ANCAP Test Protocol. Whiplash Protection v3.2 JANUARY 2018
PREFACE During the test preparation, vehicle manufacturers are encouraged to liaise with ANCAP and to observe the way cars are set up for testing. Where a vehicle manufacturer feels that a particular feature should be altered, they should raise this with the ANCAP assessor present at the test, or in writing to the ANCAP Chief Executive Officer if no assessor is present. ANCAP will consider the matter and at their sole discretion and give direction to the test facility. Vehicle manufacturers warrant not to, whether directly or indirectly, interfere with testing and are forbidden from making changes to any feature that may influence the test, including but not limited to dummy positioning, vehicle setting, laboratory environment etc. Illustrations in this protocol are reproduced from Euro NCAP publications, and therefore show Euro NCAP markings on left-hand-drive vehicles. Where relevant, the layouts depicted should be adapted to right-handdrive application. VERSION PUBLISHED DETAILS 3.2 July 2017 First version of ANCAP protocol. COPYRIGHT ANCAP 2017 This work is the intellectual property of ANCAP with certain content reproduced with the permission of Euro NCAP. A licence is granted for this material to be shared for non-commercial, educational purposes, provided this copyright statement appears on the reproduced materials and notice is given that the copying is by permission of ANCAP. To disseminate otherwise or to republish will be considered a breach of intellectual property rights. DISCLAIMER. ANCAP has taken all reasonable care to ensure that the information published in this protocol is accurate and reflects the current technical decisions taken by the organisation. In the event this protocol contains an error or inaccuracy, ANCAP reserves the right to make corrections and determine the assessment and subsequent result of the affected requirement(s).
AUSTRALASIAN)NEW)CAR)ASSESSMENT)PROGRAM)(ANCAP)) TESTING)PROTOCOL) )WHIPLASH)PROTECTION) Table)of)Contents) ) ) ) ) ) ) ) ) ) ) Page)No.) ) 1 INTRODUCTION 1 2 DEFINITIONS 2 3 COORDINATESYSTEM 4 4 SLEDSEATMOUNTINGANDPOSITIONING 5 5 HKPOINTMACHINE&DUMMYPOSITIONING 14 6 HEADRESTRAINTPOSITIONS 17 7 BioRIDATDREQUIREMENTS 25 8 TESTSLEDREQUIREMENTS 29 9 TESTSLEDINSTRUMENTATION 30 10 WHIPLASHASSESSMENTCRITERIA 31 AppendixIKManufacturersSpecifiedSettings 38 AppendixIIKRCARGLORIAJIG&CALIBRATIONPROCEDURE(HKPM/HRMDCALIBRATION)39 AppendixIIIKPRELIMINARYADJUSTMENTSTOTHEHRMDANDHKPOINTMACHINE 48 AppendixIVKSledPulseSpecifications 49 AppendixV SEATMOVEMENTDEFINITIONS 53 )
1) INTRODUCTION) Thisprocedureenablestheusertodynamicallytestamotorvehicleseatandheadrestraintassembly toassesstheextenttowhichtheyreflectbestpracticeinpreventingsofttissueneckinjuries.thistest procedureisdesignedtoevaluateallforwardfacingfrontseatsonly.protectioninsidefacingorrear seats is not covered by this edition. The details of the seat(s) that will be tested by ANCAP are containedinsection2.7oftheancapcarspecification,sponsorship,testingandrektestingprotocol. Thistestprocedurefeaturesthreepulsesoflow,mediumandhighseverity.Realworldcrashpulse recorderstudiesshowthatavarietyofpulsesandpeakaccelerationsareseeninrealworldcrashes andformthebasisforthelowseveritypulse.themediumseveritypulsewasderivedfrominsurance Industryresearchfeaturinganumberofcartocartests.Ahighseveritypulseisusedtopreventlong term injuries since these are seen in more severe crashes. The pulse requirements are defined in AppendixIV. Thetestisundertakenonasledandusesthevehicle sseatplacedinasimilargeometricpositionas fitted in the test car. A BioRID rear crash dummy is used and is seated in a standardised position restrainedbyathreepointbelt. Version3.2 July2017 1
2) DEFINITIONS)) Forthepurposeofthisprocedure,thefollowingdefinitionsshallapply: 2.1) Head) restraint means a device designed to limit the rearward displacement of an adult occupant sheadinrelationtothetorsoinordertoreducetheriskofinjurytotheneckinthe eventofarearimpact.) 2.1.1) Integrated)head)restraintorfixed)head)restraintmeansaheadrestraintformedbytheupper partoftheseatback,oraheadrestraintthatisnotheightadjustableand/orcannotbedetached fromtheseatorthevehiclestructureexceptbytheuseoftoolsorfollowingthepartialortotal removaloftheseatfurnishings.) 2.1.2) Adjustable)head)restraintmeansaheadrestraintthatiscapableofbeingpositionedtofitthe anthropometryoftheseatedoccupant.thedevicemaypermithorizontaldisplacement,referred toas tilt adjustmentand/orverticaldisplacement,knownas height adjustment.) 2.1.3) ReQactive)head)restraintmeansadevicedesignedtoimproveheadrestraintgeometryduring animpact. It will usually be deployed by the occupant s mass within the seat operating a mechanismduringthecrash.theyalsousuallyreksetafterloadingtoaprekaccidentcondition.) 2.1.4) ProQactive)head)restraintmeansadevicedesignedtoautomaticallyimproveheadrestraint geometrypriortoanimpact,whichutilisessensorstotriggerpyrotechnics,magneticorother devicetoreleasestoredenergyinordertodeployheadrestraintorseatbackelements.such systemsrequirenoinputfromtheoccupanttooperate.theyareusuallynotreksettablefollowing adeploymentandremainintheirdeployedstate.) 2.1.5) Automatically)adjusting)head)restraintmeansaheadrestraintthatautomaticallyadjustsits positiondependingonthestatureoftheseatedoccupant.) 2.1.6) Locking refers to an adjustable head restraint fitted with a device to prevent inadvertent downwardorrearwardmovementfromitsadjustedposition,i.e.whenarearseatoccupantuses afrontseatheadrestraintasahandholdtofacilitateeasyentryorexitfromthevehicle.a lockingdevicemaybefittedtoboththehorizontalandverticaladjustmentsoftheheadrestraint. A locking device shall incorporate a mechanism that requires intervention to allow downward/rearward head restraint adjustment after which the mechanism shall rekengage automatically.) 2.2) HQPoint)manikin)(HPM)meansthedeviceusedforthedeterminationof H pointsandactual torso angles. (SAE Standard J826, SAE Handbook, Vol 3, 1999) modified according to the Insurance Corporation of British Columbia (ICBC) Instruction Manual for the HRMD, see AppendixIII.) 2.3) HRMD(HeadRestraintMeasuringDevice)meansaseparateheadKshapeddeviceusedwith thehkpointmachinetomeasurethestaticgeometryofavehicleheadrestraint.itwasdeveloped underthesponsorshipoftheinsurancecorporationofbritishcolumbia(icbc)k(saepaper 1999K01K0639).TheHRMDisequippedwithtwoprobestomeasureheadrestraintheightand backset. The height probe projects horizontally, level with the top of the head, to provide a reference line for the vertical measurement to the top of the restraint. The backset probe simulatestherearprofileoftheheadandneckandprojectshorizontally,toprovidethehorizontal measurementtotherestraint.) 2.3.1) HRMD)Height)isdefinedastheverticalmeasurementbetweentheheightprobeoftheHRMD andthetopoftheheadrestraint.) Version3.2 July2017 2
2.3.2) HRMD) Backset is defined as the horizontal measurement between the back surface of the HRMDheadandthefrontsurfaceoftheheadrestraintasmeasuredbythebacksetprobeof thehrmd.) 2.3.3) BioRID)Reference) Backset is derived from the horizontal measurement between the back surfaceofthehrmdandtheselectedreferencepointonthefrontsurfaceoftheheadrestraint. TheBioRIDReferenceBacksetis15mmgreaterthantheHRMDbacksetandwillbeusedto positionthedummypriortotest.) 2.3.4) BioRID)Backset is defined as the horizontal measurement between the back surface of the BioRIDheadandtheselectedreferencepointonthefrontsurfaceoftheheadrestraint.) 2.4) Seat)Movement)Definitions.Foranillustrationofseatmovementdefinitions,seeAppendixV.) Version3.2 July2017 3
3) COORDINATE)SYSTEM)) 3.1) SledCoordinates 3.1.1) The coordinate system used must be an ordinary Cartesian cokordinate system with 90 betweentheaxes.) 3.1.2) TheoriginforallmeasurementsmadeusingCMMistobelocatedontheuppersurfaceofa seatmountingbolthole,inthestationarypartoftheseatrunner.thiscommonoriginwillprovide a means of comparing seat positions across test laboratories, where required. In the first instance,therighthandrearmountingholeshallbeused.ifthisisnotpresent,thenextavailable fixationpointshallbechosen,consideringavailableoptionsinthefollowingorder:lefthandrear, lefthandfront,righthandfront.) 3.2) DummyCoordinates 3.2.1) ThecoordinatesystemfortheBioRIDinstrumentationusedmustbeinaccordancewithSAE J211.) Version3.2 July2017 4
4) SLED)SEAT)MOUNTING)AND)POSITIONING)) ForthebaseseatsetupspecificationsusedinSection4.2to4.5,manufacturerswillberequestedto providedatalistedinappendixipriortotestpreparation.alternatively,physicalvehiclemeasurements maybeused.inallcasesthevehicleshouldbeplacedonlevelgroundwithnooccupantloadanda fulltankoffuel.ensurethatthevehiclehasitssparewheelandalltoolssuppliedonboardandalltyre pressures set to manufacturer s recommendations. For vehicles with active suspension and/or automatic levelling the suspension should be set to a driving speed of 40km/h in normal running conditionsasspecifiedbythemanufacturer. Allbaseseatsetupspecificationsmustbeachievedwithin0.2 and5mmoflineartolerance,withthe exceptionofseatbeltattachments. Theheadrestrainttestpositionshouldbeestablishedonallseatsprovidedforwhiplashassessment priortoanyinstallationonthesled.furtherdetailsofestablishingthecorrectpositionarecontainedin Section7.2. 4.1) PackagingIssues 4.1.1 ANCAPreservestherighttorefusethesledtestingofaseatwheretheperformanceoftheseat orheadrestraintcouldbeinfluencedbythevehicleenvironmentorpackaging.thereshouldbe nostiffstructureinthevicinityoftheheadrestraintthatcouldbecontactedbytheheadinarear impact or that could influence the dynamic deflection of the seat back. There should be no additionalsupportfortheseatbackthatisnotpresentinthesledtestsetkup.) 4.1.2) Wheresuchcircumstancesexist,forexamplewith2seatersportscars,thevehiclemanufacturer maybeofferedtheopportunitytotestwithabodykinkwhiteortosimulateallrelevantstructures onthesledsetkup.theadditionaltestcostsandprovisionofabodykinkwhiteshallbepaidfor bythemanufacturerinthesecircumstances.) 4.1.3) Themidtrackseatpositionshouldallowaseatbackangleof25degreesadjustmentinallcases. Whereabulkheadorsimilarstructurepreventsthis,theseattrackshallbeadjustedforward until25degreesisachieved.) 4.2) SeatStructureReferencePoint Inadditiontothecoordinatesystemorigindeterminedin3.1.2,afurtherseatstructurereferencepoint shallalsobechosen.thisisdefinedasafixedpointontheseatstructurewhichstaysinthesame positionrelativetothevehicle,independentofanyseatadjustment.record(withaphotograph)the locationusedandensurethatthisisconsistentbetweenvehicleandsledmeasurementsforaparticular seat. For vehicle manufacturers sourced seat setups, this reference point must also be specified. Figure1showsanexampleseatreferencepointbeingthefrontleftbolthole,butothernonKmoving partsoftheseatmountingstructureareacceptable.theseatstructurereferencepointshallbechosen suchthattherelationshipoftheseattothevehiclefloorcanbeaccuratelyreproducedonthesled. Version3.2 July2017 5
