Procedures for Assembly, Disassembly, and Inspection (PADI) of the Hybrid III 5 th Percentile Adult Female Crash Test Dummy (HIII-5F), Alpha Version

Transcription

1 Procedures for Assembly, Disassembly, and Inspection (PADI) of the Hybrid III 5 th Percentile Adult Female Crash Test Dummy (HIII-5F), Alpha Version revised JUNE 2002 National Highway Traffic Safety Administration

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3 TABLE OF CONTENTS Page Introduction...1 Construction...3 Clothing...3 Instrumentation...4 Head and Neck Instrumentation...18 Thoracic Instrumentation...31 Chest Deflection and Spine-mounted Instrumentation...38 Lower Torso Instrumentation...57 Pelvis Instrumentation...63 Femur Instrumentation...69 Lower Leg Instrumentation...76 Procedures for Assembly, Disassembly, and Inspection...5 Head and Neck Removal...6 Head...12 Neck...15 Thorax...21 Chest Deflection and Transducer Assembly...32 Shoulder Assembly...41 Arm Assemblies...46 Lower Torso...51 Pelvis...59 Leg Assemblies...65 Knee Assemblies...70 Lower Legs...74 Ankle/Foot Assemblies...77 External Dimensions...82 Mass Measurements...86 Instrumentation Cable Routing...92 Appendix A. Flesh Repair... A-1 Appendix B. Joint Torque Adjustments...B-1 Appendix C. Procedure for Checking Recorded Sensor Polarity...C-1 Appendix D. Procedure for Determining Moment of Inertia of Impact Probes... D-1 Appendix E. Procedures for Determining the Free Air Resonant Frequency of Probes Used for Dummy Calibration...E-1 i

4 LIST OF FIGURES Page Figure 1. Hybrid III 5 th Percentile Adult Female Dummy...1 Figure 2. Extending shoe tongue for ease of fit...4 Figure 3. Complete Hybrid III Small Adult Female Test Dummy...5 Figure 4. Head and neck assembly...6 Figure 5. Chest jacket removed...7 Figure 6. Detaching the head and neck from the torso...7 Figure 7. Neck components...8 Figure 8. Releasing neck pivot pin set screw...9 Figure 9. Nodding block compression tool...10 Figure 10. Nodding block compression tool in use...10 Figure 11. Skull cap removal...10 Figure 12. Brass washers inside neck structural replacement...11 Figure 13. Removing head accelerometer mount...13 Figure 14. Removing neck structural replacement...13 Figure 15. Guiding neck structural replacement out of the skull...14 Figure 16. Removing head skin...14 Figure 17. Neck assembly...15 Figure 18. Neck disassembly...16 Figure 19. Neck cable removal...16 Figure 20. Neck components...17 Figure 21. Nodding block orientation...17 Figure 22. Upper neck load cell...18 Figure 23. Upper neck load cell cables...19 Figure 24. Head accelerometer orientation with respect to the upper neck load cell...19 Figure 25. Upper torso assembly...22 Figure 26. Removing shoulder bolt...23 Figure 27. Detaching the shoulder assembly...23 Figure 28. Shoulder pivot components...24 Figure 29. Removing the lower neck bracket...24 Figure 30. Removing rib stiffener strips...25 Figure 31. Rib stiffener strip identification...25 Figure 32. Rib removal...26 Figure 33. Removing upper rib stops...26 Figure 34. Chest deflection slider removal...27 Figure 35. Chest depth gage...27 Figure 36. Checking rib assembly for permanent deformation...28 Figure 37. Location of the four sternum stops...28 Figure 38. Orientation of rib support with respect to the rib and spine box...30 Figure 39. Using a C-clamp to compress the clavicle bumper...30 Figure 40. Orientation of sternum-mounted accelerometers...31 Figure 41. Chest deflection assembly...33 Figure 42. Separating the upper and lower torso...33 ii

5 Figure 43. Removing the spine box from the spine tower...34 LIST OF FIGURES Page Figure 44. Removing the chest accelerometer mount...34 Figure 45. Chest accelerometer mounting bracket removal...35 Figure 46. Detaching the adapter assembly...35 Figure 47. Removing the chest deflection transducer assembly...36 Figure 48. Detaching the transducer arm assembly...36 Figure 49. Removing the chest potentiometer from the bracket...37 Figure 50. Orientation of chest triaxial accelerometer array...38 Figure 51. Spine-mounted accelerometers...39 Figure 52. Close-up of spine-mounted accelerometers to demonstrate orientation...39 Figure 53. Thoracic spine load cell...40 Figure 54. Clavicle assembly...42 Figure 55. Clavicle assembly section view...42 Figure 56. Separating the clavicle link from the clavicle...43 Figure 57. Clavicle link spacers, spring stop, and shoulder screw...43 Figure 58. Removing the shoulder yoke...44 Figure 59. Components of the clavicle...44 Figure 60. Removing the steel stop from the shoulder yoke assembly...44 Figure 61. Arm assembly...47 Figure 62. Removing the elbow pivot bolt...48 Figure 63. Components of the elbow joint...48 Figure 64. Removing wrist from lower arm...49 Figure 65. Removing wrist rotation assembly...49 Figure 66. Removing the upper arm lower part...50 Figure 67. Pelvis assembly...52 Figure 68. Lumbar spine assembly, lumbar-thorax adapter, and lumbar-pelvic adapter...53 Figure 69. Removing the lumbar-pelvic adapter...54 Figure 70. Removing the lumbar-pelvic adapter...54 Figure 71. Detaching the lumbar spine from the pelvic adapter...55 Figure 72. Detaching the thoracic adapter from the lumbar spine...55 Figure 73. Components of the lumbar spine and lumbar-thoracic adapter...56 Figure 74. Lumbar pad removed from lumbar-pelvis adapter...57 Figure 75. Lumbar spine load cell...58 Figure 76. Loosening the femur set screw...59 Figure 77. Removing the femur flange from pelvis...59 Figure 78. Removal of the femur bolt...60 Figure 79. Typical femur removal tool...60 Figure 80. Removing the ASIS load cell simulator bolts...61 Figure 81. Removal of ASIS load cell simulator from pelvis assembly...61 Figure 82. Location of H-point...62 Figure 83. H-point tool...62 Figure 84. ASIS load cell...63 iii

6 Figure 85. Orientation of pelvic accelerometer in mounting bracket...64 Figure 86. Pelvic accelerometers installed into pelvis assembly...64 LIST OF FIGURES Page Figure 87. Leg assembly...66 Figure 88. Separating leg into upper and lower segments...67 Figure 89. Detaching the upper leg from femur load cell replacement...67 Figure 90. Detaching knee from femur load cell replacement...68 Figure 91. Components of the upper leg and knee...68 Figure 92. Femur load cell...69 Figure 93. Knee assembly...71 Figure 94. Knee slider assembly...72 Figure 95. Components of the knee assembly...72 Figure 96. Lower leg structural replacement...74 Figure 97. Detaching the ankle/foot assembly...74 Figure 98. Removing the flesh from the lower leg structural replacement...75 Figure 99. Detaching the knee clevis...75 Figure 100. Instrumented lower leg...76 Figure 101. Ankle assembly...78 Figure 102. Detaching the ankle assembly from the foot...79 Figure 103. Loosening the ankle friction set screw...79 Figure 104. Removing the ankle bumper...80 Figure 105. Components of the ankle assembly...80 Figure 106. Foot heel pad...81 Figure 107. External dimensions...85 Figure 108. Load cells and cable routing...92 Figure 109. Head accelerometer and upper neck load cell cable routing...93 Figure 110. Cable slack to allow for head motion...93 Figure 111. Routing the head instrumentation cables through the rib cage...94 Figure 112. Cable bundle exiting the thoracic cavity below rib # Figure 113. Grounding cable...95 Figure 114. Routing of sternum accelerometer cables...96 Figure 115. Routing the cables from the interior of the spine box...96 Figure 116. Routing of cables in the abdominal area...97 Figure 117. Pelvis accelerometer cable routing...98 Figure 118. Femur load cell cable routing...98 Figure 119. Femur load cell cable shown taped to the side of the pelvis...99 Figure 120. Cable routing under chest jacket (rear view) Figure 121. Cable routing under chest jacket (side view) Figure B1. 1G setting of shoulder yoke clevis bolt...b-3 Figure B2. 1G setting of shoulder rotation hex nut...b-3 Figure B3. 1G setting of elbow rotation bolt...b-4 Figure B4. 1G setting of elbow pivot bolt...b-4 Figure B5. 1G setting of wrist pivot bolt...b-5 iv

7 Figure B6. 1G setting of wrist rotation bolt...b-5 Figure B7. 1G setting of femur ball set screw...b-6 Figure B8. 1G setting of knee pivot bolt...b-7 Figure B9. 1G setting of ankle ball set screw...b-7 Figure C1. Polarity of x-axis accelerometer data channel...c-3 Figure C2. Polarity of y-axis accelerometer data channel...c-3 Figure C3. Polarity of z-axis accelerometer data channel...c-4 Figure C4. Accelerometer perpendicular to the force of gravity in two orientation 180 degrees apart...c-4 Figure D1. Determination of moment of inertia of probes used for dummy calibration... D-1 Figure E1. Probe impacted with hammer to excite resonance...e-1 Figure E2. Probe accelerometer response versus time...e-2 Figure E3. Probe accelerometer response between milliseconds...e-3 v

8 LIST OF TABLES Page Table 1. Threaded Fastener Abbreviations...2 Table 2. Fastener Torque Specification...3 Table 3. Instrumentation...4 Table 4. Hybrid III Small Adult Female External Dimensions...83 Table 5. Hybrid III Small Adult Female External Dimension Details...84 Table 6. Hybrid III Small Adult Female Total and Segment Masses...86 Table 7. Head Segment...86 Table 8. Neck Segment...87 Table 9. Upper Torso Segment...87 Table 10. Lower Torso Segment...88 Table 11. Left Upper Leg Segment...88 Table 12. Right Upper Leg Segment...89 Table 13. Left hand Segment...89 Table 14. Right Hand Segment...89 Table 15. Left Lower Leg Segment...90 Table 16. Right Lower Leg Segment...90 Table 17. Left Foot Segment...90 Table 18. Right Foot Segment...90 Table 19. Upper Arm Segment (left and right)...91 Table 20. Lower Arm Segment (left and right)...91 Table C1. Instrumentation for Small Female Dummy...C-7 Table C2. Dummy Manipulations for Checking Recorded Instrumentation Polarity Relative to SAE J211 Sign Convention for Positive Polarity...C-8 vi

9 INTRODUCTION The National Highway Traffic Safety Administration has prepared this document under the title AProcedures for Assembly, Disassembly, and Inspection of the Hybrid-III 5 th Percentile Adult Female Crash Test Dummy,@ otherwise known as PADI for the H-III5F. The document is based on drawings and test procedures described in the Final Rule that incorporated the H-III5F crash test dummy into Part 572 as subpart O (alpha version). The H-III5F is designed for use in the seated position. Its anthropometry, weight distribution, motion ranges, and general body segments= configuration reflect those of a small adult female. A photograph of the Hybrid III small adult female, H-III5F, is shown in Figure 1. 1 Revised JUNE 2002

