9 m!s I. Occupant ridedown accelerations should satisfy the following: Vehicle Trajectory Longitudinal and Lateral Occupant Ridedown Accelerations - g 's Preferred Maximum 15 20 For test RNC6 (NCHRP Report 350 mod. test 3-50): Longitudinal ridedown was -16.6 g' s and lateral ridedown was -1.5 g' s. For test RNC7 (NCHRP Report 350 mod. test 3-50): Longitudinalridedown was -13.7 g's and there was no contact in the lateral direction. For test RNC2 (NCHRP Report 350 test 3-51): Longitudinal ridedown was -18.3 g's and lateral ridedown was 2.6 g's. K. After collision it is preferable that the vehicle's trajectory not intrude into adjacent traffic lanes. None of the impacting vehicles intruded into adjacent traffic lanes as they came to rest directly behind the TMA. 44
In a memo entitled: Action: Identifying Acceptable Highway Safety Features, FHW A suggests the following supplemental evaluation factors and terminology be used for visual assessment of test results: + PASSENGER COMPARTMENT INTRUSION 1. Windshield Intrusion a. No windshield contact RNC2 b. Windshield contact, no damage c. Windshield contact. no intrusion RNC7 d. Device embedded in windshield, no significant intrusion e. Complete intrusion into passenger compartment f, Partial intrusion into passenger compartment windshield deformed inward in RNC6 No windshield contact occurred in the test with the pickup (NCHRP Report 350 test 3-51) In test RNC6 (NCHRP Report 350 mod. test 3-50), the vehicle underrode the TMA which allowed the rear edge of the TMA to contact the windshield area of the impacting vehicle and dish the windshield inward causing the inner layer of glass to shatter into the occupant compartment. In test RNC7 (NCHRP Report 350 mod. test 3-50), the hood deformed and was pushed into the windshield of the impacting vehicle which cracked the windshield in the lower comers. 2. Body Panel Intrusion No body panel intrusion occurred in any of the tests. + LOSS OF VEIDCLE CONTROL 1. Physical loss of control 3. Perceived threat to other vehicles 2. Loss of windshield visibility 4. Debris on pavement Loss of vehicle control was not an issue for these tests as the vehicles were subsequently brought to a controlled stop directly behind the support vehicle!tma. + PHYSICAL THREAT TO WORKERS OR OTHER VEHICLES 1. Harmful debris that could injure workers or others in the area 2. Harmful debris that could injure occupants in other vehicles None of the debris was judged to be a physical threat to occupants in other vehicles, or the workers or others in the area. 45
+ VEIDCLE AND DEVICE CONDITION 1. Vehicle Damage a. None b. Minor scrapes, scratches or dents c. Significant cosmetic dents d. Major dents to grill and body panels e. Major structural damage (all tests) All impacting vehicles sustained major structural damage to the front of the vehicle. 2. Windshield Damage a. None RNC2 b. Minor chip or crack c. Broken, no interference with visibility d. Broken and shattered. visibility restricted but remained intact RNC7 e. Shattered, remained intact but partially dislodged RNC6 f. Large portion removed g. Completely removed In test RNC2 (NCHRP Report 350 test 3-51), the windshield was not damaged. In test RNC6 (NCHRP Report 350 mod. test 3-50), the impacting vehicle underrode the TMA which allowed the lower edge of the rear of the TMA to contact the windshield area of the impacting vehicle and deform the windshield inward causing the inner layer of glass to shatter into the occupant compartment. In test RNC7 (NCHRP Report 350 mod. test 3-50), the hood deformed and was pushed into the windshield of the impacting vehicle which cracked the windshield in the lower comers. 3. Device Damage a. b. c. None Superficial Substantial, but can be straightened d. Substantial, replacement parts needed for repair Cannot be repaired All tests In all tests, damage to the RENCO TMAs was substantial and could not be repaired. All the TMAs would have to be replaced. 46