Figure)1:)Definition)of)the)Seat)reference)point) 4.3) ToeBoard Thetoeboardisdefinedasasimulatedfloorandtoepan,consistingofahorizontalsectionsufficiently large to rest the dummy s feet and connected to a section oriented 45 from the horizontal. When positionedfortest,thegapbetweenthefrontoftheseatandrearofthetoeboardshallbenomore than 100mm. Both surfaces shall be covered with shortkpiled carpet. A suitable arrangement is illustratedinfigure2. 4.4) HeelSurface Figure)2:)Toe)board)arrangement)showing)correct)positioning)of)BioRID)feet) Theheelsurfaceisdefinedasthehorizontalplaneofthetoeboard(i.e.sledfloorormovablefootrest) onwhichthedummy sheelrests.itstargetpositionisdeterminedusingtheheelrestpointlocation Version3.2 July2017 6
definedfromthevehiclemeasurements,orfrominformationprovidedbythevehiclemanufacturer.an accurateheightsettingshouldbeobtainedatthisstagekhoweveraninitialapproximatedhorizontal positionmaybeset.thefinalhorizontalpositionwillbeobtainedinsection6.6.8. 4.4.1) Determineheelrestpointlocation. The heel rest point is defined in the vehicle (with removable floor mats not fitted) by using the acceleratorpedalasfollows:) Findthegeometriccentrepointoftheacceleratorpedalcontactsurface(bothlaterallyandvertically). Placeastraightedgebetweentheacceleratorpedalcentrepointandthefixedcarpetingonthevehicle floorsuchthatthestraightedgeistangentialtotheacceleratorpedalsurfaceatthecentrepoint.the heelrestpointlocationisthenthecontactpointofthestraightedgeonthevehiclefloor,seefigure3.) Figure)3:)Heel)rest)point) ) 4.5) SeatMountingtosled 4.5.1) Theseat,includingallofitsadjustmentmechanismsandhardwarethatnormallyconnectsitto thevehiclefloor(e.g.longitudinaladjustmentrails),shouldbesecurelyfastenedtothetestsled platform.) 4.5.2) Theattachmentshouldbemadesothattheseat sorientationrelativetothehorizontalisthe same as it would be in its vehicle as defined by physical vehicle measurements or vehicle manufacturerdata.theactualheightoftheseatfromthesledplatformmaybedifferentfromits heightabovethevehiclefloor.) 4.5.3) The toe board is also attached to the sled platform. The horizontal floor portion should be mountedatthesameheightrelativetotheseatbolts/railsastheheelrestpoint.thefore/aft positionofthetoeboardshouldbeadjustable.figure4showsanexampleseatbothinkvehicle andmountedonthesledplatform.) 4.5.4) Theseatstructurereference,seatrailangleandheelrestpointshouldberecordedinthetest report.seatmountsshouldberigidandnonkdeformable,andtheseatmountinterfacetothe seatshouldapproximatethatoftheinterfacetothevehiclefloor.thevehiclemanufacturerwill beaskedtoprovidedetailsoftherelevantseatmountingmeasurements/tolerancesandwillbe invitedtoexaminethefixturepriortotest.alternatively,thecarmanufacturermayprovidethe testlabwithasuitableseatattachmentframeorfixture.) Version3.2 July2017 7
) Figure)4:)Attachment)of)seat)to)test)sled) 4.6) SeatPosition 4.6.1) Seatswithautomaticallyadjustingheadrestraints. TheBioRIDdummyusedforthesedynamictestsrepresentsamidsizeadultmaledriverorvehicle occupant.consequently,seatsequippedwithheadrestraintsthatautomaticallyadjustdependingon otherseatadjustments(e.g.seattrackorheight)shouldbesettoapositionmostlikelytobeusedby aseatoccupantofthesamesizeasthedummy.therefore,theseatshallbeadjustedtoitsmidtrack andmidheightposition.) Sincetheseat sstartingpositioncanaffectthefinalpositionoftheheadrestraint,aconsistentsetup sequenceshouldbefollowed.duringsettingofthemid/midposition,theseatshouldalwaysbemoved rearwardfromtheforwardmostposition,anddownwardfromthefullyupposition.theseatbackshould thenbepositionedfollowingtheprocedureinsection5.3.allotherseatsettingsthathavenotalready beenadjustedshallbesetaccording4.6.2. 4.6.2) Settingmanualseatadjustments. Thevariousseatadjustmentspossibleonmanymodernvehicleseatsshouldbesetaccordingtothe followinginstructions.becausethesettingofsomeadjustmentsmayaffecttheadjustmentrangeof otheradjustments,theseatshouldbesetbyfollowingtheorderoftheprocedureoutlinedhere.ifthe seatisnewandhasneverbeensaton,apersonofmass75kg±10kgshouldsitontheseatfor1 minute,twice,toflexthecushions.theseatshallhavebeenatroomtemperatureforatleastsixhours andnotloadedforatleastonehourprevioustotheinitialinstallationofthehkpointmanikin.following thisprekconditioning,theseatsetupmaybeundertaken.theseatbackanglewillbesetinsection5.3, theinitialsettingisnotimportantsolongasitdoesn tinterferewithotheradjustments.) Seat adjustments should now be set using the sequence described in Section 4.6.2.1 to 4.6.2.7. Subsequentseatadjustmentsmayaffecttheoriginalpositionofaprevioussetting.Ifthisisthecase thereshouldbenorekadjustmentoftheprevioussettings. 4.6.2.1) Initialadjustmentofseatadjustmentcontrols Allseatcontrolsshouldbesetinsequenceasfollows.AppendixVprovidesmoredetaileddescriptions withillustrationofeachoftheseseatadjustments.) Version3.2 July2017 8
Seat)trackshouldbeinitsmostrearwardlockingposition. Seat)heightshouldbesettoitslowestposition. Seat)tiltshouldbesettotheextremeofitsrangethatputsthecushionangleclosesttozero (horizontal).section4.6.2.2describesthemethodformeasuringthecushionangle. Cushion)heightshouldbesettoitslowestposition. Cushion)tiltshouldbesettotheextremeofitsrangethatputsthecushionangleclosesttozero (horizontal).section4.6.2.2describesthemethodformeasuringthecushionangle. Lumbar)supportshouldbesettoitsmostrearwardorleastprominentposition. Upper)seat)back,ifseparatelyadjustablefromthelowerportionshouldberotatedfullyrearward. Cushion)extension)shouldbesettoitsmostrearwardorleastextendedposition. Side)bolstersshouldbesettothewidestposition. Arm)Restsshouldbesetinthestowedposition. 4.6.2.2) Measurementofcushionangle. Locate and mark a point on the forward edge of the top surface of the seat cushion and midway betweentherightandleftedgesofthecushion.locate,mark,andrecordasecondpointthatis400mm rearwardalongalineparalleltothedirectionofthesledmovement.thecushionangleisthereading fromadigitalprotractorsittingonthesurfaceoftheseatwiththerearmostendontherearseatmark. Asuitablelengthprotractorshouldbechosensuchastheentirelengthofitsunderside(measurement surface)isincontactwiththecentralpaneloftheseatcushion.theanglemeasurementshouldnotbe influenced by padding or bolstering on the front of the seat base. Alternatively, if a coordinate measurementmachine(cmm)isusedtorecordthelocationsoftheseatmarks,thenthesineofthe cushion angle is the difference in the ZKcoordinates(in mm) of these 2 points(first minus second) dividedby400mm.seefigure5.) Figure)5:)Measurement)of)cushion)angle) Version3.2 July2017 9
4.6.2.3) Setting)seat)track)adjustment)to)the)midrange.)Markbothsidesoftheseattrackand adjacentportionoftheseatsupportstructure.movetheseattoitsmostforwardmostlocking adjustmentpositionandmarktheseattrackadjacenttotherepositionedmarksoneitherside oftheseatsupportstructure.onbothsidesoftheseat,measurethedistancebetweenthetwo seattrackmarksandmarkthetrackmidwaybetweenthefirsttwomarks.) Alternatively,aCMMmaybeused.Withtheseatintherearmostposition,markahardpointonthe seat and record its location. Move the seat to its most forward adjustment position and record the positionoftheseathardpoint. Movetheseatrearwarduntilthemarkontheseatsupportstructurealignswithcentreseattrackmark, oruntilthemarkedhardpointismidwaybetweenthetwopreviouslyrecordedhardpointlocations.the finalpositionwilldependonwhethertheseattrackadjustscontinuouslyorincrementally. Theseatshouldbecheckedtoensurethatbothseatrunnersaresetandlockedcorrectly.Insome casestheremaybedifferentamountsoftravelbetweenthetwoseatrunners,careshouldbetakento ensurethatinsuchcasesbothseatrunnersarelockedinthecorrectpositions. 4.6.2.3.1) Continuously)adjusting)seat)track.Theseatmarkshouldalign(±2mm)withthemidKtrack mark. Alternatively, the hard point should have an XKcoordinate that is midway (± 2mm) betweenthexkcoordinatesoftheforwardmostandrearwardmostadjustmentpositions.) 4.6.2.3.2) Incrementally)adjusting)seat)track.Ifthemidrangeadjustmentdoesnotcorrespondtoan incrementaladjustmentposition(±2mm),thentheseatshouldbesettothefirstincremental positionrearwardofthecalculatedmidrangeposition.) 4.6.2.4) Setting)seat)height)adjustment)to)midrange.)Marktwohardpointsonthesideofthe seat,whichareattachedtoandmovewiththecushionframe,onenearthefrontofthecushion andoneneartherear.recordthelocationsofbothpointswithacmmormeasurethevertical heightsofthepointsrelativetoafixedreferencewithameasuringtape.usetheseatheight adjustercontrol(s)tomovetheseattoitshighestposition.ifthefrontandrearoftheseatadjust separately,thenmakesurethatboththefrontandrearoftheseatareraisedtotheirhighest positions. Record the locations of the two hard points with the CMM or measure the vertical heightsofthepointsrelativetoafixedreferencewithameasuringtape.thenlowertheseat untilbothhardpointsaremidwaybetweentheirhighestandlowestpositions.thefinalposition willdependontypeofseatheightadjuster.) 4.6.2.4.1) Single)control)seat)height.Iftheheightiscontrolledbyasingleadjuster,itsfinalposition willdependonwhetheritiscontinuouslyorincrementallyadjusting.) 4.6.2.4.1.1) Continuously)adjusting)seat)height.)Forsinglecontrolheightadjusters,therearhard pointshouldbe±2mmofthecalculatedmidpoint.) 4.6.2.4.1.2) Incrementally)adjusting)seat)height.Ifthemidrangeadjustmentdoesnotcorrespond toanindexedadjustmentposition(±2mm),thentheseatshouldbesettothefirstindexed positionbelowthecalculatedmidrangeposition.) 4.6.2.4.2) Dual)control)seat)height.Ifthefrontandrearoftheseatadjustseparately,thenusethe frontadjustertolowerthefronthardpointandtherearadjustertolowertherearhardpoint. Thefinalpositionwilldependonwhetheritiscontinuouslyorincrementallyadjusting.Note thattheadjustmentofthefrontandrearcontrolsmayneedtobeiteratedinordertoachieve thecalculatedmidpoints.) 4.6.2.4.2.1) Continuously) adjusting) seat) height.) Both hard points should be ± 2mm of the calculatedmidpoints.ifthisisnotpossible,thentherearhardpointshouldbe±2mmofthe Version3.2 July2017 10