10 Purpose This document contains the procedures for disassembly, assembly, and adjustment of the dummy for the purpose of inspecting and preparing it for testing. Calibration tests are specified in Part 572 Subpart O Final Rule to ensure that the dummy is capable of repeatable and reproducible performance while its responses remain within the specified biofidelity corridors. This document serves as a guide for the user to properly inspect, assemble, and adjust the dummy=s various parts as needed. Each section is written to be independent so that, depending on the user=s objectives, the various sections can be referred to directly. Part Numbers All part numbers in this document refer to the drawing package in 49 CFR, Part 572 Subpart O. Copies of the drawing package for this dummy can be obtained from Reprographic Technologies, 9000 Virginia Manor Road, Beltsville, MD 20705; Telephone: (301) Abbreviations The abbreviations used throughout the document are listed in Table 1. Table 1. Threaded Fastener Abbreviations Abbreviation SHCS FHCS BHCS SHSS SSCP RHMS Description Socket Head Cap Screw Flat Head Cap Screw Button Head Cap Screw Socket Head Shoulder Screw Socket Screw, Cup Point Round Head Machine Screw Torque Specifications Unless specified otherwise, the torque requirements for the fasteners used throughout the dummy are shown in Table 2. 2 Revised JUNE 2002

11 Table 2. Torque Specifications Screw Type Size Torque (in-lb) Torque (N-m) SHCS/BHCS / / SHSS 1/ CONSTRUCTION 5/ Following are some of the design highlights of the small female dummy: $ Cast aluminum skull and skull cap with removable vinyl head and skull cap skins. The vinyl skin has been tuned to give humanlike response for forehead impacts. $ A rubber segmented neck which has been tuned to give humanlike angle versus moment response in dynamic flexion (forward bending) and extension (rearward bending) articulations. $ A neck cable passing through the neck=s longitudinal axis controls the stretching responses and provides increased durability against extreme axial tension forces. $ A two-piece aluminum clavicle-link assembly contains integrally cast scapulae to provide a realistic interface with shoulder belts. $ Six spring steel ribs with polymer-based damping material approximate the human chest forcedeflection response properties. A sternum assembly connects to the front end of the ribs and contains a slider mechanism capable of measuring deflection of the rib cage relative to the thoracic spine. $ Top and bottom rib stops are incorporated to control the vertical movement of the rib cage. $ A straight lumbar spine provides the proper sitting posture for a person of small stature in the driving position. $ The pelvis contains the capability for incorporating submarining-indicating transducers. The pelvis has a humanlike shape. $ A knee slider mechanism allows for displacement of the tibia relative to the femur, simulating ligament response. $ Consistent joint articulation is achieved by use of a constant friction moveable joint assembly. CLOTHING When used in testing, the dummy should wear a snug-fitting, size medium T-shirt and size small pants, both made of 100% knit cotton. The T-shirt=s neckline should be chosen to ensure that a shoulder belt cannot contact the dummy=s skin and the pants should end above the dummy=s knee. The T-shirt and pants should each weigh no more than 0.14 kg ( 0.3 lb). The shoes are women=s low dress black oxfords, size 7 2 W that meet military specification MIL-S-21711E. Talc may also be 3 Revised JUNE 2002

12 applied to the foot to facilitate placement of the shoe on the foot. If the foot cannot be placed in the shoe after application of talc, it may be necessary to modify the shoe by extending the shoe=s tongue by approximately one inch as shown in Fig. 2. Any additional clothing requirements are prescribed in accordance with the Federal Motor Vehicle Safety Standard testing procedure or specifications. INSTRUMENTATION The dummy is capable of using the instrumentation shown in Table 3 to evaluate various types of occupant restraint systems. Table 3. Instrumentation Instrument Part Number No. of Channels Comments Head Accelerometers SA572-S4 3 Upper Neck Load Cell SA572-S11 6 Lower Neck Load Cell SA572-S27 6 optional Chest Accelerometers SA572-S4 3 Chest Deflection Transducer SA572-S51 1 Sternum Accelerometers SA572-S4 3 optional Spine Accelerometers SA572-S4 3 optional Thoracic Spine Load Cell SA572-S28 6 optional Lumbar Spine Load Cell SA572-S15 5 optional Pelvis Accelerometers SA572-S4 3 Iliac Spine (A.S.I.S.) Load Cells SA572-S16 2 each optional Single Axis Femur Load Cell SA572-S14 1 each Multi-axis Femur Load Cell SA572-S29 6 each optional 4 Revised JUNE 2002

13 DISASSEMBLY/REASSEMBLY The complete H-III5F dummy consists of 6 major assembly groups as shown in Figure 3. The subsequent section of this document will discuss the disassembly and reassembly of each group. Assembly Group Part Number Head X Neck Upper Torso Lower Torso Arms, Left Arms, Right Legs, Left Legs, Right Revised JUNE 2002

14 HEAD AND NECK REMOVAL Description Part Number Figure Number Item Number SHCS, 3/8-16 x Neck Bracket, Upper SHCS, x 5/ Bib Assembly Pivot Pin Nodding Block Clamping Washer Fig. 4. Head and neck assembly 6

15 Before beginning the disassembly of the head and neck, it may be desirable to completely remove the chest jacket. Unzip the jacket at the torso posterior and remove it by pulling the jacket forward allowing the arms to slide through the arm holes in the jacket (reference Figs. 5). Fig. 5. Chest jacket removal The head and neck are disassembled from the upper torso by removing the 3/8-16 x 1 SHCS (Item 1, Fig. 3) and the clamping washer (Item 7, Fig. 3) that holds the upper neck bracket to the lower bracket (see Fig. 6.). The clamping washer is curved on one side in order to mate with the radius on the underside of the lower neck bracket; be sure to install this properly during reassembly. After removing the 3/8-16 x 1 SHCS, the neck will remain attached via the bib assembly; allow the head and neck to hang forward until the neck can be released from the bib. Fig. 6. Detaching head and neck from torso 7

16 Release the head and neck assembly from the bib assembly and upper neck bracket by removing the hex jam nut, the lower neck cable bushing, and the four x 5/8 SHCS (Item 3, Fig. 3). The lower neck cable bushing, which is made of Delrin and has a Atop hat@ shape, is critical for minimizing electronic noise in the dummy; be certain that it is installed properly during reassembly. Fig. 7 below, provides an exploded view of the items located at the base of the neck. Fig. 7. Neck components 8

17 Before attempting to remove the pivot pin, loosen the two 8-32 x 1/4 SSCP that hold the pivot pin in the neck load cell or neck structural replacement (Fig. 8). It is recommended that the set screws not be completely removed; it is sufficient to loosen the set screws just enough to allow the pivot pin to be removed. This will minimize the risk of losing the set screws. To remove the head from the neck, a nodding block compression tool may be required (Fig. 9). In order to remove the pivot pin (Item 5, Fig. 3) without damaging it, it will be necessary to compress the nodding blocks (Item 6, Fig. 3) located between the head and the neck. Compression of the nodding blocks removes the applied load from the pivot pin. Next, slide the lower plate of the nodding block compression tool in between two of the aluminum disks of the neck. Turn the handle of the tool until the top plate contacts the surface of the head skin (Fig. 10). Carefully continue to apply pressure by turning the handle until the nodding blocks are compressed enough to relieve the load on the pivot pin. The pivot pin should now slide out of the load cell or load cell replacement, but may require a light tap with a rubber mallet. If the pin still resists removal, readjust the pressure applied by the compression tool until the pin moves with less resistance. Note: There are several designs of the nodding block compression tool used in the industry, some of which require the skull cap to be removed first. To remove the skull cap, remove the four x 2 SHCS that hold the skull cap in place (Fig. 11). Fig. 8. Releasing neck pivot pin set screw 9

18 Fig. 9. Nodding block compression Tool. Fig. 10. Nodding block compression Tool in use Fig. 11. Skull cap removal After the pin has been extracted, remove the nodding block compression tool. The neck is now free to be pulled away from the head assembly. There are two brass washers located inside of the pivot pin joint that will fall out as the head and neck are separated (Fig. 12). These washers are custom sized to provide the proper fit with each specific head and neck assembly; care should be taken so that these washers are not confused with those of other head and neck assemblies. 10

19 Fig. 12. Brass washer inside neck structural replacement Note: Newly purchased washers ( ) should be trimmed using the following procedure: 1. Trimming can be accomplished in several ways. The easiest is to rub the washers on coarse sandpaper or a file and check the fit of the joint. Repeat the trimming until the nodding joint and the load cell can be assembled snugly with the washers. 2. The fit of the joint and load cell should be snug but easily assembled. Inspection Inspect the neck for tears or breaks. Replace a neck that has any tears, breaks, or cracks. Reassembly $ Reattach the neck to the head. This may require use of the nodding block compression tool. Insert the neck pivot pin into neck load cell or structural replacement. A light tap with a mallet may be required. $ Tighten the two 8-32 x 1/4 SSCP that fix the pivot pin to the neck structural replacement. $ Reattach the skull cap to the back of the head. $ Reattach the neck and the upper neck bracket to the sternum bib. Be sure to properly install the lower neck cable bushing. The hex jam nut shall be torqued to in-lbs. $ Position the zero degree mark on the upper neck bracket so that it is aligned with the zero degree mark on the neck bracket. $ Reattach the upper neck bracket to the lower neck bracket using the 3/8-16 x 1 SHCS and the clamping washer. 11

20 HEAD Part number reference; no figure provided. Description Part Number Structural Replacement 6-axis Neck Transducer X Head Accelerometer Mount Skull, 6-Axis Neck Skull Cap Head Skin Skin, Skull Cap Head Accelerometers Triaxial Mounting Block Upper Neck Load Cell, 6-axis SA572-S4 SA572-S80 SA572-S11 SHCS, x 3/ SHCS, 1/4-28 x 7/ With the head now separated from the neck, the remaining head components can be disassembled. If the skull cap has not already been removed as necessitated by the nodding block compression tool, remove it now (Fig. 11). If the neck load cell is installed, disconnect the instrumentation cables. Also remove the head triaxial accelerometer array if it is installed. This is done by removing the four x 3/8 SHCS that hold the head accelerometer mount to the top of the neck load cell or structural replacement. The holes located at the top of the head are used to access these fasteners. Slip the appropriate Allen wrench through the access holes to loosen the four SHCS (Fig. 13). With these screws removed, the head accelerometer mount can be removed from the head through the back of the skull. 12

21 Fig. 13. Removing head accelerometer mount Remove the four 1/4-28 x 7/8 SHCS and washers that attach the six-channel upper neck load cell or structural replacement to the skull (Fig. 14). The upper neck load cell or structural replacement is removed from inside the head by guiding it out of the back of the head (Fig. 15). Note the orientation of the load cell structural replacement in Fig. 15 as this orientation is critical to removing it. Fig. 14. Removing neck structural replacement 13

22 Fig. 15. Guiding neck structural replacement out of the skull The head skin can be removed from the head assembly by lifting the skin away from the skull casting at the back of the skull and the flesh from the assembly (Fig. 16). Fig. 16. Removing head skin Inspection $ Check the head skin for tears or cracks. Replace head skins which have damage in the forehead area; do not attempt to repair them as this will have an affect on test results. If necessary, repair the head skin as described in Appendix A. $ Check the skull casting for cracks, dents, and other damage. Replace the skull if damaged. Reassembly $ Place the head skin back on to the skull casting. Be sure that the head skin fits snuggly, particularly in the forehead area. $ Insert load cell structural replacement into head; reattach using the four 1/4-28 x 7/8 SHCS. $ Reattach the skull cap using the four x 2 SHCS. 14