The following evaluation criteria apply to the support vehicle: Structural Adequacy C. Acceptable test article performance may be by redirection, controlled penetration, or controlled stopping of the vehicle. Occupant Risk The RENCO TMAs brought the impacting vehicles to a controlled stop with, in most cases, minimal forward movement of the support vehicle. Maximum roll ahead distance was 4.3 m in test RNC-2 (NCHRP Report 350 test 3-51). D. Detached elements, fragments or other debris from the test article should not penetrate or show potential for penetrating the occupant compartment, or present an undue hazard to other traffic, pedestrians, or personnel in a work zone. Deformation of, or intrusions into, the occupant compartment that could cause serious injuries should not be permitted. No detached elements, fragments or other debris were present from any of the TMAs to penetrate or show potential for penetrating the occupant compartment, or to present undue hazard to others in the area. No deformation or intrusion of the occupant compartment of the support vehicle occurred in any of the tests. F. The vehicle should remain upright during and after collision although moderate roll, pitching and yawing are acceptable. The support vehicles remained upright during and after the collision period in all tests. I. Occupant ridedown accelerations should satisfy the following: Longitudinal and Lateral Occupant Ridedown Accelerations - g 's Preferred Maximum 15 20 For test RNC6 (NCHRP Report 350 mod. test 3-50): Longitudinal ridedown was 2.6 g's. (Also note that the impact speed was 95.1 kmlh which was 4.9 km/h lower than target speed of 100 kmlh. NCHRP Report 350 allows ±4 kmlh.) 47
Vehicle Trajectory For test RNC7 (NCHRP Report 350 mod. test 3-50): Longitudinal ridedown was -1.6 g' s. For test RNC2 (NCHRP Report 350 test 3-51 ): Longitudinal ridedown was -3.2 g's. K. After collision it is preferable that the vehicle's trajectory not intrude into adjacent traffic lanes. In all tests, the support vehicle did not intrude into adjacent traffic lanes. The support vehicle did roll ahead, but the distances were minimal (maximum roll ahead distance was 4.3 min test RNC2 (NCHRP Report 350 test 3-51)). CONCLUSIONS Three crash tests (RNC2, RNC6 and RNC7) were performed to evaluate the impact performance of the new RENCO RAM look TMA in accordance with the guidelines presented in NCHRP Report 350 for Test Level3 (TL-3) safety appurtenances. Test RNC2 was NCHRP Report 350 test 3-51 with the 2000 kg pickup truck test vehicle and tests RNC6 and RNC7 were the modified NCHRP Report 350 test 3-50 (support vehicle free-standing) with the 820 kg passenger vehicle. Figure 26 illustrates comparatively the RENCO RAM look TMA after being impacted by each of the two NCHRP Report 350 test vehicles, i.e., the pickup and the small car. Tests RNC6 and RNC7 failed to meet all the evaluation criteria for NCHRP Report 350 modified test 3-50. Test RNC6 failed by excessive deformation and penetration into the occupant compartment through the windshield area. NCHRP Report 350 modified test 3-50 was performed again, test RNC7, and failed due to occupant impact velocity of 12.3 rn/s (maximum allowable is 12 rn/s). Evaluation criteria and test performance as related to all NCHRP Report 350 criteria are presented in tables I through 4 for tests RNC6 and RNC7. Test RNC2 successfully met the evaluation criteria for NCHRP Report 350 test 3-51. Evaluation criteria and test performance as related to these criteria are presented in tables 5 and 6 for test RNC2. 48
400001-RNC2 400001-RNC? Figure 26. Comparison of TMA damage. 49
Ul 0 Table 1. Performance evaluation summary for impacting vehicle during test 400001-RNC6, NCHRP Report 350 Test 3-50. Test Agency Texas Transportation Institute Test No 400001-RNC6 Test Date 11/30/99 NCHRP Report 350 Evaluation Criteria Test Results Assessment Occupant Risk D. Detached elements, fragments or other debris from the test No detached elements, fragments or other debris article should not penetrate or show potential for were present from the RAM look TMA to penetrating the occupant compartment, or present an penetrate or to show potential for penetrating the undue hazard to other traffic, pedestrians, or personnel in occupant compartment, or to present undue a work zone. Deformations of, or intrusions into, the hazard to others. The impacting vehicle occupant compartment that could cause serious injuries underrode the TMA which allowed the lower should not be permitted. edge of the TMA to contact the windshield area of the impacting vehicle and deformed the windshield inward causing the inner layer of glass to shatter into the occupant compartment. '.. Marginal F. The vehicle should remain upright during and after The impacting vehicle remained upright during collision although moderate roll, pitching and yawing