calculatedmidpointandthefronthardpointasclosetothecalculatedmidpointaspossible.) 4.6.2.4.2.2) Indexed)adjusting)seat)height.Ifeithermidrangeadjustmentdoesnotcorrespondto anindexedadjustmentposition(±2mm),thenitshouldbesettothefirstindexedposition belowthecalculatedmidrangepositionforthecorrespondingseathardpoint.) 4.6.2.5) Setting) cushion) height) adjustment. The cushion height adjustment uses the points markedonthetopsurfaceofthecushioninsection4.6.2.2.) 4.6.2.5.1) Single) control) cushion) height) adjustment. Raise the cushion to its highest adjustment andrecordthepositionoftherearcushionpoint(400mmbehindfrontedgepoint).lowerthe seatcushiontoitsmidkposition.thefinalpositionwilldependonwhetheritiscontinuously orincrementallyadjusting.) 4.6.2.5.1.1) Continuously) adjusting) seats. The rear cushion point should have a ZKcoordinate midway(±2mm)betweenthelowest(initial)andhighestpositions.) 4.6.2.5.1.2) Incrementally)adjusting)seats.Ifthemidrangeadjustmentdoesnotcorrespondtoan indexedadjustmentposition(±2mm),thentheseatcushionheightshouldbesettothefirst indexedpositionbelowmidrange.) 4.6.2.5.2) Dual)control)cushion)height)adjustment.Usetherearcushionheightadjustertoraisethe rearofthecushiontoitshighestpositionandrecordthelocationoftherearcushionpoint (400mmbehindfrontedgepoint).Againusingtherearcushionheightadjuster,lowerthe rearofthecushionsothattherearcushionpointismidwaybetweenthelowest(initial)and highestpositions.usethefrontcushionheightadjustertoraisethefrontofthecushionuntil thecushionanglematchestheanglerecordedinstep4.6.2.2.thefinalpositionwilldepend onwhetheritiscontinuouslyorincrementallyadjusting.notethattheadjustmentofthefront andrearcontrolsmayneedtobeiteratedinordertoachievethecalculatedmidpoints.) 4.6.2.5.2.1) Continuously)adjusting)seat)height.)TherearseatpointZKcoordinateshouldbe±2mm ofthecalculatedmidpointandthecushionangleshouldmatchthatrecordedinstep4.6.2.2 towithin(±0.5 ).) 4.6.2.5.2.2) Indexed)adjusting)seat)height.Ifthemidrangeadjustmentoftherearadjusterdoesnot correspond to an indexed adjustment position, then it should be set to the first indexed positionbelowthecalculatedmidrange.likewise,ifthecushionanglefrom4.6.2.2cannot bematched(±0.5 )withthefrontadjusteradjustedtoanindexedposition,thensetthefront adjustertothenextlowestindexedposition.) 4.6.2.6) Adjusting)the)Upper)seatback)angle.Measuretheanglerelativetoverticalofthehead restraintsupportpostorsomeflatpartoftheseatbackframe.withoutchangingtheadjustment ofthelowerseatback,movetheupperseatbacktoitsmostforwardpositionandmeasurethe angleoftheheadrestraintpostorseatbackframe.adjusttheupperseatbackrearwarduntilthe head restraint post or seatback frame angle is midway (± 0.5 ) between the rearmost and forwardmostangles.) 4.6.2.7) Seat)adjustments)not)set)in)steps)4.6.2.2)through)4.6.2.6shouldremainintheinitial adjustmentassetinsection4.5.1.) 4.7) SeatBelt 4.7.1) AgenericthreepointlapKshoulderseatbeltequippedwithaninertiareelshouldbeusedduring thetest,placedinsuchawaythatthebelt,whenwornbytheatd,shouldlieacrossthetorso, clavicleandpelvis,andmustalwaysberoutedabovethepelvicanglegauge.) Version3.2 July2017 11
4.7.2) For generic seat belts, where a seat is equipped with anchorages or buckles, these may be used.anyanchoragesnotattachedtotheseatshouldbepositionedasshowninfigure6.the marks,whichcorrespondtothearrangementoftheanchorages,showwheretheendsofthe beltaretobeconnectedtothesled.theanchoragesarethepointsa,bandk.thetolerance onthepositionoftheanchoragepointsissuchthateachanchoragepointshouldbesituatedat mostat50mmfromcorrespondingpointsa,bandkindicatedinfigure6.) 4.7.3) Ifafourthanchorageisnecessarytoattachtheretractor,thisanchorage:) shouldbelocatedintheverticallongitudinalplanepassingthroughk, shouldbelocated770mmverticallybelowk. Inthecaseofabeltequippedwithabeltadjustmentdeviceforheight,thisdeviceshouldbesecured toarigidframe. 4.7.4) The structure carrying the anchorages must be rigid and should be so constructed that no permanentdeformationshalloccurinthepartsbearingtheanchoragesduringthetest.) Figure)6:)Generic)seat)belt)anchorage)mounting) 4.7.5) Where a manufacturer requests and can demonstrate good reason for doing so to the Secretariat,vehiclespecificbeltsandgeometrymaybeconsidered.Inthiscaseorwhentesting seatsequippedwithintegratedbeltsthevehiclesownseatbelthardware(retractorandbuckle) should be used. Seat belt geometry and restraint equipment should then be used that approximates that of the test vehicle. Where this is agreed, the vehicle manufacturer will be askedtoprovidedetailsoftherelevantmountingmeasurements/tolerancesandwillbeinvited toexaminethefixturepriortotest.alternatively,thecarmanufacturermayprovidethetestlab withanattachmentframeorfixture.) Version3.2 July2017 12
4.8) )Triggering)of)Active)Elements)) Foreachseatitshouldbeascertainedfrommanufacturerdatawhetheractiveelements(e.g.proKactive headrestraintorseatbeltpretensioner)arefitted,andwhethertheywouldbetriggeredforeachofthe testpulses.foreachelementwhichrequiresatrigger,timetofire(ttf)shouldbespecifiedbythe vehicle manufacturer for each pulse if required. Supporting data should be provided by the manufacturer to show that the system always triggers throughout the entire range of rear impact scenarios considered by ANCAP. For example, the low severity RCAR bumper test would be considered. Version3.2 July2017 13
5) HQPOINT)MACHINE)&)DUMMY)POSITIONING) 5.1) Introduction) ThefollowingsectioncontainsthecurrentpositioningprocedureforusewiththeBioRIDdummy.The entire process for a single installation and measurement using the HPM and HRMD should last approximately15minutesmaximumperinstallation.) 5.2) HQpoint)manikin)and)HRMD)preparation) TheBioRIDtestpositionisbasedonreferencemeasurementsmadewiththeHKpointmanikin(HPM) andhrmd.partsofthefollowingtextcontainexcerptsfrom AProcedureforEvaluatingMotorVehicle HeadRestraints (issue2,rcar,february2001).aspecificpairingofmanikinandhrmdmustbe usedwhichhavebeencertifiedtogether.beforeusingthecombination,ensurethatthebuildcondition is correct. Remove the head room probe from the HKpoint machine and install the two washers (suppliedwiththehrmd)inthespacesremainingonthehkpointpivot.thefitofthehrmdonthehk pointmachineshouldbeconfirmed.lowerthehrmdinpositionontothetorsoweighthangersand ontothetopedgeofthechannelbetweenthetorsoweighthangers.ensurethatthehrmdfitseasily intoplacewithoutinducingforceswhichmightdisturbthemanikinposition.) 5.3) HQpoint)manikin)installation)) 5.3.1) Theseatshallbecoveredwithacottonclothlargeenoughtocoverbothcushionsandseatback.) 5.3.2) Theclothshallbetuckedintotheseatjointbyanamountsufficienttopreventhammockingof thematerial.) 5.3.3) TheHKpointmanikinshallbeinstalledintheseat.) 5.3.4 Thelowerlegsshallbeadjustedtothe50 th percentileleglengthsetting,andtheupperlegs shallbeadjustedtothe10 th percentileleglengthsettingkthesearethehpmsettingsclosestto theancapfrontandsideimpactprotocolsettings.) 5.3.5) ThelegsshallbeattachedtotheHPMandsettothe5 th position(no.5)onthekneejointtkbar, whichplacestheknees250mmapart.) 5.3.6) Withthelegsattachedandthebackpantiltedforward,theHPMshallbepositionedintheseat such that its mid sagittal plane coincides with the longitudinal centreline of the seat. The centrelineoftheseatmaybedefinedfromfeaturessuchastheheadrestraintsupporttubesor seatback and seat pan side bolsters. Particular attention should be paid to seats with asymmetricdesign. 5.3.7) Thebackpanshallbestraightenedtoconformtothevehicleseatback.) 5.3.8) Thefeetshallbeplacedasfarforwardaspossible,withtheheelsrestingontheheelplaneand thefeetpositionedat90 tothetibias.thetoepanshallbepositionedsufficientlyfarawayso astoavoidanyinteractionwiththefeetduringthehpminstallationprocess.) 5.3.9) ThelowerlegandthighweightsshallbeattachedtotheHPMandtheassemblyshallbelevelled.) 5.3.10)Thebackpanshallbetiltedforwardto45 fromtheseatbackandthehpmassemblypushed rearwarduntiltheseatpancontactsthevehicleseatback.whilemaintainingthebackpanat 45 totheseatback,ahorizontalrearwardforceof100nshallbeappliedusingtheplungerif presentorusingaforcegaugepressedagainstthehipanglequadrantstructure.) Version3.2 July2017 14
5.3.11)Theloadapplicationshallberepeatedand,whilekeepingthe100Napplied,thebackpanshall bereturnedtothevehicleseatbackandtheloadthenreleased.asthe100nisreleased,a smallforceshouldbemaintainedonthefrontofthetkbartopreventanylongitudinalmovement. ThissupportshouldbemaintaineduntiltheendofSection5.3.17isreached.) 5.3.12)AcheckshallbemadetodeterminethattheHPMislevel,facingdirectlyforward,andlocated inthecentrelineoftheseat.) 5.3.13)Asanapproximationofthevehicleseatbackposition,itshallbeplacedsuchthatthetorsoangle is about 21 before the buttock and chest weights are added. This angle may be varied accordingtothesubjectiveestimateoftheseatcushionstiffnessorbasedondataprovidedby themanufacturer.) 5.3.14)TheHPMtorsoangleshallbemeasuredbyplacinganinclinometeronthecalibratedblock(see AppendixII)locatedonthelowerbraceofthetorsoweighthanger.) 5.3.15)After estimating the vehicle seat back position, the right and left buttock weights shall be installed.thesixchestweights(includingthetwolargerweights)shallbeinstalledbyalternating left to right. The two larger HRMD chest weights shall be attached last, flat side down. Throughout the weight installation, maintain a light pressure to the TKbar preventing any longitudinalmovement.) 5.3.16)Tiltingthebackpanforwardtoaverticalposition,theassemblyshallberockedfromsidetoside overa10 arc,5 ineachdirection.whereseatsidebolsterspreventmovementofupto5,the assemblyshouldberockedasfaraspermissible.thisrockingshallberepeatedtwice,making atotalofthreecompletecycles.careshouldbetakentomaintainsupportofthetkbarduring therockingaction,andtoensurethatnoinadvertentexteriorloadsareapplied.ensurethatthe movements of the HPM feet not restricted during this step. If the feet change position, they shouldbeallowedtoremaininthatattitudeforthetimebeing. 5.3.17)HoldingtheTKbartopreventtheHPMfromslidingforwardontheseatcushion,thebackpan shallbereturnedtothevehicleseatback,andthehpmshallbelevelled. 5.3.18)Toensureastabletorsoposition,applyandreleaseahorizontalrearwardload,nottoexceed 10N,tothebackpanmouldingataheightapproximatelyatthecentreofthetorsoweights.Care shallbeexercisedtoensurethatnoexteriordownwardorlateralloadsareappliedtothehpm. 5.3.19)Eachfootshallbealternatelyliftedoffthefloorviatheinstepuntilnoadditionalforwardfoot movementisavailable. 5.3.20)The45degreeplaneofthetoeboardshouldbemovedtowardthefeetsuchthatthetipofthe toeliesbetweenthe230mmand270mmlinestakingcarenottodisturbthepositionofthehpm. TofacilitateeasiersettingofBioRID,thetoeboardshouldbemovedsuchthatthetoesofthe HPMfeetarepositionednearertothe230mmline. 5.3.21)Wheneachfootisinitsfinalposition,theheelshallbeincontactwiththefloor,andthesoleof thefootshallbeincontactwiththe45degreeplaneofthetoepanbetweenthe230mmand 270mmlines. 5.3.22)IftheHPMisnotlevelafterthefeethavebeenrepositioned,asufficientloadshallbeappliedto thetopoftheseatpantolevelitonthevehicleseat.thismaybeverifiedusingthebubble gaugefittedtothemanikinoralternativelybyverifyingwithcmmthatthehkpointpositionon bothsidesofthemachinearewithin±2.5mmofeachother. Version3.2 July2017 15