23 NECK Description Part Number Figure Number Item Number Nodding Joint Assembly Neck Cable Nodding Blocks Neck Cable Bushing, Upper Neck Cable Bushing, Lower Molded Rubber Neck ½-20 Hex Jam Nut FHCS, x 5/ Washer, 1.06 OD x 0.53 ID x SHCS, x 5/ Fig. 17. Neck assembly 15

24 The neck can be disassembled by removing the four x 5/8 FHCS (Item 9, Fig. 17) from the top of the nodding joint assembly (Fig. 18). With the nodding joint removed, the neck cable (Item 2, Fig. 17) can be pulled out of the neck. Remove the Delrin neck cable bushing (Items 4, Fig. 17) from the ball-end of the cable. Figure 20 depicts the various components of the neck assembly. Fig. 18. Neck disassembly Fig. 19. Neck cable removal 16

25 Figure 20. Neck components Inspection During reassembly, check the neck for deformation, tears, or breaks in the rubber. Replace the neck if any damage is observed. Check the neck cable by observing the strands. If they are not tightly wound, frayed, or the cable appears larger in diameter on one end, replace the cable. If the cable cannot be properly torqued, replace the cable. Proper orientation of the nodding blocks is critical. They must be installed so that the 90 degree angle is toward the base of the head and the 60 degree angle is toward the nodding joint (Fig. 21). If not oriented properly, the blocks will likely cause the neck responses in flexion and extension to be incorrect. Inspect the nodding blocks for deformation. Deformed blocks will cause inadequate loading of the nodding joint and should be replaced. Check the hardness of the nodding blocks often with a Shore A type Durometer. The specification is Reassembly The upper end of the neck is machined to accept the ball-end of the neck cable. During the reassembly, make sure that this area is free of any extraneous rubber material before installing the cable. Install the upper neck cable bushing into the cup at the upper end of the neck. Insert the cable into the neck such that the ball-end of the cable is seated in the cup at the upper end of the neck. Reattach the nodding joint assembly to the upper end of the neck using the four x 5/8 FHCS. Install the nodding blocks in their proper orientation (Fig. 21). Fig. 21. Nodding block orientation 17

26 Head and Neck Instrumentation The head and neck contain several provisions for instrumentation, including: head CG triaxial accelerometer array upper neck load cell (SA572-S11) lower neck load cell (SA572-S27; optional) This section will describe the installation of these items. Upper Neck Load Cell (SA572-S11) Begin the process with the head removed from the neck. Next, remove the neck load cell structural replacement as described in the head disassembly section. Orient the upper neck load cell such that it will fit inside the skull casting through the back of the head. Once it is inside the skull, rotate the neck load cell such that the two cable ports are located at the posterior of the skull and insert the load cell through the hole at the bottom of the skull casting until the mounting surface is flush with the base of the skull casting (Fig. 22). Attach the four 1/4-28 x 7/8 SHCS and washers through the bottom of the skull and into the load cell. Do not attach the load cell cables until after the head accelerometer array has been installed. Fig. 23 shows the cables attached to the load cell. Fig. 22. Upper neck load cell Head CG Triaxial Accelerometer Array First attach the individual accelerometers (SA572-S4) to the S4 Triaxial Accelerometer Mounting Block (SA572-S80). The accelerometers are mounted to the block such that an imaginary axis passing through their seismic masses and along the direction of primary sensitivity would intersect at a single point. Next, attach the mounting block to the head accelerometer mount ( ). Again, the orientation of the accelerometers is critical; mount the block as shown in Fig. 24. Next, insert the head accelerometer mount into the back of the head; Figure 24 demonstrates the orientation of the head accelerometer mount relative to the upper neck load cell; note that the accelerometer mount cannot be attached to the upper neck load cell before it is installed into the skull as the two items will not fit through the opening in the back of the skull simultaneously. Finish by installing the four x 3/8 SHCS which attach the head accelerometer mount to the upper neck load cell. 18

27 Fig. 23. Upper neck load cell cables Fig. 23. Upper neck load cell Fig. 24. Head accelerometer orientation with respect to the upper neck load cell. 19

28 Lower Neck Load Cell (SA572-S27; optional) This description assumes that the head and neck have already been removed from the upper torso. Refer back to the section on removal of the head and neck if necessary. Detach the lower neck bracket from the upper torso by removing the four 1/4-20 x 3/4 SHCS that hold it in place. Reattach the neck and the lower neck load cell to the sternum bib. Be sure to properly install the lower neck cable bushing. The hex jam nut shall be torqued to in-lbs. Attach the lower neck load cell to the upper torso with the four 1/4-20 x 3/4 SHCS. 20

29 THORAX Description Part Number Figure Number Item Number Lower Neck Bracket Spine Weldment Rear Rib Support Upper Rib Stop Assembly Sternum Slider Behind Rib Strips Stiffener Strip Bib Assembly Clavicle Link Pivot Nut Shoulder Bumper Clavicle Link Washer (Delrin) Clavicle Link Washer (Urethane) BHCS, x 5/ SHCS, 1/4-20 x 5/ Shoulder Assembly left -381 right Rib Set Lower Rib Stop Assembly Adaptor Assembly Sternum Stop Chest Transducer Assembly SHSS, 3/8 x BHCS, x 3/ Washer,.281 ID x.5 OD x SHCS, 1/4-20 x 3/ SHCS, 5/16-18 x 1/ BHCS, x 3/ Lower Neck Load Cell SA572-S27 n/a n/a Sternum Accelerometers SA572-S4 n/a n/a 21 Revised JUNE 2002

30 Fig. 25. Upper torso assembly 22 Revised JUNE 2002

31 Begin disassembling the torso by removing the arm assemblies. Remove the 3/8 x 1 SHSS which attaches each arm to the shoulder (Fig. 26). Pay close attention to placement of the washers and bushings in the shoulder. Proper assembly of these items are necessary in achieving the one G joint adjustments (ref. Appendix B). If the chest flesh was not removed during disassembly of the head and neck, remove it now. Also, lean the upper torso back and remove the abdomen insert. Fig. 26. Removing shoulder bolt Detach the shoulder assembly by removing the 3/8 x 1 SHSS (Item 24, Fig. 25) from the front of the spine box and pulling the assembly up and away from the torso (Fig. 27). When the shoulder is removed, the two clavicle link pivot washers (Item 11, Fig 25), the urethane pivot nut washer (Item 14, Fig. 25), and the pivot nut (Item 9, Fig. 25) will fall from the assembly (Fig. 28). Fig. 27. Detaching the shoulder assembly 23 Revised JUNE 2002

32 Fig. 28. Shoulder pivot components The shoulder bumper (Item 10, Figure 25), a AU@ shaped black rubber part, can now be removed. These bumpers provide tension for the clavicle link and also aid in noise damping. Next, remove the lower neck bracket from the spine box. To remove the bracket, remove the four 1/4-20 x 3/4 SHCS (Item 28, Figure 25) and washers (see Fig. 29). Fig. 29. Removing lower neck bracket 24 Revised JUNE 2002

33 Now the ribs can be disassembled. Before disassembling, note the orientation of the rib stiffener strips and the behind rib strips; in particular, recognize that there is a distinct top and bottom to each strip. This orientation is important for proper reassembly of the thorax (Fig. 31). First, detach the rib stiffeners from the bib assembly by removing the twelve x 5/8 BHCS (Item 15, Fig. 25) (see Fig. 30). The behind rib strips will fall inside the thorax when these screws are removed. The sternum bib can be removed by pulling upward and allowing the transducer arm ball to fall from the groove in the rear side of the transducer arm slider. Fig. 30 Removing rib stiffener strips Fig. 31. Rib stiffener strip identification 25 Revised JUNE 2002

34 Next, remove the twelve x 3/8 BHCS (Item 30, Fig. 25) at the rear of the spine box (see Fig. 32). After these screws are removed, the six rib stiffeners and the ribs themselves can be removed. If the individual ribs are not already identified, it is recommended that they be numbered 1 through 6, starting at the top and working down. This will be useful later when reassembling the thorax. When removing the ribs from the thorax, it may be necessary to slightly spread the ribs open to fit them around the spine box. Removing the ribs should be done carefully to insure that they are not opened so wide so as to permanently deform their shape. Fig. 32. Rib removal The upper rib stops (Item 4, Fig. 25) can now be removed by removing the two x 2 SHCS on the left and right sides (see Fig. 33). The lower rib stops (Item 20, Fig. 25) are not recommended to be removed unless the Delrin stops have been damaged. Fig. 33. Removing upper rib stop 26 Revised JUNE 2002

35 The chest deflection transducer slider can be removed from the bib assembly by removing the twelve x 3/4 BHCS (item 25, Fig. 25) (see Fig. 34) Fig. 34. Chest deflection slider removal Inspection $ Inspect the ribs for any damage. In particular, look for damage to the damping material and any debonding of the damping material from the steel ribs. Replace any ribs that have suffered significant damage. $ Using the chest depth gage, check the rib assembly for any permanent deformation (reference Fig. 35 and 36). With the rib cage fully assembled, insert the appropriate side of the gage between ribs #1 and #2. Hold surface A on the handle against the spine box surface to which rib #1 is attached on the spine box. If the end of the depth gage makes contact with the behind rib strip, then the chest depth at rib #1 is not acceptable. Surface B of the depth gage is used similarly to check the depth between ribs #5 and #6. Hold surface B on the handle against the spine box surface to which rib #5 is attached on the spine. If the end of the depth gage makes contact with the behind rib strip, then the chest depth at rib #6 is not acceptable. Ribs of unacceptable depth must be replaced. $ Check for the presence of all four sternum stops (see Fig. 37). If a sternum stop is loose, damaged, or lost, it can be replaced. The stops can be glued in place using epoxy cement. When replacing stops, be sure that they are in the proper position and do not interfere with the motion of the chest deflection transducer assembly. Fig. 35. Chest depth gage 27 Revised JUNE 2002

36 Fig. 36. Checking rib assembly for permanent deformation Fig. 37. Location of the four sternum stops 28 Revised JUNE 2002

37 Reassembly $ Reattach the upper rib stops if they have been removed. $ Reattach the ribs and ribs stiffeners to the back of the spine box. There are several important aspects to this procedure: $ Make sure that the proper rib is attached at the proper location; rib #1 is the upper most rib and rib #2 is second from the top and so on. $ The rib stiffeners must be installed such that the beveled ends of the stiffeners face the ribs (see Fig. 38). Failure to install the rib stiffeners in the proper orientation will result in improper thoracic response to impacts. $ Use the correct size fastener to mount the ribs and rib stiffeners to the spine box. The correct fasteners are the x 3/8 BHCS. $ Reattach the chest deflection transducer slider to the bib assembly using the twelve x 3/4 BHCS. Insert the ball of the chest transducer assembly into the groove in the rear side of the transducer arm slider. Then reattach the bib assembly to the ribs. During installation of the stiffener strips and the behind rib strips, make sure that the proper orientation of these units is maintained (refer back to Fig. 31). $ Reattach the lower neck bracket using the 1/4-20 x 3/4 SHCS. $ Install the shoulder bumpers, the Delrin clavicle link washers, urethane pivot nut washer, and the pivot nut. The Delrin clavicle link washers have a machined flat on the outside radius. This flat must mate with the flat on the other clavicle link washer for the opposite shoulder assembly in order to assemble the shoulders properly. $ Install the shoulder assembly to the spine box. A small C-clamp will be needed to compress the shoulder bumper enough to allow for insertion of the shoulder screw (see Fig. 39). Be careful not to apply too much pressure to the shoulder as this could cause the aluminum casting to crack. $ Place the chest jacket on the upper torso. $ Reattach the arm assemblies to the upper torso. Be certain to assemble the washers and bushings in the shoulder in the proper orientation (refer to the Arm Assembly section if needed). 29 Revised JUNE 2002