are and after the collision period. Pass acceptable. H. Occupant impact velocities sqould satisfy the following: Longitudinal OIV was 11.5 rn/s Occupant hnpact Velocity Limits (rnls) and lateral OIV was 0.8 rn/s. (Note that the impact speed was 95,1 krn!h Component Preferred Maximum which was 4.9 krn!h lower than target speed of Longitudinal and Lateral 9 12 100 krn!h. NCHRP Report 350 allows ±4 krn!h.) I. Occupant ridedown accelerations should satisfy the following:.: Occupant Ridedown Acceleration Limits (g's) Component Preferred Maximum Longitudinal and Lateral 15 20 Vehicle Trajectory Longitudinal ridedown was -16.6 g' s and lateral ridedown was -1.5 g's. K. After collision it is preferable that the vehicle's trajectory The impacting vehicle did not intrude into not intrude into adiacent traffic lanes. adiacent traffic lanes. *Cntenon IS preferable, not reqmred. Pass Pass Pass*
Table 2. Performance evaluation summary for support vehicle during test 400001-RNC6, NCHRP Report 350 Test 3-50. T es ta gency: T ex as T ranspo rtti a on rnr s ttute T est N o.: 400001 -RNC6 T est D ate: 11/30/99 NCHRP Report 350 Evaluation Criteria Test Results Structural AdeQuacx C. Acceptable test article performance may be by The RENCO RAM look TMA brought the redirection, controlled penetration, or controlled impacting vehicle to a controlled stop. Maximum stopping of the vehicle. roll ahead distance of the support vehicle was 1.1 m. Occu11ant Risk ~I D. Detached elements, fragments or other debris from the No detached elements, fragments or other debris test article should not penetrate or show potential for were present from the RAM 1 OOk TMA to penetrating the occupant compartment, or present an penetrate or show potential for penetrating the undue hazard to other traffic, pedestrians, or personnel occupant compartment, or to present undue hazard Pass in a work zone. Deformations of, or intrusions into, the to others in the area. No deformation or intrusion occupant compartment that could cause serious injuries of the occupant compartment of the support vehicle should not be permitted. occurred. F. The vehicle should remain upright during and after The support vehicle remained upright during and collision although moderate roll, pitching and yawing after the collision period. Pass are acceptable. I. Occupant ridedown accelerations should satisfy the following: : Occupant Ridedown Acceleration Limits (g' s) Longitudinal ridedown was 2.6 g's Pass Component Preferred Maximum Longitudinal 15 20 Vehicle Trajecton: K. After collision it is preferable that the vehicle's The support vehicle did not intrude into adjacent traiectorv not intrude into adiacent traffic lanes. traffic lanes. Maximum roll ahead was 1.1 m. *Cntenon ts preferable, not reqmred. Pass Pass*
T Table 3. Performance evaluation summary for impacting vehicle during test 400001-RNC7, NCHRP Report 350 Test 3-50. A est gency: T ex as T ransportauon In' stltute T est N o.: 400001 -RNC7 T est D ate: 03123/ 2000 I NCHRP Report 350 Evaluation Criteria I Test Results I Assessment I Occugant Risk D. Detached elements, fragments or other debris from the No detached elements, fragments or other debris test article should not penetrate or show potential for were present from the RAM look TMA to penetrating the occupant compartment, or present an penetrate or show potential for penetrating the undue hazard to other traffic, pedestrians, or personnel occupant compartment, or to present undue hazard Pass in a work zone. Deformations of, or intrusions into, the to others in the area. No deformation or intrusion occupant compartment that could cause serious injuries into the occupant compartment occurred. should not be permitted. F. The vehicle should remain upright during and after The impacting vehicle remained upright during and collision although moderate roll, pitching and yawing after the collision period. Pass are acceptable. H. Occupant impact velocities should satisfy the following: Occupant hnpact Velocity Limits (rn!s) Component Preferred Maximum Longitudinal and Lateral 9 12 I. Occupant ridedown accelerations should satisfy the following: Occupant Ridedown Acceleration Limits (g' s) Component. Preferred Maximum Longitudinal and Lateral 15 20 Vehicle Trajecton: Longitudinal ON was 12.3 rn!s and there was no contact in the lateral direction. Longitudinalridedown was -13.7 g's and there was no contact in the lateral direction. K. After collision it is preferable that the vehicle's The impacting vehicle did not intrude into adjacent traiectorv not intrude into adilicent traffic lanes. traffic lanes. *Cntenon IS preferable, not requrred. Marginal Pass Pass*