5.4) Installation)of)the)HRMD)) 5.4.1) ThebacksetandheightprobesshallbeinstalledandpushedflushagainsttheHRMD.) 5.4.2) TheHRMDlevellingknobshallbeconfirmedasfingertightandtheplungerswhichengageat thehpmtohrmdinterfaceshallbefullyloosened.) 5.4.3) TheHRMDshallthenbeloweredintopositionontheHPMtorsoweighthangersandonthetop edgeofthechannelbetweenthehangers.duringthefitment,ensurethatthehrmdfitseasily intoplacewithoutinducingforceswhichmightdisturbthemanikinposition.)makenoteofany longitudinalmovementofthemanikin,andensurethatthisresultsinconsistenthkpointposition inthesubsequentrepeatdropsconductedinsection6.5.) 5.4.4) The HRMD shall be levelled by loosening the levelling knob at the rear of the device and repositioningtheheadusingthehrmdbubblelevelkthelevellingknobshallthenberetightened byhand.) 5.4.5) Measurethetorsoangleonthecalibratedblockattachedtotheweighthangerbar.) 5.4.6) If the measured angle is not 25 ±1, the HRMD and chest and buttocks weights shall be removed, the seat back readjusted, and the steps to position the HPM shall be repeated, beginningwithtiltingthebackpanforwardandpushingthehpmrearwardasin5.3.10.) 5.4.7) Ifmorethan3installationsoftheHPMandHRMDarerequiredtoascertainaseatbackangle thatsupportsatorsoangleof25 ±1,thentheseatshouldbeallowedtorecoverfor15minutes withnothinginitbetweeneachthirdandfourthinstallation.itisrecommendedtoaimtosetthe SAEmanikinascloseaspossibletothenominaltargetvaluefortorsoangle.) 5.4.8) Someindexedseatbackadjustmentsmayhavemorethan2 betweenadjustmentswithnone givingatorsoanglebetween25 ±1.Insuchcases,adjusttheseatbacktothemostreclined positionthatsupportsatorsoanglelessthan24.) 5.4.9) Thetorsoangleshallberecordedwhenitfallswithintheallowedrange.) 5.5) Record)the)location)of)the)HPM)HQpoint)markers.) 5.5.1) RecordtheHKpointpositionsonbothsidesoftheHPMusingaCMMorothermeanstorecord thelocationofbothhkpointsrelativetotheseatorsled.) 5.5.2) TheHKpointpositiononbothsidesofthemachineshallbewithin±2.5mmofeachotherinX andz.ifthisisnotthecase,theinstallationprocedurefrom5.3.6shallberepeated.) Version3.2 July2017 16
6) HEAD)RESTRAINT)POSITIONS)) 6.1) HeadRestraintMeasurementPositionDefinitions 6.1.1) Down)isdefinedasthelowestachievablepositionofanadjustableheadrestraintregardlessof other adjustments(e.g. tilt) and without using tools. The lowest position should be assessed fromthepointofviewofaseatedoccupant,andwithoutusingathirdhand.) 6.1.2) Upisdefinedasthehighestadjusteddétentepositionofanadjustableheadrestraint(taking intoaccountlockingdétentepositions,asdefinedinsection2.1.6,only).) 6.1.3) Backisdefinedasthemostrearwardadjustedpositionofanadjustableheadrestraint,orifthis is difficult to ascertain, back should be taken as the position which results in the greatest HRMDbackset whensetatthetestheight.) 6.1.4) Forwardisdefinedasthemostforwardlockingadjustedpositionofanadjustableheadrestraint, orifthisisdifficulttoascertain, forward shouldbetakenasthepositionwhichresultsinthe least HRMDbackset whensetatthetestheight.) 6.2) Head)Restraint)Test)Positions)) Thesameheadrestraintpositionshouldbeusedforallthreetests.Ifanyvariabilityexistsinthelocking mechanism,suchasdifferentlevelsoffrictionthataffectthatheadrestraintpositionthentheancap Secretariatshouldbeinformedimmediately.Thedecisionofthepositiontobeusedinthetestsshall bemadebythesecretariat.wherethereisdamagetoaseatwhichaffectsthetestposition,details shouldbenotedbythetestlaboratoryandprovidedinthetestreport,thatseatshouldnotbeusedfor test. 6.2.1) Head)restraint)test)position) Thetestpositionfortheheadrestraintdependsonwhetheritisfixedoradjustableand,ifadjustable, whethertheadjustmentslock.automaticallyadjustingheadrestraintsaretestedasiftheyarefixed restraintsandtheseatadjustmentsaresetaccordingtosection4.6.1.) 6.2.2) NonQlocking)adjustable)head)restraint TheheadrestraintisfirstadjustedtoitslowestverticaladjustmentpositionasdefinedinSection6.1.1. If a nonklocking tilt adjustment is available, this should then be set to the most rearward horizontal adjustmentpositionpossibleoncetheheadrestrainthasbeensettoitslowestposition. 6.2.3) Locking)adjustable)head)restraints,)midrange)positions Theheadrestraintisadjustedtomidrangeofitsverticaland/orhorizontaladjustmentpositions.Only locking adjustments are set to the midrange positions. For example, a restraint with locking height adjustmentandnonklockinghorizontaladjustmentwouldbesettoitsmidrangeverticalpositionand most rearward horizontal position. The head restraint should first be set for the midrange vertical position.midrangetiltpositionshouldthenbesetwherethisadjustmenthaslockingnotches. Settingofmidrangeheight 6.2.3.1.1) Lowest)position.Someheadrestraintscanbeloweredbelowthelowestlockingposition and in these cases the bottom of the restraint may contact the top of the seatback. The lowestverticaladjustmentpositionisdefinedinsection6.1.1.) 6.2.3.1.2) Highest)Position.Thehighestpositionisconsideredtobethehighestlockingposition.Ifa Version3.2 July2017 17
restraint has a nonklocking position above the highest locking position, then the highest lockingpositionisstillconsideredasthehighestposition,seefigure7. Figure)7:)Examples)of)adjustment)positions)for)hear)restraints)with)nonQlocking)positions)above/and)or)below) the)locking)positions) 6.2.3.1.3) When measuring the head restraint travel for the midrange positions, the seat must be adjustedaccordingtosection4.6,theseatbackmustbeadjustedaccordingtosection5and thehpmmanikinshouldbeinstalledintheseataccordingtosection5.) 6.2.3.1.4) Markarepeatablereferencepointonthetopoftheheadrestraint.Thispointistypicallythe highestpointonthecentrelineoftheheadrestraint.usingacoordinatemeasurementdevice, thispointshouldfirstbemeasuredinthelowestpositionasdefinedbyinsection6.1.1,and theninthehighestlockingpositionwithoutalteringtiltoranyotherseatsettings.) 6.2.3.1.5) Midrangeheightpositionisdeterminedbycalculatingthegeometricmidpointbetweenthe lowest position, and highest locking vertical adjustments, considering only the vertical componentofmeasurement,seefigure8.thetestpositionwillthenbeselectedbasedon thefollowingconditions:) 6.2.3.1.5.1) Placetheheadrestraintatthegeometricmidpointifalockingpositionexiststhere,see Figure8a.) 6.2.3.1.5.2) Ifthereisnolockingpositionatthegeometricmidpoint,raisetheheadrestraintbyupto 10mm.Ifalockingpositionexistswithinthis10mmoftravel,thatpositionwillbethetest position,seefigure8b.) 6.2.3.1.5.3) Ifthereisnolockingpositionwithin10mmabovethegeometricmidpoint,lowerthehead restrainttothenextlowestlockingposition,seefigure8c.) 6.2.3.1.5.4) Ifthereisnolockingpositionbeforethelowestorstowedpositionisreached,thenthe headrestraintshouldbepositionedfullydown.) 6.2.3.1.5.5) Oncetheverticaltestpositionhasbeendetermined,ensuretheheadrestraintisreturned torearmosttiltposition.) Version3.2 July2017 18
Figure)8:)Examples)of)test)position)for)head)restraints)with)various)locking)configurations) 6.2.3.2) Settingofmidrangetilt(lockingtiltsettingsonly) 6.2.3.2.1) Following the setting of midrange height, the procedure should be repeated for locking horizontaladjustments.fornonklockingtiltadjustments,theheadrestraintshouldbetilted fullyrearward. 6.2.3.2.2) MidtiltpositionmaybeinfluencedbythepresenceoftheHRMDhead,consequentlythe settingofmidrangetiltshouldbeundertakenfollowingsuccessfulinstallationofthehkpoint machineandhrmdandshouldbecompletedwhiletheequipmentisstillinstalledinthe seat. 6.2.3.2.3) For HRMDs equipped with probes having 5mm increments only, a more accurate measurementtechniqueisrequiredtoestablishthemidpositiontowithin1mm.usingasteel rule,measuretheprobeextensionfromthefrontoftheheadformatforwardandrearward tiltsettings.fromthisdataamidpointtargetmaybederived. 6.2.3.2.4) Most)rearward)tiltshallbemadeusingHRMDprobebackset.Themostrearwardtiltposition shallbethatwhichresultsingreatestbacksetmeasurement.inthesituationwherethehead restraintcannotbeplacedatmostrearwardtilt.forexampleduetoareturnspring,themost mostrearwardtilt shallbethemostrearwardpositioninwhichthetiltcanbelocked. 6.2.3.2.5) Most)forward)tiltshallbedeterminedbyfindingthemostforwardlockingtiltposition.NonK lockingpositionslocatedfurtherforwardthanthemostforwardlockaredisregarded.during determinationof mostforwardtilt position,theheadrestraintmaycomeintocontactwith thehrmd.ifcontactisachieved,theheadrestraintshouldnotbetiltedfurtherforward,and should not be moved such that the HRMD position is effected. If a lock exists at the tilt position where the head restraint contacts the HRMD, this shall be considered the most forwardtilt position.ifnolockingpositionexistsinthislocation,theheadrestraintshouldbe tiltedrearwardsuntilalockingpositionisreached.thispositionshallthenbeconsidered mostforwardtilt. 6.2.3.2.6) Midrange) tilt) position) is determined by calculating the geometric mid point between the most rearward tilt and most forward locking horizontal adjustments, considering only the HRMDprobebacksetsmeasured.Midrangetiltsettingshallbeundertakenusingthesame rationaleasusedin0.alockingpositionshallbesoughtwithinawindow10mmforwards Version3.2 July2017 19
from the geometric mid point. If a lock is found within this window, that position shall be consideredthetestposition.intheabsenceofalockwithinthisrangetheheadrestraint shouldbemovedrearwardsuntilthenextlockingpositionisreached.ifnolockingpositions are reached before the fully rearward tilt position, then fully rearward tilt shall be the test position. 6.3) Measureandrecordtheheadrestraintgeometry 6.3.1) Beforemeasuringtheheadrestraintgeometryensurethat:) TheseatissetaccordingtoSection4.6. TheHKpointmachineandHRMDarecorrectlyinstalledintheseataccordingtoSection5. TheheadrestraintissetinthecorrecttestpositionaccordingtoSection6.2. 6.3.2) When measuring backset and height, a light force(e.g. 1N) should be applied, if needed, to ensure that any trim covering material is in contact with the underlying foams, or that the separationoftrimmaterialhasnotprovidedartificiallyfavourablemeasurements.) 6.3.3) MeasuretheHRMDbacksettothenearestmillimetre,withthebacksetprobeinfirstcontactwith theheadrestraint.forthegeometricassessment,thebacksetmustbemeasuredaccordingto the HRMD backset probe scale, taking note of the method described in section 6.2.3.2.3 for probeswith5mmincrementsonly.seefigure9.) 6.3.4) Theheightfromthetopoftheheadrestrainttotheheightprobeshouldalsobemeasured.) 6.3.5) Iftheheadrestraintistoolowtobecontactedbythebacksetprobe,recordas nocontact.) 6.3.6 Allmeasurementsnotedduring6.3.3and6.3.4shallbeusedfortheANCAPgeometrypoints calculation,asdefinedintheancapassessmentprotocol. Figure)9:)Head)restraint)probe)backset)for)static)geometry) 6.4) MeasureandrecordreferencegeometryforBioRIDsetup The HRMD probe measurements used for the geometric assessment will be different than the geometryrecordedforuseduringthebioridsetup.thisisduetothecurvatureofthehrmdprobes andisillustratedinfigure10. SincetheBioRIDissetupbasedonreferencegeometryrecordedusingtheHRMD,thereisaneedto Version3.2 July2017 20