38 Fig. 38. Orientation of rib support with respect to the rib and spine box. Fig. 39. Using a C-clamp to compress the clavicle bumper 30 Revised JUNE 2002

39 Thoracic Instrumentation The thorax contains provisions for the following instrumentation: $ chest CG triaxial array $ sternum-mounted uniaxial accelerometers $ spine-mounted uniaxial accelerometers $ chest deflection transducer $ thoracic spine load cell This section will discuss only the details of the sternum-mounted uniaxial accelerometers. The chest CG triaxial array, spine-mounted uniaxial accelerometers, chest deflection transducer, and thoracic spine load cell will be covered in the Chest Deflection and Transducer Assembly section. Sternum-mounted Uniaxial Accelerometers The front of the chest deflection transducer slider contains provisions for mounting three uniaxial accelerometers (SA572-S4). Each accelerometer is mounted to the slider using two 0-80 x 1/8 SHCS. The chest deflection transducer slider contains integral cable routing channels. These channels provide an indication of the orientation of the accelerometers. Fig. 40 has also been included to document the orientation of the accelerometers. Fig. 40. Orientation of sternum-mount accelerometer 31 Revised JUNE 2002

40 CHEST DEFLECTION AND TRANSDUCER ASSEMBLY Description Part Number Figure Number Item Number Spine Mounting Assembly Load Cell Mount Thoracic Spine Load Cell Structural Replacement Chest Accelerometer Mounting Bracket Transducer Arm Assembly Molded Stop Assembly Chest Accelerometer Mount H Chest Deflection Transducer Slider SSCP, 4-40 x 3/ Potentiometer SA572-S Potentiometer Bracket Arm Connector SHCS, x 5/ SHCS, 5/16-18 x BHCS, 1/4-20 x Chest Accelerometers SA572-S4 n/a n/a Triaxial Mounting Block SA572-S80 n/a n/a Spine Accelerometers SA572-S4 n/a n/a Thoracic Spine Load Cell SA572-S28 n/a n/a 32

41 Fig. 41. Chest deflection assembly To disassemble the chest deflection transducer assembly, the upper torso must first be separated from the lower torso. This is accomplished by removing the four 1/4-20 x 5/8 SHCS (item 16, Fig. 25) at the top of the lumbar spine mounting assembly (Fig. 42). Fig. 42. Separating the upper and lower torso With these four bolts removed, the upper torso can be lifted off of the lower torso. If the spine mounted accelerometers are installed, remove them now. This is done by removing the two 4-40 x 1/4 SHCS that hold each of the three accelerometer mounting plates to the spine box (refer to the Instrumentation instructions at the end of this section for more details). 33

42 Next, remove the six 5/16-18 x 2 SHCS (item 29, Fig. 25) that appear on the sides of the spine box (Fig. 43). Fig. 43. Removing the spine box from the spine tower. With these six bolts removed, the adapter assembly (sometimes referred to as the spine tower) can now be removed from the spine box. The adapter assembly includes the spine mounting assembly, the thoracic load cell or load cell simulator, and the chest accelerometer mount bracket. The chest accelerometer triaxial array, if installed, can be disassembled by removing the four x 2 SHCS that hold the chest accelerometer mount to the accelerometer bracket (Fig. 44). Fig. 44. Removing the chest accelerometer mount 34

43 Remove the four x 5/16 SHCS (Item 15, Fig. 41) that hold the chest accelerometer mounting bracket to the load cell or structural replacement (Fig. 45). Fig. 45. Chest accelerometer mounting bracket removal The adapter assembly can be disassembled by first removing the four 5/16-18 x 2 SHCS (Item 18, Fig. 41) that attach the load cell or structural replacement to the spine mounting assembly. These fasteners are located at the bottom of the adapter assembly (Fig. 46) Fig. 46. Detaching the adaptor assembly 35

44 Next, remove the chest deflection transducer assembly. This is accomplished by removing the 1/4-20 x 2 BHCS (item 19, Fig. 41) that secures the potentiometer bracket to the spine mounting assembly (Fig. 47). Fig. 47. Removing the chest deflection transducer assembly The transducer arm assembly can be removed by loosening the 4-40 SSCP (item 11, Fig. 41) in the potentiometer connector (Fig. 48). Fig. 48. Detaching the transducer arm assembly 36

45 Remove the potentiometer from the potentiometer bracket by loosening the jam nut (item 8, Fig. 41) (Fig. 49). Fig. 49 Removing the potentiometer from the bracket. Inspection $ Inspect for the presence of and the condition of the sternum stops. If they are missing or damaged, replace them. The sternum stops can be reattached using an epoxy cement. $ Inspect the chest deflection potentiometer by rotating the pot arm through its range of motion. The motion should feel smooth and free of restrictions; if it does not feel smooth, have it inspected by an electronics technician. Reassembly $ Slide the potentiometer body into the bracket, making sure that the roll pin in the bracket is properly aligned on the potentiometer body. This insures that the potentiometer body will not turn. Tighten the jam nut. $ Reattach the transducer arm to the arm connector. $ Reattach the potentiometer bracket to the adapter assembly. $ Reattach the chest accelerometer mounting bracket to the load cell simulator. $ Install the chest accelerometer mounting block to the mounting bracket. If installing accelerometers, make sure that the accelerometers are properly oriented (reference Fig. 50). $ Reattach the load cell simulator to the spine mounting assembly. If the thoracic spine load cell is being installed, position the transducer so that the cables are toward the rear of the spine box (Fig. 53). This will help to prevent damage to the cables when inserting the adapter assembly into the spine box (next step). $ Place the adapter assembly inside the spine box. Align the holes in the thoracic load cell or load cell simulator with the holes in the spine box and insert the six 5/16-18 x 2 SHCS. Tighten the bolts only after all six have been aligned and started. $ Install the three spine mounted accelerometers if needed. $ Place the thorax on the upper torso and reattach it to the lumbar spine mount assembly using the four 1/4-20 x 5/8 SHCS. 37

46 Instrumentation The chest deflection assembly contains provisions for the following instrumentation: $ chest CG triaxial accelerometer array $ spine-mounted uniaxial accelerometers $ chest deflection transducer $ thoracic spine load cell Chest CG Triaxial Accelerometer Array First attach the individual accelerometers (SA572-S4) to the S4 Triaxial Accelerometer Mounting Block (SA572-S80) using two 0-80 x 1/8 SHCS. The accelerometers are mounted to the block such that an imaginary axis passing through their seismic masses and along the direction of primary sensitivity would intersect at a single point. Next, attach the mounting block to the chest accelerometer mount (H ). Next, attach the chest accelerometer mount to the chest accelerometer bracket. Figure 50 shows the chest CG triaxial accelerometer array mounted to the chest accelerometer bracket in the proper orientation. Fig. 50. Orientation of the chest triaxial accelerometer array. Spine-mounted Uniaxial Accelerometers The front of the spine box contains provisions for mounting three uniaxial accelerometers (SA572-S4). Each accelerometer is mounted to the appropriate accelerometer mounting plate using two 0-80 x 1/8 SHCS. Next, the mounting plates are attached to the spine box using two 4-40 x 1/4 SHCS in the orientation shown in Figures 51 and 52. It is recommended that particular attention be given to the location and orientation of each of the three spine accelerometer mounting plates so that they are reassembled properly. Although they appear to be similar, each one is unique. All three accelerometers are mounted such that their direction of positive polarity are towards the posterior of the dummy. 38

47 Fig. 51. Spine-mounted accelerometer Fig. 52 Close-up of spine-mounted accelerometers to demonstrate orientation 39

48 Chest Deflection Transducer In general, the chest deflection transducer remains installed in the dummy and is typically only removed for calibration and/or inspection purposes. Refer back to the appropriate section for details on removing and installing the chest deflection transducer. Thoracic Spine Load Cell Attach the thoracic spine load cell to the load cell mount using the four 5/16-18 x 2 SHCS. Be sure that the instrumentation cables are oriented such that they are facing the rear side of the dummy (Fig. 53). Fig. 53. Thoracic spine load cell. 40

49 SHOULDER ASSEMBLY Description Part Number Figure Number Item Number Clavicle Link Clavicle (machined) (left), -335 (right) (left), -337 (right) Clavicle Stop Spring Clavicle Spacers SHCS, x 3/ Shoulder Stop Assembly Clavicle Stop Spring Clavicle Spacers Shoulder Yoke Steel Stop Shoulder Stop Assembly Shoulder Yoke Pivot Bushing Shoulder Yoke Pivot Washer Retaining Washer Shoulder Joint Spring Washer Steel Washer Clavicle Link Washer SHSS, 3/8 x SHCS, 6-32 x SHCS, x 3/ Lock Nut, 5/ Clavicular Link Bearing

50 Fig. 54. Clavicle Assembly Fig. 55. Clavicle assembly section view 42

51 Instructions for removing the clavicle from the upper torso are contained in the Thorax section; refer to that section if necessary. Remove the 3/8 x 1 SHSS (item 17, Fig. 55) to separate the clavicle link from the clavicle (Fig. 56). After removing the shoulder screw and pulling the two pieces apart, the two clavicle spacers (Item 4, Fig.54) and the urethane spring stop (Item 3, Fig. 54) can be removed from the assembly. Figure 57 below shows the spacers and spring stop. Fig. 56. Separating the clavicle link from the clavicle Fig. 57. Clavicle link spacers, spring stop, and shoulder screw Next, remove the shoulder yoke by loosening the 5/16-18 lock nut (item 20, Fig. 55) located inside the machine clavicle (Fig. 58). The shoulder yoke can then pulled away from the machined clavicle. After the shoulder yoke is removed the steel shoulder yoke washer (item 15, Fig. 55), retaining washer (item 13, Fig. 55), and urethane spring washer (Item 14, Fig. 55) will be free to be removed from the machined clavicle as well. Fig. 59 below shows the various clavicle components. 43

52 Fig. 58. Removing the shoulder yoke Fig. 59. Components of the clavicle The steel stop (Item 9, Fig. 55) on the shoulder yoke can be disassembled by removing the two 6-32 x 2 Nylok SHCS (Fig. 60). The steel stop works in conjunction with the stop assembly mounted to the machined clavicle to control the range of motion of the arm. Fig. 60. Removing the steel stop from the shoulder yoke. 44