Table 4. Performance evaluation summary for support vehicle during test 400001-RNC?, NCHRP Report 350 Test 3-50. T est A gency: T ex as T ransportation In" stitute T est N o.: 400001 -RNC7 T est D ate: 03/23/2000 I NCHRP Report 350 Evaluation Criteria I Test Results I Assessment I Structural Adeguacy c. Acceptable test article performance may be by The RENCO RAM look TMA brought the redirection, controlled penetration, or controlled impacting vehicle to a controlled stop. Maximum stopping of the vehicle. roll ahead distance of the support vehicle was 0.7m. Occu11ant Risk D. Detached elements, fragments or other debris from the No detached elements, fragments or other debris test article should not penetrat,e or show potential for were present from the RAM look TMA to penetrating the occupant compartment, or present an penetrate or show potential for penetrating the undue hazard to other traffic, pedestrians, or personnel occupant compartment, or to present undue hazard Pass in a work zone. Deformations of, or intrusions into, the to others in the area. No deformation or intrusion occupant compartment that could cause serious injuries of the occupant compartment of the support vehicle should not be permitted. occurred. F. The vehicle should remain upright during and after The support vehicle remained upright during and collision although moderate roll, pitching and yawing after the collision period. Pass are acceptable. I. Occupant ridedown accelerations should satisfy the following: Occupant Ridedown Acceleration Limits (g's) Longitudinal ridedown was -1.6 g' s Pass Component Preferred Maximum Longitudinal 15 20 Vehicle Trajectory K. After collision it is preferable that the vehicle's The support vehicle did not intrude into adjacent trajectory not intrude into adjacent traffic lanes. traffic lanes. Maximum roll ahead was 0.7 m. *Criterion is preferable, not required. Pass Pass*
Table 5. Performance evaluation summary for impacting vehicle during test 400001-RNC2, NCHRP Report 350 Test 3-51. T est A gency: T ex as T ransportation In' stitute T N 400001 RNC2 est o.: - T D est ate: 04115/9 9 NCHRP Report 350 Evaluation Criteria Test Results Assessment Occunant Risk D. Detached elements, fragments or other debris from the No detached elements, fragments or other debris test article should not penetrate or show potential for were present from the RAM 1 OOk TMA to penetrating the occupant compartment, or present an penetrate or show potential for penetrating the undue hazard to other traffic, pedestrians, or personnel occupant compartment, or to present undue hazard Pass in a work zone. Deformations of, or intrusions into, the to others in the area. No deformation or intrusion occupant compartment that could cause serious injuries into the occupant compartment occurred. should not be IJerrnitted. F. The vehicle should remain upright during and after The impacting vehicle remained upright during and collision although moderate roll, pitching and yawing after the collision period. Pass are acceptable. H. Occupant impact velocities should satisfy the following: Occupant Impact Velocity Limits (rnls) Longitudinal ON was 11.7 m/s and lateral ON was 0.9 m/s Component Preferred Maximum Pass Longitudinal and Lateral 9 12 I. Occupant ridedown accelerations should satisfy the following: Occupant Ridedown Acceleration Limits (g's) Longitudinal ridedown was -18.3 g's and lateral ridedown was 2.6 g' s. Component Preferred Maximum Pass Longitudinal and Lateral 15 20 Vehicle Trajectory K. After collision it is preferable that the vehicle's The impacting vehicle did not intrude into adjacent tr!liectorv not intrude into adiacent traffic lanes. traffic lanes. *Cntenon 1s preferable, not requrred. Pass*