measureanequivalentfeatureonbothdevices.therearmostpointonthehrmdskull(i.e.thescrew onthebacksetprobe)isequivalenttotherearmostpointonthecentrelineofthedummy sskullcap. Thispointcanbefoundusingameasuringtapethatcontourstotheshapeoftheskullcap:thepointis 95mmfromthetopoftheskullcapalongthemidsagittalplaneoftheskull. 6.4.1) Markanidentifiablepointontheheadrestraintalongitsverticalcentreline.Asuggestedpointis definedbyfirstcontactpointbetweenbacksetprobeandheadrestraint.) 6.4.2) Ensure that the backset probe is installed and pushed flush against the HRMD, i.e. stowed/retracted.) 6.4.3) LocatethescrewonthecentreoftherearsurfaceoftheHRMDbacksetprobe.) 6.4.4) MeasureandrecordtheBioRIDreferencebacksetusingCMM(asdefinedinSection2.3.3). ThisisthehorizontaldistancebetweentherearmostpointontheHRMDskull(i.e.thescrewon theretractedbacksetprobe)andtheidentifiablepointontheheadrestraint+15mm,seefigure 10.) 6.4.5) Ensurethattheheadrestrainthasbeenmarkedsuchthatitcanreliablybereturnedtothetest position. Move the head restraint to the lowest position as defined in Section 6.1.1. Whilst maintainingthatlowestposition,movetheheadrestrainttothemostrearwardtiltpossibleas definedbysection6.1.3and6.2.3.2.4.measurethehrmdbacksetandheighttothenearest millimetreusingtheprobes. 6.4.6 All measurements noted during 6.4.5 shall be used for the ANCAP ease of adjustment assessment,asdefinedintheancapassessmentprotocol. 6.4.7) UsingthemarksmadeinSection6.4.5,returntheheadrestrainttothetestposition. 6.5) RepeatMeasurements Figure)10:)Measuring)BioRID)reference)backset) 6.5.1) RemovethemanikinandHRMDandrepeatSections5.3to6.4.6twofurthertimesandrecord ALLmeasurementstakenforeachinstallationinboththetestposition(Section7.3.3)andthe downandbackposition(section7.4.5).fortherepeatinstallations,theseatbackangleshould notbeadjusted.however,whereachangeinseatbackangleisrequiredtoobtainatorsoangle of25 ±1,theinstallationprocedureshallberepeateduntilthreeconsecutiveinstallationshave beenperformedwhichrequirenoseatbackangleadjustment.) 6.5.2) For each individual seat, ensure that the HKpoint X, HKpoint Z and reference backset Version3.2 July2017 21
measurements are within ± 5mm between the three sets of measurements. Outlying measurementsshouldbeinvestigated,andrepeatedtoachieveconsistentstaticmeasurement resultsasnecessary.) 6.5.3) Once each individual seat has been measured three times, calculate the average HKpoint positionrecordedinsection5.5andaveragereferencebacksetrecordedinsection6.4.these shallbethebioridsetuptargetsfromthethreemeasurementstakenoneachindividualseat.) 6.6) InstallBioRID 6.6.1) Theseatshouldhavealreadybeensettogiveatorsoangleof25º±1ºmeasuredontheHKpoint machinefittedwithhrmdasdescribedinsection5.allowtheseattorecoverfor15minutes withnothinginitbeforeinstallingthebiorid.note,bioridhandlingshouldonlybeundertaken using dedicated lifting tools and associated locations on the dummy following the BioRID manufacturer recommendations. Typically, during the installation of BioRID the HKpointwill initiallybeinstalledfurtherrearwardintheseatthanisrequired.thereforethepelvisshouldbe movedforwardtoachievethetargetsetkuppositioning.) 6.6.2) Carefullyplacetheseatbeltacrossthedummyandlockasnormal,ensurethereissufficient slackinthebelttoallowpositioningofbiorid.) 6.6.3) AlignBioRID smidsagittalplanewiththecentrelineoftheseat.) 6.6.4) AdjustBioRID smidsagittalplanetobeverticalktheinstrumentationplatformintheheadshould belaterallylevel.) 6.6.5) Adjustthepelvisangleto26.5ºfromhorizontal(±2.5º).) 6.6.6) PositiontheHKPoint20mmforward(±10mm)andatthesameZKheight(±10mm)asthelocation recordedinsection6.5.3,whilekeepingthepelvisangleat26.5º(±2.5º).itisrecommendedto aimtosettheatdascloseaspossibletothenominaltargetvalues,andthatthetolerance windowshouldonlybeusedifthereisanissueachievingtherequiredhkpointtargetorbackset value.thebioridsetuptolerancesaresummarisedintable1.) 6.6.7) Adjustthespacingofthelegssothatthecentrelineofthekneesandanklesis200mm(±10mm) apartandensurethatthekneesarelevelusinganinclinometerorbubblegauge.) 6.6.8) Adjustthedummy sfeetsothattheheelofbiorid sshoeisrestingontheheelsurface.thetip oftheshoeshallrestonthetoepanbetween230mmand270mmfromtheintersectionofthe heelsurfaceandtoeboard,asmeasuredalongthesurfaceofthetoeboard.figure2shows proper positioning of the feet.note, the heel point from a vehicle is not replicated,only heel planeheightissetaccordingtovehiclegeometry.) 6.6.9) PositiontheBioRID sarmssothattheupperarmsareasclosetothetorsosidesaspossible. Therearoftheupperarmsshouldcontacttheseatback,andtheelbowsshouldbebentsothat thesmallfingersofbothhandsareincontactwiththetopofthevehicleseatcushionwiththe palmsfacingthedummy sthighs.) 6.6.10)Leveltheinstrumentationplaneofthehead(front/rearandleft/rightdirections)towithin±1º. Electronictiltsensorsshallbeusedtoperformthischeck.) 6.6.11)The BioRID backset (as defined in Section 2.3.4) is the horizontal distance between the rearmostpointonthehead,andthesameidentifiablelocationontheheadrestraintthatwas foundwhenmeasuringthehrmdinsection6.4.1.) Version3.2 July2017 22
6.6.11.1) Mark the farthest rearward point on the centreline of the dummy s skullcap. Note, as definedin6.4,thispointis95mmfromthetopoftheskullcapalongthemidsagittalplaneofthe skullmeasuredusingatapethatcontourstotheshapeoftheskullcap.) 6.6.11.2) MeasuretheBioRIDbackset,usingthepointidentifiedontheskullcapin6.6.11.1and thesameidentifiablelocationontheheadrestraintthatwasfoundwhenmeasuringthehrmd insection6.4.1.seefigure11.) 6.6.12)IftheBioRIDbacksetisdifferentfromtheBioRIDreferencebacksetobtainedinSection6.4.4 (±5mm),thendothefollowing:) 6.6.12.1) Tiptheheadfor/aftnomorethan±1 fromlevelinordertomeetthebacksetrequirement.) 6.6.12.2) IftheBioRIDbacksetcannotbebroughtclosertotheBioRIDreferencebackset±5mm bystep6.6.12.1,adjustthepelvisangleandhkpointpositionwithintheirrespectivetolerance bands.inthiscasebeginatsection6.6.5andadjustthebioridpositionaccordingly.) Figure)11:)Measuring)BioRID)backset) 6.6.13)Removetheslackfromthelapsectionofthewebbinguntilitisrestinggentlyaroundthepelvis ofthedummy.onlyminimalforceshouldbeappliedtothewebbingwhenremovingtheslack. Therouteofthelapbeltshouldbeasnaturalaspossibleandmustbeabovethepelvicangle gauge.) 6.6.14)Placeonefingerbehindthediagonalsectionofthewebbingattheheightofthedummysternum. Pullthewebbingawayfromthechesthorizontallyforwardandallowittoretractinthedirection ofthedkloopusingonlytheforceprovidedbytheretractormechanism.repeatthisstepthree times,only. 6.6.15)Oncethebeltispositionedthelocationofthebeltshouldbemarkedacrossthedummychest toensurethatnofurtheradjustmentsaremade.markalsothebeltatthelevelofthedkloopto besurethattheinitialtensionismaintainedduringtestpreparation. Version3.2 July2017 23
Table)1:)BioRID)setup)summary) Location TargetMeasure Tolerance HKpoint(XKaxis) +20mmforward* ±10mm HKpoint(ZKaxis) 0mm* ±10mm Pelvisangle 26.5 ±2.5 Headplaneangle 0 (level) ±1 Backset 15mmforward* ±5mm *ReferencemeasurementstakenusingHKPointmachinefittedwithHRMD Version3.2 July2017 24
7) BioRID)ATD)REQUIREMENTS)) The tests should be conducted with a BioRID IIg dummy built with mould 2 jacket and fitted with electronic tilt sensors capable of measuring X and Y tilt for head and pelvis. The instrumentation umbilical should exit at the front/side of the pelvis such that it is ensured there will be no seatbelt interaction.thedummyshouldcomplywithbothspinestatureanddynamicresponsespecifications beforethetest. 7.1) Spine) Curvature) Check.) With the pelvis adapter plate placed on a level surface with the occipitalcondyle(oc)angleat29.5 (±0.5 ),thet2angleat37 (±0.5 ),andtheneckplate laterallylevel(±0.5 ),thedistancein(x)betweenthehkpointandtheocpinshouldbe156mm (±5mm)andthedistancein(Z)betweentheHKPointandtheOCpinshouldbe609mm(±5mm). See Figure 12. The curvature check shall be performed after every 15 tests and all measurementsshouldberecordedandfullydocumented.) Figure)12:)Spine)curvature)check) 7.2) Certification.)ThedynamicresponseofBioRIDischeckedbyattachingthespine,torsoand headtoaminiksledthatisimpactedthroughfoambya33.4kgprobeandavelocityof4.76m/s ±0.1m/s.Thespecifiedresponseofthedummyanddetailedtestspecificationsaredescribed in Test Procedure: Calibration of BioRID available from Denton ATD, Inc. Generally, if the dummy s spine curvature changes so that it does not meet the dimensional specifications describedinsection7.1,thenlikelyitwillnolongermeetthedynamicresponsespecifications. It is recommended that the BioRID be rekcertified after every 15 tests and all certification documentsprovidedinthelaboratorytestreport.) 7.3) Adjustment)of)the)dummy)extremities) 7.3.1) Thestiffnessofbotharmsandlegsshallbecheckedandadjusted,wherenecessary,priorto everysledtest.theadjustmentprocedureisasfollows:) Version3.2 July2017 25
7.3.2) Arms) 7.3.2.1) Extendthecompletearmlaterallyoutwardtoahorizontal)position.Twistthearmsothe elbowcannotrotate)downward.tightentheshoulderyokeclevisboltso)thearmissuspended at1g,seefigure13.) 7.3.2.2) Rotatethecompletearmassemblysoitpointsforwardandishorizontal.Twistthearm sotheelbowcannotrotatedownward.adjusttheshoulderyokerotationhexagonalnutsothe armissuspendedat1g.) 7.3.2.3) Bendtheelbowby90 sothehandmovestowardthechest.adjusttheelbowrotation boltthroughaccessintheupperarmtoholdthelowerarmhorizontallysuspendedat1g.) 7.3.2.4) Repositionthearmsoitpointsforwardandishorizontal.Twistthelowerarmattheelbow, so the lower arm can pivot downward to vertical. Adjust the elbow pivot bolt through access holesinthelowerarmfleshattheelbowtoholdthelowerarmsuspendedat1g,seefigure13.) 7.3.2.5) Extendthearmandtwistthepalmsoitfacesdown.Adjustthewristpivotboltatthebase ofthehandsoitissuspendedat1g.) 7.3.2.6) Adjustthewristrotationboltthroughaccessinthewristfleshtoholditsuspendedat1g.) 7.3.2.7) Repeatprocedureforotherhandandarm.) 7.3.3) Legs) 7.3.3.1) Removethejacketfromthedummy.) Figure)13:)Dummy)extremity)settings) 7.3.3.2) Withthelowerlegat90 totheupperleg,andthedummyinseatedposition,lifttheupper leg assembly above horizontal. Adjust the femur back set screw so the upper leg is held suspendedat1g.) 7.3.3.3) Rotatethelowerlegassemblysoitishorizontal.Adjustthekneeclevisboltsothelower legisheldsuspendedat1g.) 7.3.3.4) Adjusttheankleballjointscrewsothefootisheldsuspendedat1g.Theankleadjustment isnotcriticalandisdeterminedbyindividualfeet.) 7.3.3.5) Repeattheprocedureontheotherlegandfoot.) Version3.2 July2017 26