53 Inspection $ Inspect the plastic and Delrin pieces - the shoulder yoke pivot washer and bearing, and the clavicle spacers - for damage. Also inspect the urethane pieces - the clavicle stop spring and the shoulder yoke spring washer. Replace any pieces which are damaged. $ Inspect the clavicle link and machined clavicle castings for structural damage and cracking. Replace any casting that is damaged. Reassembly $ Reattach the steel stop to the shoulder yoke if it was removed. $ Install the shoulder yoke bushing and washer on to the two dowel pins which are pressed into the machined clavicle. $ Replace the shoulder yoke retaining washer, urethane spring washer, and steel shoulder yoke washer into the machined clavicle. Insert the shoulder yoke and align the holes in the retaining washer with the press pins in the shoulder yoke. Reattach the 5/16-18 lock nut to the shoulder yoke. $ If removed, replace the urethane spring stop into the clavicle link. Place the two Delrin clavicle spacers onto the machined clavicle and attach the machined clavicle to the clavicle link with the 3/8 x 1 SHSS. 45

54 ARM ASSEMBLIES Description Part Number Figure Number Item Number Upper Arm Molded Assembly Elbow Washer Elbow Bushing Elbow Pivot Nut Elbow Pivot Washer Lower Arm Molded Assembly Wrist Rotation Assembly Hand Assembly (left), -723 (right) 61 8 Upper Arm, Lower Part SHCS, 3/8-16 x SHSS, 3/8 x SHSS, 5/16 x 3/ Washer

55 Fig. 61. Arm assembly 47

56 If the arms have not already been detached from the upper torso, remove them now (refer back to the Thorax section if needed). Begin by separating the arm into its upper and lower portions. This is done by removing the 3/8 x 1 SHSS (item 12, Fig. 61) at the elbow joint (see Fig. 62). Pay attention to the configuration of the components in the elbow joint so that they can be reassembled properly later (Fig. 61 and 63). Fig. 62. Removing the elbow pivot bolt Fig. 63. Components of the elbow joint 48

57 Detaching the hand from the lower arm is achieved by removing the 3/8-16 x 1 SHCS (Item 10, Fig. 61) at the base of the hand (see Fig. 64). Fig. 64. Removing wrist from lower arm Next, the wrist rotation assembly (Item 7, Fig. 61) can be detached from the lower arm, as well, by removing the 5/16 x 3/4 SHSS (Item 13, Fig. 61) located at the wrist end of the lower arm (see Fig. 65). Fig. 65. Removing wrist rotation assembly 49

58 In the upper arm near the elbow exists a feature which allows the lower arm to rotate relative to the upper arm. This feature, referred to as the upper arm lower part (Item 9, Fig. 61), can be detached by removing the 5/16 x 1-1/4 SHSS from the upper arm (Fig. 66). The upper arm lower part can then be pulled away from the upper arm through the arm flesh. Fig. 66. Removing upper arm lower part Inspection $ Inspect the arm flesh for damage. If the damage is minor, repair the flesh referring to Appendix A. For more significant damage, the arm may be returned to the manufacturer for remolding. $ Inspect the washers and bushing of the elbow joint, replacing any part that has sustained serious damage. Reassembly $ Reattach the wrist rotation assembly to the wrist end of the lower arm. $ Reattach the hand to the wrist rotation assembly. $ Reattach the upper arm lower part to the elbow end of the upper arm. $ Finally, reattach the lower arm to the upper arm. Pay close attention to reassemble all of the washers and bushings in the proper order (refer to Figs. 61 and 63). Proper assembly of this joint is critical to its performance. 50

59 LOWER TORSO Description Part Number Figure Number Item Number Molded Pelvic Assembly Molded Lumbar Spine Spine Cable Lumbar-Thorax Adapter Lumbar-Pelvic Adapter Abdominal Insert SHCS, 5/16-18 x 5/ SHCS, 1/4-20 x 5/ SHCS, 5/16-18 x 7/ Jam Nut, Accelerometer Mount SHCS, x Pelvic Plunger Set Screw Femur with Bumper left, -421 right Modified Screw Anterior Superior Iliac Spine Load Cell Simulator left, -2 right SHCS, 3/8-24 x 3/ Lumbar Cable Insert, Upper Lumbar Cable Insert, Lower Femur Bumper left, -427 right Pelvis Accelerometer SA572-S4 n/a n/a Triaxial Mounting Block SA572-S80 n/a n/a Iliac Spine (A.S.I.S.) Load Cells SA572-S16 n/a n/a 51

60 Fig. 67. Pelvis Assembly 52

61 Description Part Number Figure Number Item Number Upper Lumbar Cable Insert Lower Lumbar Cable Insert Lumbar Pad SHCP, 1/4-20 x 3/ Lumbar Spine Load Cell SA572-S15 n/a n/a Fig. 68. Lumbar spine assembly, lumbar-thorax adaptor, and lumbar-pelvic adaptor 53

62 Lumbar Spine The first step in disassembling the lower torso is to remove the lumbar spine assembly, lumbarthorax adapter, and lumbar-pelvic adapter. Remove the two 5/16-18 x 5/8 SHCS (Item 7, Fig.67) located at the base of the spine, inside the abdominal insert area (see Fig. 69) Fig. 69. Removing lumbar-pelvic adaptor. Next, remove the two 5/16-18 x 7/8 SHCS (Item 9, Fig. 67) which are located inside the pelvic instrumentation cavity at the rear of the pelvis (see Fig. 70). The lumbar spine assembly, lumbarthorax adapter, and lumbar-pelvic adapter can now be removed from the pelvis. Fig. 70. Removing lumbar-pelvic adaptor 54

63 Detach the lumbar spine assembly (item 2, Fig. 67) from the lumbar-pelvis adapter (item 5, Fig. 67) by removing the four 1/4-20 x 3/4 SHCS (item 4, Fig. 68) (see Fig. 71). Fig. 71. Detaching the lumbar spine from the Pelvic adapter Next, separate the lumbar spine assembly from the lumbar-thoracic adapter (item 4, Fig. 67). First remove the two 1/4-20 x 5/8 SHCS (item 8, Fig. 67) (see Fig.72). Then remove the 2-20 jam nut (item 10, Fig. 67). The lumbar thoracic-adapter and the upper lumbar cable insert (item 1, Fig. 68) will be free from the assembly Fig. 72. Detaching the thoracic adapter plate from the lumbar spine The cable (item 3, Fig. 67) can now be removed from the lumbar spine. Finally, remove the lower lumbar cable spine insert (item 2, Fig. 68) from the lumbar spine. 55

64 Fig. 73 below shows the various components of the lumbar spine assembly. Fig. 73. Components of the lumbar spine assembly and lumbar-thoracic adaptor 56

65 Inspection $ Inspect the lumbar spine for cracking in the molded rubber; replace it if damaged. $ Inspect the upper and lower cable spine inserts for any damage; replace them if damaged. $ Inspect the lumbar spine cable for broken or frayed wires; replace it if damaged. $ Inspect the lumbar-pelvis adapter for presence of the lumbar pad (item 3, Fig. 68). The lumbar spine pad is important for preventing electronic noise caused by the spine cable contacting the lumbar-pelvis adapter. Fig. 74. Lumbar pad removed from lumbar-pelvis adapter Reassembly $ Install the lower lumbar cable insert in the lumbar spine. $ Insert the spine cable into the lumbar spine. $ Place the lumbar-thoracic adapter over the threaded end of the spine cable. Place the upper lumbar cable insert onto the threaded end of the spine cable and insert it through the lumbar thoracic adapter and into the lumbar spine. Install the two 1/4-20 x 5/8 SHCS that hold the lumbar thoracic adapter to the lumbar spine. $ Fasten the 2-20 jam nut to the threaded end of the spine cable. The jam nut should be torqued to 11 +/- 1 in-lbs during assembly and should be checked before using the dummy for testing. Note: The spine cable nut should not be left torqued when the dummy is in storage. This may cause permanent deformation to the spine. $ Make certain that the lumbar spine pad is installed in the lumbar-pelvic adapter. Reattach the lumbar-pelvic adapter to the lumbar spine using the four 1/4-20 x 3/4 SHCS. Instrumentation The lower torso contains provisions for the following instrumentation: $ lumbar spine load cell $ anterior superior iliac spine (ASIS) load cells $ pelvis triaxial accelerometer array The details for installing the lumbar spine load cell will be discussed here; the ASIS load cells and pelvis triaxial array will be handled in the pelvis section. 57

66 Lumbar Spine Load Cell These instructions assume that the lumbar-pelvic adapter has already been removed from the lower torso. If it has not already been removed, remove it now referring back the appropriate section. Attach the lumbar spine load cell to the molded lumbar spine assembly using the four 1/4-20 x 3/4 SHCS. Next, attach the load cell to the pelvic assembly using the two 5/16-18 x 5/8 SHCS in the front and the two 5/16-18 x 7/8 SHCS in the rear. Fig. 75 demonstrates the proper orientation of the lumbar load cell with respect to the pelvis assembly. Fig. 75. Lumbar spine load cell 58

67 PELVIS The femurs can be removed from the lower torso; however, due to the difficult nature of the task, it is recommended that they only be removed when damage to the femur is suspected. The first step in removing the femurs from the lower torso is to loosen the femur plunger set screws (item 13, Fig. 67). These screws are located in the abdominal insert area (Fig. 76) and are used to adjust the femur joint to the one G specification for testing (see Appendix B). Fig. 76. Loosening femur plunger set screw The femur flange is disassembled from the pelvis bone by removing the three x ½ SHCS (Item 12, Fig. 67). These screws are located in the access holes on the sides of the pelvis (see Fig. 77). Fig. 77. Removing femur flange from pelvis 59

68 With these three screws removed, the femurs can be removed from the pelvis flesh. Removing the femur is a difficult task and requires use of a tool which simulates the upper leg bone (Fig. 79). First detach the leg assemblies by removing the femur bolt (p/n ) from each femur (see Fig. 78). Once the femur bolt has been removed, pull the leg assemblies from the femur. Fig. 78. Removal of the femur bolt Attach the femur removal tool (Fig. 79) to the femur using the femur bolt. Use the tool to pull the femur from the pelvis flesh. Fig. 79. Typical femur removal tool Next, detach the anterior superior iliac spine (ASIS) load cell simulators (Item 16, Fig. 67) from the pelvis. Each ASIS load cell simulator is held in place with two 3/8-24 x 3/4 SHCS (Item 17, Fig. 67). To remove theses fasteners, use the access ports located on the rear side of the pelvis (see Fig. 80). 60

69 Fig. 80. Removing the ASIS load cell simulator bolts The ASIS load cell simulators can then be removed by guiding them out of the pelvis flesh, through the rectangular cut-out sections provided (see Fig. 81) Fig. 81. Removal of ASIS load cell simulator from pelvis assembly H-Point Features The H-Point is a dummy reference point which is commonly used for positioning the dummy in a test vehicle seat. The H-Point represents the location of the centerline for both the right and left 61

70 hip sockets. A square hole is present in the pelvis assembly which can be used for determining the location of the H-point. The H-point is located 68 mm (2.69 in) forward and 59 mm (2.33 in) below the center of the square hole (see Fig. 82). In practice, it is common to use an H-point tool (TE- 2504) for finding the dummy s H-point (see Fig. 83). The tool is also useful for determining the pelvic angle. Fig. 82 Location of H-point Fig. 83. H-point tool Inspection Inspect the pelvis flesh for cracks and/or tears; repair damaged flesh (reference Appendix A). Inspect the pelvis plunger set screws for the presence and condition of the nylon which push down on the femur to achieve the 1G torque setting. If the nylon is damaged, replace the pelvic plunger set screws. 62