Table 6. Performance evaluation summary for support vehicle during test 400001-RNC2, NCHRP Report 350 Test 3-51. T est A gency: T ex as T ransportatwn In" stltute T est N o.: 400001 -RNC2 T est D ate: 04115/99 I NCHRP Report 350 Evaluation Criteria I Test Results I Assessment I Structural Adeguacy c. Acceptable test article performance may be by The RENCO RAM look TMA brought the redirection, controlled penetration, or controlled impacting vehicle to a controlled stop. Maximum stopping of the vehicle. roll ahead distance of the support vehicle was 4.3 m. Occugant Risk D. Detached elements, fragments or other debris from the No detached elements, fragments or other debris test article should not penetrate or show potential for were present from the RAM 1 OOk TMA to penetrating the occupant compartment, or present an penetrate or show potential for penetrating the undue hazard to other traffic, pedestrians, or personnel occupant compartment, or to present undue hazard Pass in a work zone. Deformations of, or intrusions into, the to others in the area. No deformation or intrusion occupant compartment that could cause serious injuries of the occupant compartment of the support vehicle should not be permitted. occurred. F. The vehicle should remain upright during and after The support vehicle remained upright during and collision although moderate roll, pitching and yawing after the collision period. Pass are acceptable. I. Occupant ridedown accelerations should satisfy the following: Occupant Ridedown Acceleration Limits (g's) Longitudinal ridedown was -3.2 g's Pass Component Preferred Maximum Longitudinal 15 20 Vehicle TrajectoO' K. After collision it is preferable that the vehicle's The support vehicle did not intrude into adjacent traiectorv not intrude into adiacent traffic lanes. traffic lanes. Maximum roll ahead was 4.3 m. *Cntenon IS preferable, not reqmred. Pass Pass*
APPENDIX A. CRASH TEST PROCEDURES AND DATA ANALYSIS The crash test and data analysis procedures were in accordance with guidelines presented in NCHRP Report 350. Brief descriptions of these procedures are presented as follows. ELECTRONIC INSTRUMENTATION AND DATA PROCESSING The test vehicle was instrumented with three solid-state angular rate transducers to measure roll, pitch, and yaw rates; a triaxial accelerometer near the vehicle center of gravity (e.g.) to measure longitudinal, lateral, and vertical acceleration levels; and a back-up biaxial accelerometer in the rear of the vehicle to measure longitudinal and lateral acceleration levels. These accelerometers were ENDEVCO Model2262CA, piezoresistive accelerometers with a ±100 grange. The accelerometers are strain gage type with a linear millivolt output proportional to acceleration. Rate of tum transducers are solid state, gas flow units designed for high g service. Signal conditioners and amplifiers in the test vehicle increase the low level signals to a ±2.5 volt maximum level. The signal conditioners also provide the capability of an R-Cal or shunt calibration for the accelerometers and a precision voltage calibration for the rate transducers. The electronic signals from the accelerometers and rate transducers are transmitted to a base station by means of a 15 channel, constant bandwidth, Inter-Range Instrumentation Group (l.r.i.g.), FMIFM telemetry link for recording on magnetic tape and for display on a real-time strip chart. Calibration signals, from the test vehicle, are recorded minutes before the test and also immediately afterwards. A crystal controlled time reference signal is simultaneously recorded with the data. Pressure-sensitive switches on the bumper of the impacting vehicle are actuated just prior to impact by wooden dowels to indicate the elapsed time over a known distance to provide a measurement of impact velocity. The initial contact also produces an "event" mark on the data record to establish the exact instant of contact with the installation. The multiplex of data channels, transmitted on one radio frequency, is received at the data acquisition station, and demultiplexed onto separate tracks of a 28 track, (l.r.i.g.) tape recorder. After the test, the data are played back from the tape machine, filtered with Society of Automotive Engineers (SAE J211) filters, and digitized using a microcomputer, at 2000 samples per second per channel, for analysis and evaluation of impact performance. All accelerometers are calibrated annually according to SAE J211 4.6.1 by means of an ENDEVCO 2901, precision primary vibration standard. This device along with its support instruments is returned to the factory annually for a National Institute of Standards Technology (NIST) traceable calibration. The subsystems of each data channel are also evaluated annually, using instruments with current NIST traceability, and the results factored into the accuracy of the total data channel, per SAE J211. Calibrations and evaluations will be made at any time a data channel is suspected of any anomalies. 57
