First Technology Safety Systems. Design Freeze Status. Flex-PLI-GTR Development

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1 Based on TEG Nov JAMA-JARI JARI First Technology Safety Systems Design Freeze Status Flex-PLI-GTR Development Full Calibration Test Procedures Bernard Been FTSS Europe Comments addressed from Design Freeze meeting February 20 th 2008, JARI, Tsukuba, Japan Update February 29 th, 2008

2 Current Status Calibration bone core status presented here is not fully reviewed by load cell specialists in USA HQ New material calls for new approach and new line of thought Some details presented may change Appreciate feedback and experience from JARI/JAMA group with FLEX-PLI-GT

3 Flex-GTR Full Calibration Test Procedures (Overview) Evaluate Long Bone Cores Bending Characteristic Obtain Strain (mv) to Moment Conversion values Frequency After manufacturing Each year [After exceeding 400Nm (~125% of IARV*)] After failure of dynamic test Step 1: Bone Core 7 tests Quasi-static 3-Point Bending Test (Femur bone core, Tibia bone core) Evaluate Assembly Bending Characteristics Check ultimate bending moment Frequency Step 2: Femur and Tibia 2 tests After manufacturing Quasi-static 3-Point Bending Test Each year (Femur, Tibia) [After exceeding 400 Nm (~125% of IARV)] After femur or tibia assembly-/parts exchange After failure of dynamic test Evaluate Knee Bending Characteristics Evaluate Knee Ligament Elongation Values Frequency After manufacturing Each year [After exceeding IARV] After knee assembly-/parts exchange After failure of dynamic test Evaluate consistency of the assembly Frequency Each [1-10] tests After exceeding IARV After knee or femur or tibia assembly-/parts exchange *IARV : Injury Assessment Reference Value Step 3: Knee, 1 test Quasi-static 3-Point Bending Test Step 4: Assembly 1 test Femur-Knee-Tibia Dynamic Calibration Test

4 NEW JARI Proposals February 01 Conduct this kind of test at center position of each gages Load transducer (type: KYOWA LU-1TE) Quasi static V = 10 mm/min F c Ram (Surface shape: r = 25 mm) Support Moment M c (Nm) = F/2 65/1000 F/2 F/2 Support Support length: 130 mm 4

5 Step 1: Bone Core 7 tests Quasi-static 3-Point Bending Test Quasi static test Loading rate 10mm/min. Calibration of bone only mm Supply of calibrated spare parts N Measurement of test force, deflection and strain gauge voltage Force deflection corridor Accurate control of probe and Pivoted end supports L mv support distance L 0 Roller support to annihilate tension - compression in bone Compensation for support distance change δl due to bending FLEX-PLI-GTR Development, 12 February 2008 δl L Support pivot optimization

6 SAE J2570 Performance Specification Transducers SAE J2570 is not applicable to FLEX-PLI bone by definition Max deflection < 0.254mm Relevant criteria Hysteresis 1% of full scale capacity Non-linearity 1% of full scale capacity These are design goals! May be difficult to meet due to flexible nature of the bone Little experience with high deflection! FLEX-PLI-GTR Development, February 29 th, 2008

7 Bone Calibration Analysis Bone Calibration Procedure GTR thickness [mm] 10.5 Width [mm] 40 Youngs modulus JARI spec F kg/mm^2 [N/mm^2] Ultimate strength 70kg/mm^2 [N/mm^2] 687 Distance support [mm] 130 Test load [N] Test load centre [N*m] (peak 350 Nm) 325 Bone bending Radius at loading point [mm] Vertical deflection [mm] 2.69 Horizontal bone shortening estimate triangle [mm] 0.19 Horizontal bone shortening estimate Circle [mm] 0.33 Horizontal bone shortening average Circle/triangle [mm] 0.26 Error due to support distance variation [%] Error due to support distance accuracy 0.2mm [%] Error due to friction roll pin 2.0mm diam [%] Max error due to calibration load cell [%] Total error [%] Peak strain [micro strain] 10.0 JARI Please check bone properties

8 Details of Calibration Fixtures Accurate support distance control Conical indents on sides at neutral plane of bone Alignment cones on supports Pivot 1-2mm diameter for minimum friction Hardened steel pin 60HRc Roller end supports