71 Reassembly If the femurs have been removed, reattach them first. Insert the femurs through the pelvis flesh. Fasten the femur flange to the pelvis bone using the three x ½ SHCS. Reassemble the ASIS structural replacements. Insert the structural replacements into the pelvis through the rectangular cut-out section in the abdominal area of the pelvis. Install the 3/8-24 x 3/4 SHCS (two for each ASIS structural replacement). Reassemble the femur plunger set screws if they have been removed from the pelvis. Instrumentation The pelvis contains provisions for the following instrumentation: Anterior Superior Iliac Spine (ASIS) Load Cells Pelvic Triaxial Accelerometer Array Anterior Superior Iliac Spine (ASIS) Load Cells Begin by removing the ASIS structural replacements (refer back to the appropriate section if needed). Insert the ASIS load cell through the rectangular cut-out section in the abdominal area of the pelvis such that the cables are facing toward the interior of the dummy s abdomen (Fig. 84). Install the 3/8-24 x 3/4 SHCS (two for each ASIS load cell). Fig. 84. ASIS Load Cell 63

72 Pelvic Triaxial Accelerometer Array First attach the individual accelerometers (SA572-S4) to the S4 Triaxial Accelerometer Mounting Block (SA572-S80) using two 0-80 x 1/8 SHCS. The accelerometers are mounted to the block such that an imaginary axis passing through their seismic masses and along the direction of primary sensitivity would intersect at a single point. Next, attach the mounting block to the pelvic accelerometer mount (part number ) (Fig. 85). Insert the pelvic accelerometer mount into the pelvic cavity and attach the mount using the 3/8-16 x 3/4 SHCS (Fig. 86). Cover the pelvic cavity with the cover plate, routing the cable wires out through the access hole provided and using the x ½ SHCS to attach the cover. Fig. 85. Orientation of pelvic accelerometer in mounting Bracket Fig. 86. Pelvic accelerometers installed into pelvis cavity 64

73 LEG ASSEMBLY Description Part Number Figure Number Item Number Upper Leg Weldment Upper Leg Flesh (left), -503 (right) L (left), -530R (right) SHCS, 3/8-16 x 1-1/ Sliding Knee Assembly L (left), -528R (right) 87 4 SHCS, 3/8-16 x 1-3/ Femur Load Cell Simulator FHCS, x 3/ Lower Leg Structural Replacement Lower Leg Flesh Bolt, Ankle to Leg A Ankle Assembly Ankle Bumper Assembly SHSS, 1/4 x 5/ Foot Assembly (left), -651 (right) Single Axis Femur Load Cell SA572-S14 n/a n/a Multi-axis Femur Load Cell SA572-S29 n/a n/a 65

74 Fig. 87. Leg assembly 66

75 The leg assemblies should already be removed from the lower torso assembly; if not, remove them by removing the femur bolt (p/n ) from each leg (reference Fig. 78). Begin by separating the leg into its upper and lower segments. This is done by removing the eight x 3/8 FHCS (Item 7, Fig. 87) (four on each side of the knee) found at the knee joint (see Fig. 88). Fig. 88. Separating leg into upper and lower segments Next, separate the upper leg weldment from the femur load cell structural replacement by removing the 3/8-16 x 1-2 SHCS (Item 3, Fig. 87) that connects the two items (see Fig. 89). Fig. 89. Detaching upper leg from femur load cell replacement 67

76 Now the knee can be separated from the femur load cell structural replacement. This is done by removing the 3/8-16 x 1-3/4 SHCS (Item 5, Fig. 87) located nearest the knee (see Fig. 90). Figure 91 demonstrates the various components of the upper leg. Fig. 90. Detaching knee from load cell replacement Fig. 91. Components of the upper leg and knee Inspection $ Inspect the upper leg flesh for damage. The flesh can be removed from the upper leg by pushing the upper leg weldment out at the end that attaches to the pelvis. If the flesh has sustained minor damage, repair it by referring to Appendix A. If the damage is beyond repair, replace it with a new unit. Reassembly $ Reattach the femur load cell structural replacement to the knee using the 3/8-16 x 1-3/4 SHCS. Pay attention to use the correct bolt. $ If the upper leg flesh was removed, replace it on the upper leg weldment. $ Reattach the upper leg to the femur load cell structural replacement using the 3/8-16 x 1-1/2 SHCS. $ Reattach the upper and lower leg segments using the eight x 3/8 FHCS. 68

77 Instrumentation The leg contains provisions for mounting a femur load cell. There are two type of femur load cells: the single axis femur load cell (SA572-S14) and the multiple axis femur load cell (SA572-S29). Both load cells are installed in the same manner. Femur Load Cell Remove the femur load cell structural replacement. Insert the femur load cell into the knee in the orientation shown in Fig. 92. Reinstall the 3/8-16 x 1-3/4 SHCS. Insert the opposite of the load cell into the upper leg weldment and reinstall the 3/8-16 x 1-1/2 SHCS. Fig. 92. Femur load cell 69

78 KNEE ASSEMBLY Description Part Number Figure Number Item Number Knee Flesh Knee Insert Machined Knee Cap Knee Slider Assembly, Right Linear Pot Shaft Support, Right Rotation Stop Arm Rotation Stop Cover Shoulder Bolt Washer Compression Washer BHCS, 8-32 x SHCS, 8-32 x Potentiometer Shaft Pin Potentiometer SA572-S RDMS, 1-72 x 5/

79 Fig. 93. Knee Assembly 71

80 Detach the knee slider assembly (Item 4, Fig. 93) from the knee by removing the modified shoulder bolt (Item 10, Fig. 93) (see Fig. 94). Fig. 94. Knee slider removal This modified shoulder bolt controls the 1G joint torque setting for the knee joint (refer to Appendix B). Once removed, the inboard and outboard halves of the knee slider will be free of the knee cap. The outboard slider contains a steel washer (item 11, Fig. 93) and two compressible spring washers (item 12, Fig. 93). Be careful not to lose these parts as they are critical to achieving the 1G joint torque setting. The various components of the knee assembly are shown in Fig. 95 below. Fig. 95. Components of the knee assembly 72

81 Located between the knee flesh and the machined knee cap is the knee insert (Item 2, Fig. 93). The knee insert is critical to the system performance in the knee impact calibration test. It can be accessed by removing the knee flesh from the knee cap. Inspection $ Inspect the knee insert for any damage. If it is damaged, replace it. $ Inspect the knee flesh for any damage. Repair all minor damage (reference Appendix A). If the damage is significant, have the knee flesh replaced with a new one. Reassembly $ If the knee insert was removed, reinstall it now. Make sure that the knee insert is properly installed and fully seated inside the knee flesh. $ Reattach the knee slider assembly using the knee joint shoulder screw. Make sure that the compression washers and steel washer are present and in the right positions. The compression washers go into the outboard slider first; the steel washer fits directly under the head of the knee joint shoulder screw. 73

82 LOWER LEG Description Part Number Figure Number Item Number Lower Leg Weldment Dowel Pin, 1/8 x 3/ Knee Clevis Assembly SHCS, 1/4-28 x Fig. 96. Lower leg structural replacement Detach the ankle/foot assembly from the lower leg by removing the modified shoulder bolt located at the ankle (Item 10, Fig. 87) (see Fig. 97). Fig. 97. Detaching the ankle/foot assembly 74

83 With the modified shoulder bolt removed, the ankle/foot assembly will slide off the lower portion of the lower leg. Remove the flesh from the lower leg structural replacement. This is best accomplished by pulling on the knee clevis while holding the flesh. Fig. 98 below shows the flesh being removed from the structural replacement. Fig. 98. Removing flesh from the lower leg structural replacement The knee clevis can be detached from the lower leg by removing the four 1/4-28 x 2 SHCS (Item 4, Fig. 96) (see Fig. 99). Fig. 99. Detaching the knee clevis 75

84 Inspection Inspect the lower leg flesh for any damage. Repair all minor damage (reference Appendix A). If the damage is significant, have the lower leg flesh replaced with a new one. Reassembly $ Attach the knee clevis to the lower leg using the four 1/4-28 x 2 SHCS. $ Reassemble the lower leg structural replacement into the lower leg flesh. Insert the ankle end of the structural replacement into knee of the flesh. Continue to push the structural replacement until it is completely inside the flesh. If necessary, a small amount of talcom powder may be used to assist in the procedure. $ Reattach the ankle/foot assembly to the lower leg using the modified shoulder bolt. Instrumentation Instrumented lower legs are commercially available for optional use in the lower leg assembly. The instrumented lower leg replaces the lower leg structural replacement in the assembly. Simply insert the instrumented lower leg into the flesh and attach the ankle/foot assembly. A picture of the instrumented lower leg appears in Fig Fig Instrumented lower leg 76

85 ANKLE/FOOT ASSEMBLY Description Part Number Figure Number Item Number Ankle, Upper Shell Ankle, Lower Shell Ankle Shaft Stop Pin Retainer Dowel Pin, 3/16 x 3/ Ankle Friction Pad A SSCP, 5/16-18 x 3/ SSCP, 8-32 x 1/ BHCS, 6-32 x Ankle to Leg Attachment Bolt A FHCS, 6-32 x SSCP, 5/16-18 x 3/

86 78

87 Detach the foot from the ankle by removing the 1/4 x 5/8 SHSS (item 13, Fig. 87). Fig Detaching the ankle assembly from the foot Next disassemble the ankle. Begin by loosening the 5/16-18 x 3/8 SSCP (item 12, Fig. 101). This set screw, in conjunction with the ankle friction pad, provides the joint torque for the ankle joint. It is used for setting the 1G joint torque requirement (see Appendix B). Fig Loosening the ankle friction set screw 79

88 Next, remove the four 6-32 x 2 BHCS (item 9, Fig. 101) that hold the ankle bumper (item 12, Fig. 87) to the lower ankle shell (see Fig. 104). With these four fasteners removed, the ankle bumper can now be removed. Fig Removing the ankle bumper Releasing the pressure on the two 8-32 x 1/4 SSCP set screws (item 8, Fig. 101) will allow the brass stop pin retainer (item 4, Fig. 101) to be removed from the upper ankle shell. The 3/16 x 3/8 dowel pin (item 5, Fig. 101) can also be extracted now. Remove the three 6-32 x 2 FHCS (item 11, Fig. 101) and the lower ankle shell can now be separated from the upper ankle shell. The ankle shaft (item 3, Fig. 101) is now free to be removed. The various components of the ankle assembly are displayed in Fig. 105 below. Fig Component of the ankle assembly 80