The digitized data were then processed using two computer programs: DIGITlZE and PLOT ANGLE. Brief descriptions of the functions of these two computer programs are provided as follows. The DIGITIZE program uses digitized data from vehicle-mounted linear accelerometers to compute occupant/compartment impact velocities, time of occupant/compartment impact after vehicle impact, and the highest 10-ms average ridedown acceleration. The DIGITlZE program also calculates a vehicle impact velocity and the change in vehicle velocity at the end of a given impulse period. In addition, maximum average accelerations over 50-ms intervals in each of the three directions are computed. For reporting purposes, the data from the vehicle-mounted accelerometers were then filtered with a 60-Hz digital filter and acceleration versus time curves for the longitudinal, lateral, and vertical directions were plotted using a commercially available software package (Excel). The PLOT ANGLE program uses the digitized data from the yaw, pitch, and roll rate transducers to compute angular displacement in degrees at 0.0005-s intervals and then instructs a plotter to draw a reproducible plot: yaw, pitch, and roll versus time. These displacements are in reference to the vehicle-fixed coordinate system with the initial position and orientation of the vehicle-fixed coordinate system being that which existed at initial impact. ANTHROPOMORPHIC DUMMY INSTRUMENTATION An Alderson Research Laboratories Hybrid Il, 50th percentile male anthropomorphic dummy, restrained with lap and shoulder belts, was placed in the driver's position of the 820C vehicle. The dummy was uninstrumented. Use of a dummy in the 2000P vehicle is optional according to NCHRP Report 350 and there was no dummy used in the tests with the 2000P vehicle. PHOTOGRAPHIC INSTRUMENTATION AND DATA PROCESSING Photographic coverage of the test included three high-speed cameras: one overhead with a field of view perpendicular to the ground and directly over the impact point; one placea perpendicular to the left side of the TMA; and a third placed to have a field of view perpendicular to the right side of the TMA. A flash bulb activated by pressure-sensitive tape switches was positioned on the impacting vehicle to indicate the instant of contact with the installation and was visible from each camera. The films from these high-speed cameras were analyzed on a computer-linked Motion Analyzer to observe phenomena occurring during the collision and to obtain time-event, displacement, and angular data. A BetaCam, a VHS-format video camera and recorder, and still cameras were used to record and document conditions of the test vehicle and installation before and after the test. 58
TEST VEHICLE PROPULSION AND GUIDANCE The test vehicle was towed into the test installation using a steel cable guidance and reverse tow system. A steel cable for guiding the test vehicle was tensioned along the path, anchored at each end, and threaded through an attachment to the front wheel of the test vehicle. An additional steel cable was connected to the test vehicle, passed around a pulley near the impact point, through a pulley on the tow vehicle, and then anchored to the ground such that the tow vehicle moved away from the test site. A two to one speed ratio between the test and tow vehicle existed with this system. Just prior to impact with the installation, the test vehicle was released to be free-wheeling and unrestrained. The vehicle remained free-wheeling, i.e., no steering or braking inputs, until the vehicle cleared the immediate area of the test site, at which time brakes on the vehicle were activated to bring it to a safe and controlled stop. 59
APPENDIX B. TEST VEHICLE PROPERTIES AND INFORMATION DAlE' _c1_o_1 L/.><3-><0L/_,9.><9 TEST,0. 'EAR,1_,9_,9~4~--- TIRE INFLATION PRESSURE: 400001-RNC6 VI',o,, 2C1 MR2463R6717365 MAKE: GEO MODEL:~Moc=E_,_T,Ro,Oc ODOMETER: L7-"4-'!4c<2J;8L ~ TIRE SIZE: 145 8QR 12 1st Use 2nd or More Use:~ Minor Domoge Charged to Project: MASS DISTRIBUTION (kg) CF,2c_,5!_!7c CR!1'..{7_o,6> RR!1~5"4t DESCRIBE ANY DAMAGE TO VEHICLE PRIOR TO TEST: 0 ACCELER~METERS note N WHEEL / '~' ::::J -l::::j \I \r, '+' /( '.. (j'; VEHICLE l r-" Wl-IEEL ENGINE 1YPE 3 CYL. ENGINE CID: c1~ 0<0.=l TRANSMISSION TYPE: WHEEL Oil\~ ' 1- u!-r,: ~ I I, IP:; ~ 1--' GEOMETRY - TIRE DIA-1-e- [--o- ~T- M, (mm) ' c v ' )---- TEST INERT111L C.M. n.!![~~ ~ 1M \l \ M,,_ R f l f I X AUTO _MANUAL OPTIONAL EQUIPMENT: DUMMY DATA" TYPE: 50th perceowe mqle MASS:-'"-'"------~ SEAT POSITION:~-~-- A 1460 620 8 745 3635 c 2270 G 913.5 D 1325 H 675 ' K 455 0 95 ' M 370 0 1365 13.40 530 330 R 340 s 49.5 940 u 2445 MASS - (kg) CURB TEST INERTIAL GROSS STATIC M, 482 M, 284 M, 766 490 330 820 520 374 894 Figure 27. Vehicle properties for test 400001-RNC6. 61