7.4) BioRID)Clothing) 7.4.1) ThedummyshouldbedressedwithtwopairsofcloseKfitting,kneeKlength,spandex/lycrapants andtwoclosekfitting,shortksleevedspandexshirts.theunderlayerofclothesshouldbeworn withtheshiny/smoothsideofthefabricfacingoutandtheoverkclotheswiththeshiny/smooth sideagainsttheunderclothes(i.e.dullsidefacingout).thedummiesfeetshouldbeshodwith size11(45europeanor279mm)oxfordkstyle,hardksoled,workshoes(e.g.milksk13192p). 7.5) BioRID)Instrumentation)) 7.5.1 The instrumentation required to perform the ANCAP evaluation is listed in Table 2. The T1 acceleration should be the average of right and left side accelerometer measurements. All instrumentationshallbecalibratedbeforethetestprogramme. 7.5.2) Thechannelamplitudeclass(CAC)foreachtransducershallbechosentoaccordingtoTable 2.Inordertoretainsensitivity,CACswhichareordersofmagnitudegreaterthantheminimum amplitudeshouldnotbeused.atransducershallberekcalibratedifitreachesitscacduring anytest.allinstrumentationshallberecalibratedafteroneyearregardlessofthenumberof testsforwhichithasbeenused.alistofinstrumentationalongwithcalibrationdatesshallbe suppliedaspartofthetestreport. Table)2:)Required)instrumentation) Position Function Measurement CFC CAC SledX Pulseacceptance Acceleration(g) 60 100 Pulseacceptance Velocity(m/s) 30 NA Reboundvelocity Displacement(m) NA NA NIC Acceleration(g) 60 100 Acceleration(g) 1000 100 HeadX HeadCoGX Reboundvelocity Velocity(m/s) 30 NA NeckT1X(LHandRH) NIC Acceleration(g) 60 100 NeckForceX Force(N) 1000 1400 NeckForceX MyOCandNkm Force(N) 600 1400 NeckForceZ Force(N) 1000 4500 NeckMomentY MyOC Moment(Nm) 600 115 HeadRestraintContactTime TKHRC start & Time(ms) NA NA (TKHRC) TKHRC end NeckT1X Force(N) 1000 5000 NeckT1Z Force(N) 1000 5000 NeckT1MomentY Moment(Nm) 600 200 1 st LumbarX Acceleration(g) 60 200 1 st LumbarZ Acceleration(g) 60 100 SeatBeltForce(lapsection) Force(kN) 60 16 7.6) Data)Acquisition)and)Processing)) 7.6.1) ThemeasurementdatashallberecordedaccordingtoISO6487orSAEJ211/1ataminimum samplefrequencyof10khztable2specifiesthechannelfrequencyclassesforeachnecessary measurement. 7.6.2) Measurementdatashallbeconsideredforevaluationuntilthepointintimeatwhichthehead reboundsfromtheheadrestraintorat300msaftertkzero,whicheveroccursfirst. 7.6.3) Priortotestalldatachannelsshallbeoffsettozero,wherezero(acceleration/force/moments) Version3.2 July2017 27
isdefinedbytheaveragequiescentchannelvalueover100samplesat10khz(orequivalent) beforetimeoffset.thisshouldberecordedasignificantdurationpriortot0suchthatthesled acceleration/decelerationphaseisavoided. Version3.2 July2017 28
8) TEST)SLED)REQUIREMENTS) 8.1) Acceleration)or)deceleration)sleds.)Thedynamictestisintendedtosimulateatypicalrear crash in which the rearkstruck vehicle is initially stationary or moving forward very slowly. Consequently, an acceleration sled with the dummy seated facing the direction of motion is recommendedforthesetests.adecelerationsled,onwhichthedummyisseatedfacingagainst thedirectionofmotion,andisinitiallymovingrearwardattheappropriatetestspeedandthen stopped,maybeusedifcarefulattentionispaidtodummypositioningimmediatelypriorto(t=0). Ineithercase,somesledmotionisallowedattheinitiationofthetest(T=0).Toaccommodate differentsledtypesanddifferentrelationshipsbetweensledmotionandtherecordingoftest data,testtimewillbeindexedasdescribedinappendixiv.thesledshouldnotbrakebefore 300msfromT=0.) 8.1.1) BioRIDpositioningrequirementsfortestsusingdeceleratingsled Thedummy shead,t1vertebra,andthesledshouldhavethesamevelocity±0.1m/satt=0.the backofthedummy sheadandt1vertebrashouldbeinthesameposition(±5mm)relativetothehead restraintatt=0astheinitialtestsetkup.theseparametersshallbecheckedbythetestlaboratoryfrom thedataoutputs,anynonkcomplianceshallberecodedinthelaboratorytestreport. 8.2) Test)time)indexing.Tonormalisethetimeindexamongsledlaboratoryprotocolswithdifferent TKzerotriggerlevels,thetimeindexingproceduredescribedinAppendixIVshallbeused.) 8.3) Laboratory)environment.)Thetemperatureinthetestlaboratoryshouldbe22.5º±3ºCanda relativehumidityofbetween10%and70%.thebioridtestdummyandseatbeingtestedshall besoakedatthistemperatureatleast3hourspriortothetest.) 8.4) Acceleration) pulse.) The target sled accelerations and pulse specifications are given in AppendixIV.Sledaccelerationsshouldbemeasuredbyanappropriateaccelerometerattached tothesledplatform,recordedaccordingtosaerecommendedpracticej211 Instrumentation forimpacttesting Part1 ElectronicInstrumentation.Priortoestablishingconformancewith the acceleration pulse specification, any quiescent signal bias should be removed from the accelerationmeasurementandthedatashouldbefilteredinaccordancewithtable2. Version3.2 July2017 29
9) TEST)SLED)INSTRUMENTATION) 9.1) Record the XKacceleration of the sled in accordance with SAE recommended practice J211. Theinstrumentationshouldbedirectlyattachedtothesledplatformandnottoanyotherpartof thetestdevice.) 9.1.1) If necessary, remove any data channel DC bias. Typically, the value of the average measurementover100samplesofthequiescentdatachannelsignalissubtractedfromevery testmeasurement.) 9.1.2) FilterthesledaccelerationtochannelfrequencyclassinaccordancewithTable2.) 9.2) The time of dummy head to head restraint first contact shall be recorded with a foil contact switch. Version3.2 July2017 30
10) WHIPLASH)ASSESSMENT)CRITERIA Thepurposeofthewhiplashtestistotesttheseatandheadrestraintassemblyinordertoassessthe extenttowhichtheyreflectbestpracticeinpreventingsofttissueneckinjuries.thisisbasedonthe followingperformancecriteria: HeadRestraintContactTime(TKHRC(Start) TKHRC(End)) T1xKacceleration( T1 ) UpperNeckShearForce( Fx )anduppernecktension( Fz ) HeadReboundVelocity NIC Nkm SeatbackDynamicOpening. AsummaryofhowthecriteriaarecalculatedisprovidedinTB021 DataFormatandInjuryCriteria Calculation.Belowamoreextensivedescriptionisgivenforthemostimportantassessmentcriteria 10.1) Head)Restraint)Contact)Time) Head restraint contact time should be ascertained using a contact switch method, comprised of a proprietarylightweight,selfadhesiveconductivefoilplacedoverthesurfaceoftheheadrestraint,and therearoftheatdskullcap. HeadRestraintContactTimeTKHRC (Start) isdefinedasthetime(calculatedfromt=0)offirstcontact betweentherearoftheatdheadandtheheadrestraint,wherethesubsequentcontinuouscontact durationexceeds40ms.forthepurposesofassessment,tkhrc (start) shallberoundedtothenearest millisecond. Minorbreaksinthecontacttime(upto1ms)arepermissibleifitcanbeproventhatthesearedueto poor electrical contacts, however these must be investigated with reference to the film to ascertain whetherthebreaksincontactarenotduetobiomechanicalphenomenasuchasatdramping,head restraint or seatback collapse, or bounce of the head during nonkstructural contact with the head restraint.forthesubsequentcriteria,theendofheadrestraintcontactmustalsobefoundktkhrc (end). This is defined as the time at which the head first loses contact with the head restraint, where the subsequentcontinuouslossofcontactdurationexceeds40ms. 10.2) T1)XQAcceleration)) BioRIDisfittedwithtwinaccelerometersonthefirstthoracicvertebra(T1),oneoneithersideofthe lowerneckloadcellassembly.thedatachannelsacquiredfromtheseaccelerometersshouldbothbe filtered to channel frequency class (CFC) 60 as defined by SAE J211. An average channel, T1(t), shouldthenbeproducedfromthetwofilteredsignals,asfollows: where: T1left ( t) + T1 T1( t) = 2 T1 left (t)=accelerationchannelmeasuredbythelefthandt1accelerometer. T1 right (t)=accelerationchannelmeasuredbytherighthandt1accelerometer. right ( t) Version3.2 July2017 31
Themaximum(T1 max )shouldbegeneratedfromthisaveraget1channel,consideringonlytheportion ofdatafromtkzerountiltkhrc (end) asfollows: T1 max = Max T HRC( end ) [ T1( t)] 10.3) UpperNeckShearForce(Fx)andUpperNeckTension(Fz) TheupperneckloadcelloftheBioRIDrecordsbothshearandtensileforces.Iftheinstrumentationis configured in accordance with SAE J211, positive shear should be indicative of a headkrearwards motionandpositivetensionshouldbeassociatedwithpullingtheheadupwards,generatingatensile forceintheneck.firstly,boththefxandfzchannelsshouldbefilteredatcfc1000. Peakvalues,Fx max andfz max, shouldthenbedeterminedforeachoftheforces,consideringonlythe portionofdatafromtkzerountiltkhrc (end),asfollows: 10.4) Head)Rebound)Velocity) )Acceleration)Sled)Technique)) Theheadreboundvelocity(inthehorizontal/Xdirection)shouldbedeterminedusingtargettracking. IdeallythisshouldbeperformedusingfootageacquiredfromonKboardcamerasystems,howeveroffK board systems can provide suitable views providing the camera positioning is correct and compensationismadeforthemovementofthesled.variousproprietaryfilmanalysispackagesinclude functions to achieve this analysis consequently this method will not be covered in detail in this document.refertotheancapfilmandphotoprotocolforadditionalconsiderationsregardingthe useofhighspeedcameras. 10.4.1)Time)for)occurrence)of)peak)rebound)velocity)) Theoretically,thepeakreboundvelocityshouldoccurduetotheelasticenergyreleasefromtheseat assembly,afterthepeaksledaccelerationhasoccurred.inthecaseofanaccelerationsledthisshould alsobepriortothesledbraking,whichattheearliestshouldoccurfrom300ms.itshouldbeverified thatthereissufficienttimebeforetheonsetofsledbrakingfortheparticularsledbeingused,andthat any peak rebound velocity analysis is not undertaken during the sled braking phase. The rebound velocity of the ATD is usually generated due to the release of stored elastic energy within the seat structure, suspension and foam. The time of occurrence of peak rebound velocity should be the maximumhorizontalcomponentofheadreboundvelocitycalculatedbetweent=0and300ms. 10.4.2)Target)Placement)) TheATDshouldbeequippedwithasuitabletargetplacedonthesideoftheheadflesh,coincident with the head centre of gravity(dt6error) Reference) source) not) found.). Additionally, three sled targetswillberequired.twofixedtargetsofknownseparationshouldbeplacedonthesledinthe samexzplane,suchthatafixedreferencecanbeobtainedthatwillnotbeobscuredduringthetest (B1 and B2 targets). In the case of an on board view, a small compensation may be required for cameramovementorshake.thiscanbemadeusingthetwofixedtargetsofknownspacingonthe sled,andathirdtargetfromwhichasledcoordinatesystemmaybecreated. AlltargetpointsusedforanalysisshouldbedepthscaledtocompensateforanydifferencesintheYK Version3.2 July2017 32