89 The foot is comprised of two basic components: the molded foot assembly and the Ensolite heel pad. The heel pad can be removed for inspection by simply sliding it out the side of the foot (Fig 106). Fig Foot heel pad Inspection $ Inspect the ball-end of the ankle shaft and the hemispherical portions of the upper and lower ankle shells for any damage or galling. Any damage in these areas can cause problems with proper ankle joint torque. Replace any damaged parts. $ Inspect the ankle friction pad (item 5, Fig.101) for presence and condition. This item also plays an important role in determining the proper joint torque. $ Inspect the ankle bumper for any damage; replace it if damaged. $ Inspect the foot for the presence and condition of the heel pad. If the heel pad is damaged, replace it with a new one. Reassembly $ Insert the ankle shaft into the upper ankle shell. $ Insert the 3/16 x 3/8 dowel pin into the upper ankle shell and align it into the slot in the ankle shaft. $ Place the lower ankle shell over the ankle shaft and assemble the lower shell to the upper shell using the three 6-32 x 2 FHCS. $ Insert the stop pin retainer into the upper ankle shell and fasten it in place using the two 8-32 x 1/4 SSCP. $ Install the ankle bumper using the four 6-32 x 2 BHCS. $ Make certain that the ankle friction pad is inserted into the upper ankle shell and tighten the 5/16-18 x 3/8 SSCP until the proper joint torque is achieved (reference Appendix B). 81

90 EXTERNAL DIMENSIONS 1. Remove the dummy=s chest jacket and the abdominal insert. 2. Seat the dummy on a flat, rigid, smooth, clean, dry, horizontal surface as shown in Fig The seating surface must be at least 406 mm (16 in) wide and 406 mm (16 in) deep, with a vertical section at least 406 mm (16 in) wide and 914 mm (36 in) high attached to the rear of the seating fixture. The dummy=s midsaggital plane is vertical and centered on the test surface. 3. Remove the four 1/4-20 x 5/8 SHCS that attach the lumbar spine to the thoracic spine. Lift the upper torso off of the lower torso. Check the torque on the 2-20 jam nut that attaches to the end of the lumbar spine cable. The torque should be Nm (10-12 in-lbs). 4. Reassemble the upper torso to the lower torso. 5. Secure the dummy to the test fixture so that the button head screws (that attach the top rib to the spine box) and the adapter plate (that connects the upper torso to the lower torso) are against the vertical surface of the fixture. The rear surface of the buttocks now contacts the fixture. 6. Position the dummy=s H-point so it is /- 2.5 mm (3.3 +/- 0.1 in) above the horizontal seating surface and /- 2.5 mm (5.8 +/- 0.1 in) forward of the rear vertical surface of the fixture. (Note: the H-point is located 68.6 mm (2.7 in) forward and 58.4 (2.3 in) downward from the center of the square hole in the pelvis.) 7. Extend the dummy=s neck so that the base of the skull is level both fore-and-aft and side-toside, within 0.5 degrees. The rear surface of the skull cap should be /- 2.5 mm (1.8 +/- 0.1 in) from the vertical surface of the test fixture. A strap or bungee cord may be placed around the forehead of the dummy to stabilize the head in this position. 8. Position the upper and lower legs parallel to the midsagittal plane so the centerline between the knee pivot and the screw attaching the ankle to the lower tibia is vertical. 9. Position the feet parallel to the dummy=s midsagittal plane with the bottoms horizontal and parallel to the seating surface. 10. Position the upper arms downward vertically so the centerline between the shoulders and elbow pivots is parallel to the rear vertical surface of the fixture. 11. Position the lower arms horizontally so the centerline between the elbow and wrist pivots is parallel to the seat surface. 12. Record the dimensions listed in Table 4, except for dimension Y and Z (reference Fig. 107). 13. Install the abdominal insert and chest jacket. Reposition the dummy on the test fixture. The head need not be level as previously specified. 14. Mark the locations and record the dimensions Y, Z, AA, and BB as specified in Table 4 and Fig

91 Table 4. Hybrid III Small Adult Female External Dimensions Dim. Description Spec. English (in) Tolerance +/- Spec. Metric (mm) Tolerance +/- A Total Sitting Height B Shoulder Pivot Height C H-Point Height D H-Point Forward E Shoulder Pivot from Back Line F Thigh Clearance G Back of Elbow to Wrist Point H Head Back from Backline I Shoulder to Elbow Length J Elbow Rest Height K Buttock to Knee Length L Popliteal Height M Knee Pivot Height N Buttock Popliteal Length O Chest Depth without Jacket P Foot Length R Buttock to Knee Pivot Length S Head Breadth T Head Depth U Hip Breadth V Shoulder Breadth W Foot Breadth X Head Circumference Y Chest Circumference with Jacket Z Waist Circumference AA Reference Location for dim. AY@ BB Reference Location for dim. AZ@

92 Table 5. External Dimension Details Dim. Description Details A Total Sitting Height seat surface to highest point on top of head B Shoulder Pivot Height centerline of shoulder pivot bolt to seat surface C H-Point Height REFERENCE D H-Point Forward REFERENCE E Shoulder Pivot from Back Line center of shoulder clevis to rear vertical surface F Thigh Clearance seat surface to highest point on the upper femur segment G Back of Elbow to Wrist Point back of elbow flesh to wrist pivot bolt H Head Back from Backline REFERENCE - back of skull cap to vertical surface I Shoulder to Elbow Length highest point on top of the shoulder clevis to the lowest part of the flesh on the elbow, in line with the elbow pivot bolt J Elbow Rest Height the flesh below the elbow pivot bolt to the seat surface K Buttock to Knee Length most forward surface of the knee flesh to the rear surface of the buttocks, in line with the knee pivot and hip pivot L Popliteal Height seat surface to the horizontal plane of the bottom of the feet M Knee Pivot Height knee pivot bolt to horizontal plane of the bottom of the feet N Buttock Popliteal Length the rearmost surface of the lower leg to the same point on the rear surface of the buttocks used for dim. AK@ O Chest Depth without Jacket measured /- 5.1 mm (12 +/- 0.2 in) above seat surface P Foot Length tip of toe to rear of heel R Buttock to Knee Pivot Length the rear surface of the buttocks to the knee pivot bolt S Head Breadth the widest part of the head T Head Depth back of the head to the forehead U Hip Breadth the widest part of the hip V Shoulder Breadth outside edges of right and left shoulder clevises W Foot Breadth the widest part of the foot X Head Circumference measured at the point as in dim. AT@ Y Chest Circumference with Jacket measured /- 5.1 mm (12 +/- 0.2 in) above seat surface Z Waist Circumference measured /- 5.1 mm (6.5 +/- 0.2 in) above seat surface AA Reference Location for dim. AY@ REFERENCE BB Reference Location for dim. AZ@ REFERENCE 84

93 Fig External dimensions 85

94 MASS MEASUREMENTS Check the masses of the various dummy segment assemblies. They should conform to the specifications in Table 6. Consult Tables 7-20 which define the contents of each segment. Table 6. Hybrid III Small Adult Female Total and Segment Masses English (lbs) Metric (kg) Segment Spec. Tolerance +/- Spec. Tolerance +/- Head Assembly Neck Assembly Upper Torso Assembly with Torso Jacket Lower Torso Assembly Upper Arm, Left or Right Lower Arm, Left or Right Hand, Left or Right Upper Leg, Left or Right Lower Leg, Left or Right Foot, Left or Right Total Dummy Mass Table 7. Head Segment Description Part Number Qty Head Assembly X 1 Triaxial Mounting Block SA572-S80 1 Uniaxial Peizoresistive Accelerometer (or mass equivalent) SA572-S4 3 SHCS, 0-80 x 1/ SHCS, 2-56 x 5/

95 Table 8. Neck Segment Description Part Number Qty Neck Assembly Washer, Clamping SHCS, 3/8-16 x Bib Simulator Table 9. Upper Torso Segment Description Part Number Qty Upper Torso Assembly SHCS, 1/4-20 x 5/8 (connect lumbar-thoracic adapter to upper torso assembly) Upper Arm Washer (right and left) Upper Arm Bushing (right and left) Upper Arm Pivot Nut (right and left) Upper Arm Pivot Washer (right and left) SHSS, 3/8 x 1 (right and left) Washer Chest Accelerometer Mount H SHCS, 1/4-24 x 2 (for chest accel. mount, H ) Triaxial Mounting Block SA572-S80 1 Uniaxial Peizoresistive Accelerometer (or mass equivalent) SA572-S4 3 SHCS, 0-80 x 1/ SHCS, 2-56 x 5/

96 Table 10. Lower Torso Segment Description Part Number Qty Lower Torso Assembly Pelvic Accelerometer Mount SHCS, 3/8-16 x 3/4 (for pelvic accel mount, ) Triaxial Mounting Block SA572-S80 1 Uniaxial Peizoresistive Accelerometer (or mass equivalent) SA572-S4 3 SHCS, 0-80 x 1/ SHCS, 2-56 x 5/ Table 11. Left Upper Leg Segment Description Part Number Qty Upper Leg Weldment Upper Leg Flesh L 1 SHCS, 3/8-16 x Femur Load Cell Simulator SHCS, 3/8-16 x 1-1/ Knee Insert Rotation Stop Cover Knee Skin Machined Knee Cap

97 Table 12. Right Upper Leg Segment Description Part Number Qty Upper Leg Weldment Upper Leg Flesh R 1 SHCS, 3/8-16 x Femur Load Cell Simulator SHCS, 3/8-16 x 1-1/ Knee Insert Rotation Stop Cover Knee Skin Machined Knee Cap Table 13. Left Hand Segment Description Part Number Qty Hand Assembly, Left Table 14. Right Hand Segment Description Part Number Qty Hand Assembly, Right

98 Table 15. Left Lower Leg Segment Description Part Number Qty Lower Leg Flesh Lower Leg Structural Replacement Ankle Assembly Ankle Bumper Ankle Bolt A Knee Slider Assembly, Left Table 16. Right Lower Leg Segment Description Part Number Qty Lower Leg Flesh Lower Leg Structural Replacement Ankle Assembly Ankle Bumper Ankle Bolt A Knee Slider Assembly, Left Table 17. Left Foot Segment Description Part Number Qty Foot Assembly, Left SHSS, 1/4 x 5/ Table 18. Right Foot Segment Description Part Number Qty Foot Assembly, Right SHSS, 1/4 x 5/

99 Table 19. Upper Arm Segment (Left and Right) Description Part Number Qty Upper Arm Assembly, Molded Upper Arm, Lower Part SHSS, 5/16 x 1-1/ Note: Quantity is for each upper arm segment. Table 20. Lower Arm Segment (Left and Right) Description Part Number Qty Washer, Elbow Bushing, Elbow Elbow Pivot Nut Washer, Elbow Pivot Lower Arm Molded Assembly Wrist Rotation Assembly SHCS, 3/8-16 x SHSS, 3/8 x SHSS, 5/16 x 3/ Washer Note: Quantity is for each lower arm segment. 91

100 INSTRUMENTATION CABLE ROUTING The dummy contains provisions for numerous electronic instruments to evaluate various types of occupant restraint systems. Typically, the instruments are connected to the data acquisition system through the use of long cables. The instrumentation cables must be routed in and around the dummy in a manner which insures that the dummy=s motion is not affected by the cables while also being careful not to place the cables in a position where they are susceptible to damage from the test event. There are many acceptable methods of routing the cables and the following section is intended to be used as a reference. Below is a schematic of the small female dummy which indicates some of the instrumentation and sample cable routing (Fig. 108). Fig Load Cell and Cable Routing. 92