Table 7. Exterior crush measurements for test 400001-RNC6. VEIDCLE CRUSH MEASUREMENT SHEET' Complete When Applicable End Damage Side Damage Undeformed end width Bowing: Bl -- XI -- Comer shift: AI B2 -- X2 A2 -- End shift at frame (CDC) Bowing constant (check one) XI + X2 = <4inches 2 -- z 4 inches Note: Measure Cl to C6 from Driver to Passenger side in Front or Rear impacts Rear to Front in Side impacts. Direct Damage Specific Impact Plane* of Width** Max*** Field Number C-Measurements (CDC) Crush L** c, c, c, c, c, c, ±D 1 At front bumper 650 190 1350 120 140 140 150 150 135 0 'Table taken from National Accident Sampling System (NASS). *Identify the plane at which the C-measurements are taken (e.g., at bumper, above bumper, at sill, above sill, at beltline, etc.) or label adjustments (e.g., free space). Free space value is defined as the distance between the baseline and the original body contour taken at the individual C locations. This may include the following: bumper lead, bumper taper, side protmsion, side taper, etc. Record the value for each C-measurement and maximum crush. **Measure and document on the vehicle diagram the beginning or end of the direct damage width and field L (e.g., side damage with respect to undamaged axle). ***Measure and document on the vehicle diagram the location of the maximum crush. Note: Use as many lines/columns as necessary to describe each damage profile. 62
Table 8. Occupant compartment measurements for test 400001-RNC6. Small Car Occupant Compartment Deformation BEFORE AFTER F A1 1528 1478 A2 2088 2049 A3 1531 1490 81 981 1000 82 907 928 83 978 1005 84 861 861 85 856 856 81. 82. 83 84. 85. 86 87. 88. 89 86 857 857 87 770 770 ~ --- 88 662 662 LJ ~--c,--l LJ 89 771 771 C1 710 580 C2 695 675 C3 566 555 D1 304 290 D2 81 85 D3 292 285 E1 1230 1265 E2 1232 1255 F 1212 1200 G 1212 1200 H 1100 1080 1100 1070 63
DATE 03/23/00 TEST '0. 400001-RNC? VI'" ' KNJPT06H6M6134708 YEAR: 1991 MAKE: FORD MODEL: FESTIVA TIRE INFIJ\TION PRESSUREc ------ ODOMETER: S,!8S,!8CL7~3'.<2'----- TIRE SIZE: 155R 12 1st Use:~ 2nd or More Use:_ Minor Damage Charged to Project: MASS DISTRIBUTION (kg) LF -~2o-5o,9; RF_~2"'4~1, LR 1ec7Cc9; RR c1~4_c1 DESCRIBE ANY DAMAGE TO VEHICLE PRIOR TO TEST: 1\ ACCELEROMETERS note: N WHEEl '~' ~::J ::J j_ +' I II ~ \r- '+' ~VEHICLE l WHEEL ['~' ENGINE TYPE 4 CYL. ENGINE CID:_1~ ~3~l~--- TRANSMISSION TYPE: ~ ~~~~ t--o GEOMETRY - R 'l TIRE DIA-1-e- WHE L DIA- t-o- I----T- M, (mm) ' c c ' )---- TEST INERTIAL C.M. /n II~~ l II\ ' M,,_ f f I X AUTO _MANUAL OPTIONAL EQUIPMENT: DUMMY DATA: lype: 50th rerceofle mq!e MASS: ~"-1"'------- SEAT POSITION:-Crrr= A 1500 E 550 B 635 3485 c 2300 G 897.6 D 1460 H 740 1395 R 390 1530 ' 0 1395 s 500 ' 1195 p 535 T 940 M 380 Q 330 u 2380 MASS - (kg) CURB TEST INERTIAL GROSS STATIC M, 567 M, 287 M, 854 500 541 320 354 820 895 Figure 28. Vehicle properties for test 400001-RNC7. 64
Table 9. Exterior crush measurements for test 400001-RNC?. VEHICLE CRUSH MEASUREMENT SHEET 1 Complete When Applicable End Damage Side Damage Undeformed end width Bowing: Bl -- XI -- Comer shift: AI B2 -- X2 A2 -- End shift at frame (CDC) Bowing constant (check one) Xl + X2 = < 4 inches 2 -- > 4 inches Note: Measure Cl to C6 from Driver to Passenger side in Front or Rear impacts Rear to Front in Side impacts. Direct Damage Specific Impact Plane* of Width** Max*** Field Number C-Measurements (CDC) Crush L** c, c, c, c, c, c, ±D I Front bumper 700!50 1470 75!50!50 130 100 65 'Table taken from National Accident Sampling System (NASS). *Identify the plane at which the C-measurements are taken (e.g., at bumper, above bumper, at sill, above sill, at beltline, etc.) or label adjustments (e.g., free space). Free space valne is defmed as the distance between the baseline and the original body contour taken at the individual C locations. This may include the following: bumper lead, bumper taper, side protrusion, side taper, etc. Record the value for each C-measurement and maximum crush. **Measure and document on the vehicle diagram the beginning or end of the direct damage width and field L (e.g., side damage with respect to undamaged axle). ***Measure and document on the vehicle diagram the location of the maximum crush. Note: Use as many lines/columns as necessary to describe each damage profile. 65