coordinates. 10.4.3)Determination)of)Rebound)Velocity)) Usingasuitable targettracking filmanalysistechnique,generatetracesasfollows: HeadcentreofGravitytargetvelocity(absolutelaboratoryreference) Sledvelocity(absolutelaboratoryreference) BothtracesshouldbeoffsetadjustedthenfilteredatCFC30.Headreboundvelocityisthendefinedas thedifferencebetweenthesledvelocityandtheheadvelocity.reboundvelocitycanbecalculatedas: V Rebound =V HeadCKofKG(abs) V Sled(abs) Where: V Rebound =InstantaneousreboundXKvelocityoftheheadcKofKg,relativetothesled V HeadCKofKG(abs) =InstantaneousXKvelocityofheadcentreofgravity,absolute. V Sled(abs) =InstantaneousXKvelocityofsled,absolute. Generateathirdtraceofheadcentreofgravityreboundvelocity,relativetothesled.Themaximum valueandthetimeatwhichthisoccursshouldbenoted.itshouldbeverifiedusingtheendofhead restraintcontacttime,tkhrc (end),thatthismaximumisduringthereboundfromtheheadrestraintand isnotgeneratedwithinthesledbrakingphase.shouldhigherpeaksbegeneratedinthesledbraking phase,theseshouldbedisregardedandtheinitialpeakofreboundvelocitywhichoccursatorvery neartoinitialreboundfromtheheadrestraintshouldbetakenasthepeakvalue. 10.5) NIC)Calculation)) TheNICisbasedontherelativehorizontalaccelerationandvelocityoftheoccipitaljointrelativetoT1. TocalculateNIC,twodatachannelsareneeded,whicharetheheadxKaccelerationandaverageT1 xkacceleration. Eachchannelshouldfirstbeconvertedfrom g tometrespersecondsquared(m/s²),andtheheadxk accelerationshouldbefilteredatcfc60.theaveraget1channel(previouslycalculated)istheresult of combining two channels, both of which were filtered at CFC 60. Reference should be made to Section10.2fordetailsofhowthisaveragechannelisproduced. The relativexkacceleration betweenheadandt1shouldbegeneratedbysubtractingthehead xkacceleration fromthet1xacceleration. Thischanneliscalculatedasfollows: TherelativexKvelocity(V x rel )betweenheadandt1shouldbecalculated,byintegratingtherelative accelerationchannelwithrespecttotime,asfollows: TheNICchannelisthencalculatedasacombinationofrelativeaccelerationmultipliedby0.2,and addedtothesquareoftherelativevelocity.thecalculationisaccordingtothefollowingequation: Version3.2 July2017 33
ThemaximumoverallNICvalue,NIC max,shouldbeobtainedfromthetraceconsideringonlytheportion ofdatafromtkzerountiltkhrc(end)asfollows: Thismaximumvalueshouldbenoted,alongwiththetimeatwhichitoccurs. 10.6) Nkm)Calculation)) The following definition is provided following the commonly accepted convention that derives the Anterior/Posterior directionsfromthetorsomotionrelativetothehead.consequently,torsoforward motion relative to the head would be referred to as anterior, and providing SAE J211 compliant instrumentationisused,wouldproduceanassociatedpositiveupperneckshearforce,f x upper.( Head rearwardrelativetothetorso ) Conversely,themovementofthetorsorearwardrelativetotheheadisreferredtoas posterior and producestheoppositesignofshearforce. TheNkmcriterionisbasedonacombinationofmomentandshearforces,usingcriticalinterceptvalues fortheloadandmoment.theshearforceinterceptvalueisidenticalforanteriororposteriorvalues, being845ninbothdirectionsofloading.however,thecriticalinterceptvalueforthebendingmoment dependsonthedirectionofloading,havingavalueof47.5nminextension(headrotationrearwards), butavalueof88.1nminflexion(headrotationforwards).twochannelswillberequiredtoperformthe Nkmcalculation,upperneckshearforceF x upper,innewtons(n)andmoment,my upper innewtonkmetres (Nm). Typically the shear force will be acquired in kiloknewtons (kn), and so in those cases, a conversionfromkiloknewtons(kn)tonewtons(n)willberequired. Onceithasbeenconfirmedthatbothshearforceandmomentareinthecorrectunits,filterM y upper at CFC600,accordingtoSAEJ211.ToallowcombinationoftheM y upper andfx upper channels,another F x upper channelshouldbeproduced,filteredatcfc600. DuetotheconstructionoftheBioRID,acorrectionmustthenbemadetoconverttheactualmoment measured by the upper neck loadcell into the moment about the Occipital Condyle (OC). Thecorrectedmoment,M y OC isequaltotheupperneckshearforcefx upper multipliedbyaconstant,d, thensubtractedfromthemeasuredmoment,m y upper.calculatethemomentabouttheocaccording tothefollowingequation: WhereD=0.01778m. M y OC (t)=my upper (t) DFx upper (t) ThefourcomponentsofNkmarethencalculatedusingtheupperneckshearforceF x upper andthe correctedmomentabouttheoc,m y OC. Version3.2 July2017 34
Eachchannelfirstneedstobeseparatedintoit spositivekornegativekgoingcomponentsbygenerating fournewchannelsasfollows: Generatetwonewchannels,F xa andf xp,basedonf upper forcechannel. Generatetwonewchannels,M yf andm ye basedonthem y OC momentchannel. Each of the new channels should contain only selected positive or negativekgoing portions of the respectivef x orm y channels,withallunwanteddatapointsbeingreplacedbynullorzerovalue,as definedby: F xa) channelcontainsonlythepositiveportionofthef x upper forcechannelasfollows: IfF x upper (t)>0,thenfxa (t)=f x upper (t),elsefxa (t)=0k F xp channelcontainsonlythenegativeportionofthef x upper forcechannelasfollows: IfF x upper (t)<0,thenfxp (t)=f x upper (t),elsefxp (t)=0k M yf channelcontainsonlythepositiveportionofthem y OC momentchannelasfollows: IfM y OC (t)>0,thenmyf (t)=m y OC (t),elsemyf (t)=0k M ye channelcontainsonlythenegativeportionofthem y OC momentchannelasfollows: IfM y OC (t)<0,thenmye (t)=m y OC (t),elsemye (t)=0. ThefourcomponentsofNkmarethendefinedas: 1. Neck)Extension)Posterior,)N ep,orthecombinednegativekgoingportionoftheshearforce channel(f xp )andnegativekgoingportionsofthemomentchannel(m ye ),asdefinedby: where:f xkint =K845N,M yekint =K47.5Nm. 2. Neck) Extension) Anterior ) N ea, or the combined positivekgoing portion of the shear force channel(f xa )andnegativekgoingportionsofthemomentchannel(m ye ),asdefinedby: where:f xkint =845N,M yekint =K47.5Nm. 3. Neck) Flexion) Posterior ) N fp, or the combined negativekgoing portions of the shear force channel(f xp )andpositivekgoingportionsofthemomentchannel(m yf ),asdefinedby: Version3.2 July2017 35
where:f xkint =K845N,M yfkint =88.1Nm. 4. Neck)Flexion)Anterior N fa,orthecombinedpositivekgoingportionsoftheshearforcechannel (F xa )andpositivekgoingportionsofthemomentchannel(m yf ),asdefinedby: where:f xkint =845N,M yfkint =88.1Nm. Eachofthefourcomponentsshouldbecalculatedasanewdatachannel,usingonlythepositiveKor negativekgoingportionsofthefxandmychannelsasappropriate,andtherelevantcriticalintercept values.maximaforeachofthefourcomponentsshouldbecalculated,consideringonlytheportionof datafromtkzerountiltkhrc (end),asfollows: TheNkmvalueistakenasthemaximumvaluereachedbyanyoneofthefourcomponentsN ea,n ep, N fa,n fp.itshouldbenotedwhichcomponentofthefourreachedthemaximumvalueandthetimeat whichthisoccurred. 10.7) Seatback)Dynamic)Deflection)) Usingasuitabletargettrackingfilmanalysistechnique,measuretheseatbackdynamicopeningfrom thetargetsdefinedintheancapfilmandphotoprotocolasfollows: Definealinebetweentheupperandlowerseatbacktargets,ST2andST3. Defineasecondlinebetweentheforwardandrearwardsledbasetargets,B1andB2. Calculate the angle between these two lines at the TKzero position. The instantaneous seatbackdeflectionisdefinedastheinstantaneousdifferenceinanglebetweenthetkzero positionandthedeflectedposition. Trackthechangeininstantaneousanglebetweenthesetwolines,throughoutthedynamic test. TheSeatbackDynamicOpeningisdefinedasthemaximumchangeinangleachievedatanytime duringthetestbetweenthetzeropositionandtkhrc (end).notethismaximumangle,andthetimeat whichitoccurred. Version3.2 July2017 36
ForseatswithtwoKpointadjustingback,thesameseatbackdeflectioncriterionwillapplyusingtargets ST2andST3,howeveritisrecommendedtousethetwooptionaltargetsST2 andst3 suchthatany contributionfromdeflectioninthetwopointmechanismcanbeunderstood. Version3.2 July2017 37
Appendix)I)Q)Manufacturers)Specified)Settings) Prior to preparation of the sled and seats, the following information should be provided by the manufacturertoallowforthetestpreparation. Adjustment) ) Whiplash)preparation) ) Seatmountinginformation,drawingsetc. Requiredinformation: Floormountingpattern Seatrailangles Seatrailtravel(especiallyifdifferent onbothsides) Fixation/supportinformation Alternatively, the manufacturer may supplysuitableseatmountingstothe laboratory. Heelplaneheight Seatbeltanchoragepositions Anticipatedseatsettings Seatbackangle(e.g.3notchesfromforward) Triggeringinformationforactivesystems(preK tensioners,activehr) Whererequired Seatbackanglereferencepointwrt. SeatreferencepointorHRtube angle. Triggeringsystemdetails,ALL relevantinformation(magnetic, electronic,requiredcurrent/voltage, pulsedurationetc.) Version3.2 July2017 38
Appendix)II)Q)RCAR)Gloria)Jig)&)Calibration)Procedure)(HQPM/HRMD)Calibration) * ) 1) Introduction) ForthepurposesofstandardizedseatingpositionsforanthropomorphictestdevicestheSAE(Society ofautomotiveengineers)designedthehkpointmachine(hkpm)thatallowedauniformdefinitionof thehumanhkpoint.muchofthisworkwascompletedinthelate1950 swiththemachinestillinconstant usetoday.thesaej826procedure[1]wasalsodefinedtoallowconsistentandauthoritativehkpoints andseatingreferencepointstobedefined. Sincetheheightprobewasinsufficienttomeasurebothheightandbacksetaheadformwasdesigned tofitthehkpointmachine,knownastheheadrestraintmeasuringdevice(hrmd)[2].thehrmd probesallowthemeasurementofbothheadrestraintheightandbacksetandareusedtoratewhiplash protectioninthercar(researchcouncilforautomobile)headrestraintmeasurementprocedure [3]. ResearchstudiesfromThatcham[4]andPartnershipforDummyTechnologyandBiomechanics(PDB) 5 havebothshownthelocationofthehkpointondifferenthkpmsshowslittlevariability.howeverthe location of the weight hangers shows some variability, and this location is not controlled by any calibrationprocedure.theweighthangerlocationvariabilitycanbytransferredtothehrmd,andcould affectbacksetmeasurements.thiscouldconsequentlyaffectheadrestraintstaticgeometryratings, soacalibrationprocedurewasdevelopedwiththeaimofcontrollinghkpm&hrmdunits. 2) Scope) ThisprocedureisdesignedtoallowthecalibrationofHKPMandHRMDunitsinisolationortogetherto restrictbuildtolerancevariationsofitemscurrentlypoorlycontrolledandallowmorerepeatableand reproducibleresults. 3) Definitions) 3.1) HQPoint)Machine)(HQPM)) MachinedefinedtolocatetheHKpoint.HKPMscanbeeithertheSAEJ826or3DKHtypeofmanikin, from the US or Europe respectively. It represents a 50th percentile adult male mass and basic morphology.itconsistsofamouldedgrpseat/buttockpanwithametalspinetowhichareattached weightstorepresenttheaveragehumanmale.theunithasonecentralpivotaroundthepelvisapoint which corresponds with that of the HKpoint. The unit has legs and articulated feet which are all adjustabletorepresentdifferentpercentiles.theunithasattachedtothemainpivotaheightprobe andinclinometernotusedintheheadrestraintmeasurementprocess.alsoknownasoscar. 3.1.1) SAE)J826)Seating)Manikin) USversionoftheHKPM. 3.1.2) 3DQH)Seating)Manikin) EuropeanversionoftheHKPMwithouttheforceplungerorthethighbarandwithanadditional1kg mass. * Source:RCARProcedure,Version1.3,July2007 Version3.2 July2017 39