101 Head accelerometer and upper neck load cell cables (Fig. 109) exit the head between the skull and skull cap. It is important to leave enough extra cable to allow the head and neck to rotate forward without introducing tension in the instrumentation cables (Fig. 110). Fig Head accelerometer and upper neck Load cell cable routing. Fig Cable slack to allow for head motion. 93

102 Cables are typically routed inside the thoracic cavity to protect them from damage during the test event. The head accelerometer/upper neck load cell cables are routed inside the rib cage along the side of the spine box (Fig. 111). The cables exit the rib cage just below rib number 6 and next to the lumbar spine (Fig. 112), bundled along with other instrumentation cables routed through the rib cage. The bundle of cables exiting the dummy is often referred to as the umbilical. Fig Routing the head instrumentation cables through the rib cage. Fig Cable bundle exiting the thoracic cavity below rib #6. 94

103 To reduce the possibility of static electricity discharge and subsequent noise in the data acquisition system, a small length of cable, referred to as a grounding cable, is placed between the bottom of the skull and the lower neck bracket (Fig. 113). Attach one end of the cable under one of the rear 1/4-28 x 7/8 SHCS which holds the neck load cell or structural replacement to the skull. Attach the opposite end under one of the 1/4-20 x 3/4 SHCS which holds the lower neck bracket to the top of the spine box. Next, attach one end of a second longer length of cable at this same location (at the lower neck bracket) and route the cable through the rib cage along with the rest of the instrumentation cables. The opposite end of this cable is then attached to a common ground. Fig Grounding cable If the sternum mounted accelerometers are installed, route them along the sternum bib and into the thoracic cavity along the number 1 rib. Typically, duct tape is used to secure the cables to the bib to protect them until the cables reach the interior of the rib cage (Fig. 114). From there, route the cables to the rear of the thoracic cavity and then down along the spine box. 95

104 Fig Routing of sternum accelerometer cables Cables for the chest triaxial accelerometer array, the optional thoracic spine load cell, and the optional spine mounted accelerometers will all be routed through the interior of and out the top of the spine box. The cable bundle is then turned downward along the side of the spine box and inside the thoracic cavity (Fig. 115). This cable bundle will then exit the thoracic cavity along with the other cables under the number 6 rib and next to the lumbar spine. Fig Routing the cables from the interior of the spine box. 96

105 In this example, the chest instrumentation cables have been mounted along the right side of the spine box while the head/neck instrumentation cables have been routed along the left side of the spine box (refer back to Figs. 111 and 115). In order to provide a secure exit from the dummy for all the cable, the cables mounted along the right side of the spine are then passed to the left side of the spine by routing them in front of the lumbar spine, inside the abdominal cavity (Fig. 116). Fig Routing the cables in the abdominal area. Also visible in Fig. 116 above are the cables for the A.S.I.S. load cells, the lumbar spine load cell, and the chest deflection transducer. These instruments are in close proximity to the umbilical and thus the cables can be routed directly to the rear of the spine where they are combined with the other cables into the bundle. The cables for the pelvis triaxial accelerometer array, which exit the pelvic cavity located in the posterior of the pelvis, should be routed up into the bottom of the thoracic cavity before being combined into the cable bundle (Fig. 117). 97

106 Fig Pelvis accelerometer cable routing The cables for the femur load cells will exit the thigh flesh through a small access hole provided. The cables are then routed across the top of the thigh and are typically held in place there with a small length of tape (Fig. 118). Fig Femur load cell cable routing 98

107 The cables are then routed along the side of the pelvis where another piece of tape is used to hold the cable in place (Fig. 119). Finally, the cable is routed up into the bottom of the thoracic cavity before being combined into the cable bundle. Fig. 119 Femur load cell cables shown taped to the side of the pelvis Place the chest jacket on the dummy, being careful not to pinch any of the cables in the jacket zipper. The cable bundle should exit the dummy just beneath the chest jacket (see Fig. 120 and 121). Protection of the instrumentation cable bundle from the dummy to the data collection point is important. A protective sleeve manufactured for fire hose can be used. The sleeve includes a zipper and/or velcro enclosure system and is made of rubberized cloth. 99

108 Fig Cable routing under chest jacket (rear view) Fig Cable routing under chest jacket (side view) 100

109 APPENDIX A. FLESH REPAIR Common flesh damage comes from punctures, tears, and scrapes. Typically, an iron, similar to a standard electronic soldering iron, is used to make flesh repairs. A flat paddle (duck bill) tip is often used and the iron is usually set at 60 to 90 watts. For best results, use a variable power supply to control the amount of heat provided by the iron. When repairing flesh, use a well ventilated area, clean the flesh with 99% isopropyl alcohol and remove all loose material from the damaged areas. Since the alcohol is a flammable liquid, wait until the alcoholwetted area is dry and remove the alcohol container from the area before attempting to repair the flesh. Clean the iron tip frequently by quickly tapping it on a buffing wheel or rubbing it with a wire brush. Scrapes can be repaired by rubbing the iron over the affected area. If black flakes of burnt flesh start to appear on the iron tip, the iron is either too hot or has been in the same spot too long. Larger areas of damage may require a patch. The patch should be 10 mm (0.4 in) wider than the damaged area on all sides. One method of patching is to position the iron between the patch and the piece that is damaged. When the patch and flesh take on the appearance of a gel, move the iron to a new point while holding the patch in place until they both cool. For larger areas, it may be desirable to tack it in several places around the patch, then fill in the untacked areas. Moving the iron in a circular motion will eliminate rough, uneven areas. A-1

110 APPENDIX B. JOINT TORQUE ADJUSTMENTS Throughout this document, reference has been made to the torque setting for adjusting joint stiffness. The 1G torque setting is defined as the joint torque required to support the weight of the specified segment, yet that which also allows the segment to move when a small force is applied to the unsupported end of the segment. For example, when the dummy=s arm is fully extended laterally perpendicular to the dummy=s body, the shoulder yoke clevis bolt should be tight enough to support the weight of the arm, yet loose enough so that the entire arm will fall slowly when tapped at the wrist. The 1G torque setting can be difficult to achieve and requires some patience and practice. The following guidelines may be helpful. Hands and Arms 1. Remove the chest jacket in order to have access to the shoulder yoke rotation hex nut (necessary for step 3 below). 2. Extend the arm laterally outward to a horizontal position. Orient the lower arm so the elbow cannot rotate downward. Tighten the shoulder yoke clevis bolt until the shoulder joint torque will support the weight of the arm (see Fig. B1). Tap the lower arm near the wrist with a vertical impact. The arm should slowly fall back down along the dummy=s side. If it does not fall, loosen the shoulder yoke clevis bolt. Repeat the procedure of tapping at the wrist and adjusting the shoulder yoke clevis bolt until the 1G torque requirement is satisfied. 3. Rotate the complete arm assembly so that it is horizontal and pointing forward. Orient the lower arm so the elbow cannot rotate downward. Adjust the shoulder yoke rotation hex nut, which is located internally to the machined clavicle and accessed from the bottom side, until the joint torque will support the weight of the arm (see Fig. B2). Tap the lower arm near the wrist with a vertical impact. The arm should slowly fall back down along the dummy=s side. If it does not fall, loosen the shoulder yoke rotation hex nut. Repeat the procedure of tapping at the wrist and adjusting the shoulder yoke rotation hex nut until the 1G torque requirement is satisfied. 4. Start with the arm extended horizontally and pointing forward (as in step 3). Bend the elbow 90 degrees so that the hand moves toward the chest. Adjust the elbow rotation pivot bolt through the access hole found in the upper arm until the joint torque will support the weight of the lower arm (see Fig. B3). Tap the lower arm near the wrist with a vertical impact. The lower arm should slowly fall down. If it does not fall, loosen the elbow rotation pivot bolt. Repeat the procedure of tapping at the wrist and adjusting the elbow rotation pivot bolt until the 1G torque requirement is satisfied. 5. Start with the arm extended horizontally and pointing forward (as in step 3), only this time, orient the lower arm so that it is able to pivot downward. Adjust the elbow pivot bolt until the elbow joint torque will support the weight of the lower arm (see Fig. B4) Tap the lower arm near the wrist with a vertical impact. The lower arm should slowly fall down. If it does not fall, loosen the elbow pivot bolt. Repeat the procedure of tapping at the wrist and adjusting the elbow pivot bolt until the 1G torque requirement is satisfied. 6. Extend the arm and twist the hand until the palm is facing downward. Adjust the wrist pivot bolt until the wrist joint torque is sufficient to support the weight of the hand (see Fig. B5). Tap the hand at the tip of the fingers with a vertical impact. The hand should slowly fall down. If it does B-1

111 not fall down, loosen the wrist pivot bolt. Repeat the procedure of tapping at the finger tips and adjusting the wrist pivot bolt until the 1G torque requirement is met. 7. Extend the arm and bend the wrist 90 degrees. Orient the hand so that the fingers are horizontal. Adjust the wrist rotation bolt through the access hole in the lower arm flesh until the joint torque is sufficient to support the weight of the hand (see Fig. B6). Tap the hand at the tip of the fingers with a vertical impact. The hand should slowly fall down. If it does not fall down, loosen the wrist rotation bolt. Repeat the procedure of tapping at the finger tips and adjusting the wrist rotation bolt until the 1G torque requirement is met. 8. Repeat steps 2-7 for the other arm and hand. Legs and Feet 1. Place the dummy in a seated position.. 2. Remove the abdominal insert 3. Orient the lower leg at 90 degrees relative to the upper leg. Lift the upper leg assembly above horizontal. Adjust the femur ball set screw, which is located on the pelvis inside the abdominal cavity, until the joint torque is sufficient to support the weight of the leg (see Fig. B7). Tap the leg at the knee with a vertical impact. The leg should slowly fall down. If it does not fall down, loosen the femur ball set screw. Repeat the procedure of tapping at the knee and adjusting the femur ball set screw until the 1G torque requirement is met. 4. Rotate the entire leg assembly to a horizontal position. Adjust the knee pivot bolt until the joint torque is sufficient to support the weight of the lower leg (see Fig. B8). Tap the lower leg near the ankle with a vertical impact. The lower leg should fall down slowly. If it does not fall down, loosen the knee pivot bolt. Repeat the procedure of tapping at the ankle and adjusting the knee pivot bolt until the 1G torque requirement is met. 5. Orient the lower leg at 90 degrees relative to the upper leg. Adjust the ankle ball set screw, which is accessed through the lower leg skin, until the joint torque is sufficient to support the weight of the foot (see Fig. B9). Tap the foot near the toes with a vertical impact. The foot should slowly fall down. If it does not fall, loosen the ankle ball set screw. Repeat the procedure of tapping at the toes and adjusting the ankle ball set until the 1G torque requirement is met. 6. Repeat steps 3-5 on the other leg and foot. B-2

112 Fig. B1. 1G setting of shoulder yoke clevis bolt. Fig. B2. 1G setting of shoulder rotation hex nut. B-3

113 Fig. B3. 1G setting of elbow rotation bolt. Fig. B4. 1G setting of elbow pivot bolt. B-4

114 Fig. B5. 1G setting of wrist pivot bolt. Fig. B6. 1G setting of wrist rotation bolt. B-5

115 Fig. B7. 1G setting of femur ball set screw. B-6

116 Fig. B8. 1G setting of knee pivot bolt Fig. B9. 1G setting of ankle ball set screw B-7