Table 10. Occupant compartment measurements for test 400001-RNC?. Small Car Occupant Compartment Deformation BEFORE AFTER 81. 82. 83 84. 85. 86 87. 88. 89 A1 A2 A3 81 82 83 84 85 86 87 88 89 C1 C2 C3 01 02 03 E1 E2 F G H 1548 1530 2027 2002 1540 1530 1052 1077 973 992 1049 1067 962 962 972 972 973 969 833 833 842 842 961 961 654 628 638 626 668 626 328 328 208 208 345 340 1257 1270 1240 1248 1190 1190 1190 1190 900 890 ;9;.;;0.;..0_ 895 66
DATE' _0~4~/~15~/~99~- YEAR: ~1 ~9~9~4~---- TEST NO., o4c,0"'0"'0"'0"1_-..cr_,n~c"2=... ~ VIN NO., 2FTHF25H7RCA20456 MAKE:,F_,o,.r_,d, _ MODEL: F 250 Pickup Truck TIRE INFLATiON PRESSURE: ------ 000METER:.c1"0>'6"'8,e:0oc0<o ~ TIRE ""''--'L~T'-'2"'3'-'7'--'8""5"'R-'-1"6"---- MASS DISTRIBUTION (kg) LF 547 RF_~5-"6='4 LR,4'-'3"'9 RR,4'-'5-"0'--- DESCRIBE ANY DAMAGE TO VEHICLE PRIOR TO TEST: A N f~g I 1---,_ L --' TIRE IliA- :---- - WHEEL OIA- f- o- r1 r- r~ I, "' I= '"" 0 - " 0~ c---, ~ ~ ~- ~ mr '"m'" ' " ~ :/ ':"I --. ' ' c ~ """""' -1 D-.-- fl ' ' J,_ 0 [ WHEEL TF!ACK e Denotes accelerometer location. NOTES: ENGINE TYPE 8 CYL ENGINE CID:~5,c.cC8ccl~--- TRANSMISSION TYPE: X AUTO _MANUAL OPTIONAL EQUIPMENT: DUMMY DATA: TYPE:------~ MASS:------- SEAT POSITION :--- GEOMETRY - (mm),_.1~9-'-1,_o_ 800 c 3390 D 1855 E 1210 F 5400 G 1506.9 "---- 1170 K c7_c1"'0-80,_.,4"'-3,5_ N-'1"6"'8"'0- o-'1"6"'4"'5_.,,7_,8"'0_. 0,4,.,4"'5_. 750,,9'-"2'-"0'--- 1485 "--'4'-'1"0"0'--- MASS - (kg) CURB TEST INERTIAL GROSS STATIC M, M, M, 1182 908 2090 11 11 889 2000 Figure 29. Vehicle properties for test 400001-RNC2. 67
Table II. Exterior crush measurements for test 400001-RNCZ. VEIITCLE CRUSH MEASUREMENT SHEET 1 Complete When Applicable End Damage Side Damage Undeformed end width Bowing: Bl -- XI -- Comer shift: A 1 - B2 -- X2 A2 -- End shift at frame (CDC) Bowing constant (check one) XI + X2 = < 4 inches 2 -- > 4 inches Note: Measure Cl to C6 from Driver to Passenger side in Front or Rear impacts Rear to Front in Side impacts. Direct Damage Specific Impact Plane* of Width** Max*** Field Number C-Measurements (CDC) Crush L** c, c, c, c, c, c, ±D I At front bumper 1030 250 1680 190 40 125 65 80 250 0 'Table taken from National Accident Sampling System (NASS). *Identify the plane at which the C-measurements are taken (e.g., at bumper, above bumper, at sill, above sill, at beltline, etc.) or label adjustments (e.g., free space). Free space value is defmed as the distance between the baseline and the original body contour taken at the individual C locations. This may include the following: bumper lead, bumper taper, side protrusion, side taper, etc. Record the value for each C-measurement and maximum crush. **Measure and document on the vehicle diagram the beginning or end of the direct damage width and field L (e.g., side damage with respect to undamaged axle). ***Measure and document on the vehicle diagram the location of the maximum crush. Note: Use as many lines/columns as necessary to describe each damage profile. 68
Table 12. Occupant compartment measurements for test 400001-RNC2. Occupant Compartment Deformation BEFORE AFTER A1 A2 A3 81 82 83 C1 C2 C3 01 02 03 E1 E2 F G H 867 920 910 1070 1059 1067 1376 1266 1372 311 152 308 1579 1597 1475 1475 800 800 867 920 910 1070 1059 1067 1376 1266 1372 311 152 308 1579 1597 1475 1475 800 800 69
APPENDIX C. SEQUENTIAL PHOTOGRAPHS 0.000 s 0.024 s 0.048 s 0.095 s Figure 30. Sequential photographs for test 400001-RNC6 (overhead & perpendicular views). 71
0.167 s 0.263 s 0.477 s 1.671 s Figure 30. Sequential photographs for test 400001-RNC6 (overhead & perpendicular views) (continued). 72
0.000 s 0.049 s 0.097 s 0.146 s Figure 31. Sequential photographs for test 400001-RNC7 (overhead & perpendicular views). 73
0.268 s 0.486 s 0.851 s 2.919 s Figure 31. Sequential photographs for test 400001-RNC7 (overhead & perpendicular views) (continued). 74
0.000 s 0.040 s 0.079 s 0.139 s Figure 32. Sequential photographs for test 400001-RNC2 (overhead & perpendicular views). 75