3.2) HRMD) The Head Restraint Measuring Device consists of a cast magnesium or machined aluminium head representingthebasicdimensionsofanadultmale.theheadformisattachedtoanarmrepresenting theneckwithajointatthet1areatoallowtheheadtobelevelledinthexplane.thehrmdis attachedtothehkpmviatwomachinedforksthatfitontotheweighthangerofthehkpm.theunitis locatedviaathirdtonguethatslotsintothehkpmspinebox. Tofacilitatemeasurementofheadrestraintgeometrytwoprobesareattachedtotheheadform.The firstfitsintothecentreoftheheadformandisprofiledtothatofthebackoftheskull.itisabletoslide inandoutoftheheadandhasgradationstoallowbacksetmeasurementstobetaken.asimilarheight probe slides horizontally from the top of the head and allows the height of a head restraint to be measured. WhenfittingtheHKPMtotheHRMDitshouldbenotedthattheHKPMmustfirstbemodifiedtoaccept theunit.theheightbarmustberemovedanditsspacingonthespinespindlebereplacedbytwo washers.fouroftheoriginal8hangerweightsarereplacedbytwolargercylindricalweights.these allowthehrmdforkstolocateontotheweighthanger. 4) Equipment)Requirements) 4.1) HQPM/HRMD)Calibration)Jig) TheHKPM/HRMDunitistobecalibratedtogetherasonesingleunit.TheHKPM/HRMDunitisheldin ajig,knownasgloria,whichwillfacilitatecalibration.thejigisequippedwithfeetateachcornerto facilitatelevelling.thejigholdstheseatpanbythreehorizontalbarsof20mmthicknessthatsupport theseatpanallowingthethighbartobehorizontal.thebackpanissupportedby900mmverticalbar withitsoriginatthebaseoftheseatpanintheareaofthebuttock.thisverticalsupporthasahorizontal barattheleveloftheweighthangerbarandislevel.acordisattachedtothebackpantopreventthe HKPMfallingforward.Nearthetopoftheverticalsupportarescribedmarkingstoindicatethetarget positionofthehrmdheightprobe.thisverticalsupportallowsthecalibrationofthebacksetprobe whenextended. Figure)14:)The)HQPM/HRMD)Calibration)Jig)(GLORIA)) Version3.2 July2017 40
5) Set)Up)and)Assembly)of)GLORIA)Jig) 5.1 Thecalibrationshouldbecarriedoutinaroomwithtemperatureat20 (±5 )andthehrmd, HKPMandGLORIAjigshouldhavebeensoakedinthatsameenvironmentsfor6hourspriorto commencingwithstep3.2. 5.2 TheGLORIAjigshouldbesetonanominallylevelsurfaceandlevelledbyadjustmentofthe threadedfeet.thebaseplateshouldbelevelledusinganinclinometer.surfacestobeusedas referencearethelowerhorizontalsectionofthesiderailsandtheseatpansupportrods.then thefrontandsidesurfacesoftheverticalsupportshouldbecheckedtoensurethecolumnis stillvertical.allfourmeasurementsshouldbeundertakentoensuretheunitislevel.tolerance forthislevellingoperationis±0.1. 5.3 RemovetheHKPointlocatorrodsfromthejigleftandright. 5.4 RemovetheVerticalHKPointtoweighthangerbarsupportsalongwiththeweighthangerguide assemblybyextractingtheremovablerods. 5.5 Loosen the 4 bushes on the seat pan front and rear horizontal support bars and slide them outboard. 6) Preparation)of)HQPM)prior)to)Calibration) 6.1 EnsurethattheHKPMHeadroomProbehasbeenremovedandreplacementspacersinstalled priortothiscalibrationinaccordancewiththehrmdsetupprocedure(seehrmduserguide ICBC1999) 6.EnsurethattheHKPMtobecalibratedhashadthetopedgeoftheweighthanger assemblymodifiedtoacceptthehrmdunit(figure15). Figure)15:)The)modified)weight)hanger)assembly) 6.2 RemovetheHKPointlocatorplugsfromtheseatpanleftandright. 6.3 WhenreKassemblingtheHKPMmanikinwithouttheHeadRoomProbecareshouldbetakento ensurethatthehkpointpivotnutsaretightenedtoatorqueofxkynm.whensetatthistorque themanikinbackpancanfallforwardhencetheuseofthesupportstrap. 7) )Installation)and)Calibration)of)HQPM) 7.1 FoldtheHKPMforwardtoalloweasierinstallationintothejig. Version3.2 July2017 41
7.2 InstalltheHKPMintothejigensuringthattherearoftheseatpanisincontactandsquaretothe rearupperhorizontalbar. 7.3 Centretheseatpanonthehorizontalsupportbarsandslidethebushesinboardallowingthem tocontacttheseatpan.tightenthebushes setscrews. 7.4 AdjusttherearConcentricAdjustmentBarfrombothsidestovisuallyaligntheHKpointholes forwardandaftonthehkpmseatpanwiththecorrespondingholesonthesideplatesofthejig. 7.5 AdjustthelowerConcentricAdjustmentBarfrombothsidestovisuallyaligntheHKpointholes upanddownonthehkpmseatpanwiththecorrespondingholesonthesideplatesofthejig. 7.6 Install the HKPoint locator rods through the vertical support guides and then into the HKpoint guidesofthejigbaseandthenthroughtothehkpointholesonthehkpm(figure16). Figure)16:)HQPoint)locator)bars)installed)through)vertical)support)rods,)jig)side)and)HQPM)HQPoint)location) 7.7 AdjustthefrontConcentricAdjustmentBarfrombothsidestoleveltheTKbar(±0.5 ). 7.8 CheckforhorizontalplayintheHKPMattheHKPoint/torsopivottocheckforexcessivewear. Tightenorreplaceasnecessary.(Seesection4,VIII) 7.9 Raisethebackpanuntilitrestsuponthejig sverticalsupportbarandsecurewiththeelastic straptopreventthebackfromtippingforward(figure17). Version3.2 July2017 42
Figure)17:)HQPM)back)pan)held)by)retaining)strap) 7.10 Installtheweighthangeralignmentfixtureovertheweighthangerstocheckforalignment.The fixtureshouldbeallowedtosettleunderitsownweight,noforceshouldbeappliedtofit.ifthis fixturewillnotlocatethenitindicatesthattheweighthangerbarsareoutofalignmentandwill requiremodificationandtheprocedureshouldbeterminated. 7.11 Removetheweighthangeralignmentfixtureandsupportstrap.Tipthebackpanforwardand installtheblackcylindricalweighthangerbarguidesateachoutboardendofthehkpmweight hangerbarsbetweenthebarsandthejigarms.replacethebackpanandsupportstrap. 7.12 Visuallycheckalignmentoftheweighthangerbarguideswiththeholesinthejigarms. 7.13 Ifalignmentiscorrectthenproceed.IfitisnotpossibleduetointerferencebetweentheHKPM back pan and vertical support then adjustment of the back pan to seat pan offset will be necessary which is outside the scope of this document. This procedure should therefore be terminatedhere. 7.14 IfthealignmentisnotpossibleduetothemisalignmentoftheHKPM sweighthangersupport rodsthentheseshouldbeadjustedtoachievealignment. 7.15 Raisetheweighthangerguidebarseithersideofthejigandinserttheweighthangerlocator pinsthroughtheguidebars,armsandintotheblackcylindricalweighthangerbarguides(figure 18). Figure)18:)Weight)hanger)support)pins)inserted)through)weight)hanger)guide)bars) 8) Calibration)of)the)HQPM)Unit) 8.1 OnceinstalledinthejigchecktoensurethattheflatportionoftheHKPMbackpanisparallelto theverticaljigsupportandthatthegapisnomorethan4mm.itisallowedtotouch(figure19). Version3.2 July2017 43
Zeroto4mmgap betweenhkpmback panandjigsupport Figure)19:)HQPM)installed)into)the)jig)without)HRMD)assembly.)A)check)should)be)made)to)ensure)that)the)gap) between)the)hqpm)back)pan)and)jig)vertical)support)is)no)more)than)4mm) 9) Installation)of)HRMD) 9.1 InstalltheHRMDunitwiththebacksetandheightprobespreKinstalledontotheHKPMassembly asperhrmdusermanualicbc1999 9.2 EnsurethattheplungersfittedtothecentrelocatorforkontheHRMDareingoodconditionand thattheyaretightenoughtoallowtheforktocontacttherearsurfaceofthehkpmweighthanger support. 9.3 LeveltheHRMDheadusingtheadjusterknobandtheintegralspiritlevel.Confirmthatthespirit levelisaccuratebycheckingthattherearsurfaceoftheheadisvertical(±0.3 )withacalibrated digitalinclinometer.ifnotthanadjusttheheadusingtheadjusterknobanddigitalinclinometer untilvertical.theintegralspiritlevelshouldthenbeadjustedorreplacedasappropriate. 9.4 Checkthetruenessoftheheadbubblelevel.Placeadigitalinclinometerontherearsurfaceof theheadandadjustthebubbletolevelusingthescrew.thebubblemustnotthenbealtered duringtheremainingcalibrationprocedureorduringuse. Version3.2 July2017 44
10) Calibration)of)the)HQPM/HRMD)Unit) Figure)20:)HQPM)in)calibration)jig)with)HQpoint)to)arm)supports) OncetheHKPM/HRMDassemblyisinstalledintothejigthefollowingmeasures(withtolerances)should betaken: 10.1 AdjusttheHRMDheightprobeuntilitisincontactwiththeforwardsurfaceofthejigvertical support.ifthelowersurfaceoftheheightprobecontactsthescaleat0mm(±1mm)itisdeemed tobewithincalibration.ifthisisnotpossiblethentheentirehrmdunitshouldbecheckedby themanufacturer(icbc). 10.2 AdjusttheHRMDbacksetprobetocontacttheforwardsurfaceofthejigverticalsupport.The indicatedbacksetshouldread8cm(±1mm).ifthisisnotpossiblethentheentirehrmdunit shouldbereturnedtothemanufacturer. Figure)21:)HRMD)with)backset)and)height)calibration) Version3.2 July2017 45
11) Attachment)of)Torso)Angle)Measuring)Surface) 11.1 Measurethetrunkofthelefthandweighthangerwithadigitalinclinometer. Figure)22:)Measurement)being)taken)of)the)torso)angle)at)the)weight)hanger)trunk)by)a)digital)inclinometer) 11.2 AcalibratedAngleMeasuringsurfaceblockshouldthenbeattachedtoensurethelefthand weighthangertrunktoensurethatanangleof90 (±0.3 isindicated). 11.3 Iftheangleofthelefthandweighthangerisnotat90 (±0.3)thenacalibratedandadjusted surfaceblockshouldbeinstalledinplaceofthestandarditem. 11.4 Checktheangleoftheinstalledcalibratedsurfaceblockwithadigitalinclinometertoensure thatitshowsareadingof90 (±0.3 ). Figure)23:)Calibrated)Torso)angle)measurement)surface)block)attached)to)trunk)of)weight)hanger)arm) 12) Marking)of)HQPM/HRMD)Units) 12.1 AnindeliblemetallicselfadhesivelabelshouldbeattachedtotheHKPMonLHbackpanspine tobackpanbracket. 12.2 AnidenticallabelshouldbeattachedtotheHRMDabovethebuildplate. 12.3 Theselabelsshouldhavethefollowinginformation: Version3.2 July2017 CalibrationDate 46
CalibrationCentre Serialnumbersofthetwounits Thelabelshouldalsocontainthefollowingtext: CalibratedtoHKPM/HRMDstandard Figure)24:)The)label)on)the)HQPM) Figure)25:)The)label)on)the)HRMD) 13) Checking)the)HQPoint)Torque) 13.1 After the two machines are calibrated together, set the torque on the HKpoint weight hanger pivotto3.4nm(30inklbs).thiscanbedonewithatorquewrench. References) 1. Society of Automotive Engineers (1995). SAE J826 Devices for use in defining and measuring vehicle seating accommodation.societyofautomotiveengineers,detroit.saej826. 2. Gane,J.andJ.Pedder(2000).MeasurementofVehicleHeadRestraintGeometry.SAECongress1999,Detroit.1999K 01K0639. 3. ResearchCouncilforAutomobileRepairs(2001).AProcedureforEvaluatingMotorVehicleHeadRestraints.Research CouncilforAutomobileRepairs. 4. ThatchamktheMotorInsuranceRepairResearchCentre(2005).OSCAR&HRMDMeasurementStudy.RCARBioRID UserMeeting,April2005. 5. PartnershipforDummyTechnologyandBiomechanics(PDB)(2005).ResearchoftolerancesattheHKPointMachine andhrmd.rcarbioridusermeeting,april2005. 6. InsuranceCorporationforBritishColumbia(ICBC)(1999).HeadRestraintMeasuringDeviceUserGuide.Vancouver, Canada. Version3.2 July2017 47