9 Construction Principle of calibration fixtures Alignment cones on supports Spring loaded ball plunger on opposite side Pivot 1-2 mm diameter for minimum friction Roller end supports May need additional axis to compensate fixture bending

10 Construction Principle of calibration fixtures Roller pin Need good grade tooling steel Yield strength >750MPa

11 Calibration Fixtures Space on top Rubber clamping Space at bottom Dowel pins Cavity for strain gauge

12 Calibration Fixtures Compensation for support distance change δl

13 Calibration Fixtures R300 Centre loading surface R300 Bone bending radius R500

14 Step 2: Long Bone Tibia and Femur Quasi-static 3-Point Bending Test 434 mm Load transducer F c D c Ram (flat surface) Knee side of tibia bone core Tibia-1B Tibia-2B Tibia-3B Tibia-4B Support (rotate) Tibia-1A Tibia-2A Tibia-3A Tibia-4A Sectional image Support (rotate) ground F c /2 205 mm 205 mm F c /2 Maintain F c existing : Force Center, D c procedure : Deflection Center Without M c :MomentCenter(Nm)=F Neoprene C /2 (N) x layer (m) Drawings of the fixtures available FLEX-PLI-GTR Development, February 29 th, 2008 Support Length: 410 mm

15 Long Bone Assembly Calibration Load up to IRAV [300Nm] to ensure correct IARV measurement below bending stopper working point Bending stopper cable action Moment: M c (Nm) Deflection: D c (mm)

16 Step 3: Knee Quasi-static 3-Point Bending Test [1 Load transducer] Femur side Ram (r = 50 mm) of knee F c No impact side of Nylon face [Neoprene??] during this test LCL Support (rotate) PCL ACL MCL PCL ACL Support (rotate) [2 Load transducers] [2 Load transducers] (fixed) (fixed) ground gou F 1 F 200 mm 200 mm 2 Support Length: 400 mm Maintain existing procedure F 1 : Support force of Femur side of knee M c : Moment use Center single - at Knee central joint surface load (Nm) = Fcell 1 (N) x 0.2 (m) if loading position well controlled FTSS make proposal FLEX-PLI-GTR Development, February 29 th, 2008

17 Step 2: Knee Quasi-static static 3-Point Bending Test Tentative corridor Test results Tentative corridor Test results M c (Nm) Moment: Elongation: MCL (mm) Tentative corridor Test results MCL (mm) Elongation: Force F c (N) Tentative corridor Test results tion: ACL (mm) tion: PCL (mm) Elongat 10 Elongat Force: F c (N) Force F c (N)

18 Dynamic Calibration Procedure Calibration rig with Release magnet support arm and release magnet Pin joint height Energy fine Control input pulse tuning with tibia x- Free fall acceleration Control parameters Drop height Ax tibia proximal MCL, ACL, PCL (and LCL) Tibia bending moments No pass-fail parameter femur bending moments Target corridor ±10% from average FLEX-PLI-GTR Development, January 4, 2008 Tibi ia Fe emur Supporting rig Tibia x-acceln. Knee joint surface level Existing stopper material Vertical at impact?? Leg suspension

19 Stopper material consistency test Tibia acceleration may be dependent from two parameters stopper material tibia response To be able to identify problem in case of calibration failure: tibia or stopper material Need to have additional procedure for stopper material test Control stopper material over extended time of loading/use FTSS to make proposal for dynamic (drop?) test FLEX-PLI-GTR Development, February 20 th, 2008

20 Dynamic Calibration Development Testing Continue JARI FE Model study parameter a variation at for calibration development Type A-2: With additional weight 5 kg Revolutional Complete test matrix (example) Base line test Mount at Tibia (upside down) Added mass to bottom segment [Free fall height increase] Loading surface Flat and Curved Stopper (rigid) Fixed Rubber30 Mount pivot at tibia Revolutional Joint (One degree of freedom) Decide on final procedure parameters based on model parameter variation Verify procedure details with FLEX-PLI-GT Calibrate GTR prototypes with final procedures 5 deg Initial angular velocity 6.44 rad/s Stopper (rigid) Fixed Rubber30 5 deg Joint (One degree of freedom) Initial angular velocity 6.44 rad/s Additional weight: 5 kg FLEX-PLI-GTR Development, February 21 st, 2008

21 Design frozen!

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