ATD Technical Advisory Meeting on Dummy Design Thursday, May 15, :00 am 9:00 am EST Humanetics Headquarters in Plymouth, MI and via WebEx

Transcription

1 ATD Technical Advisory Meeting on Dummy Design Thursday, May 15, :00 am 9:00 am EST Humanetics Headquarters in Plymouth, MI and via WebEx May 15, 2014 Michael S. Beebe, Mark Brown, Joe Bastian, Paul Depinet, John Below Humanetics Innovative Solutions, Inc.

2 Agenda Petition Update o Auto Alliance petition / NHTSA Small Female Jacket Eurosid Abdomen ATD Component Updates o Hybrid III Upper Arm o Small Female Skull Cap o Hybrid III Lumbar o Hybrid III Ankle J2949 o TNO 10 o FMVSS 226 Head form o IRTRACC Update Harmonization Update o Euro NCAP components o H Standard Update Regulation Dummy Update o WorldSID o THOR o Q3s Future Dummy Update o Obese o Abdominal Upgrade 5/15/2014

3 Small Female Chest Jacket Auto Alliance has been submitted to NHTSA Update drawing package for both the jacket and spine box updates Propose a 5 year phase in Draft completed currently under review 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

4 Eurosid 2 Abdomen Certification Auto Alliance has been submitted to NHTSA Eurosid- 2 after 2002 o o o 4 m/s (reduced to achieve lower abdominal force) Pendulum Force ms Total Abdomen Force ms 50/50 pass, times too short foam has changed, same European manufacturer since beginning Several adjustments have been made to both the material and process 5/15/2014

5 Hybrid III 50 th Upper Arm New prototype upper arms produced for evaluation Fit acceptable Being phased into production 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

6 H head skin and cap skin In Process Harmonized 5 th head in Huron -Both heads have large misalignment between head skin and skull cap. -The misalignment looks better with FT head skin as shown. I am not saying to use FT skin. I just want to show the difference. -No new cap skin was made -Head skin thickness spec 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

7 2. Head skin top thickness 1. -H head skin has more thickness in its top part. 2. -H head skin is about 4mm higher. 3. -This will change airbag position in testings. 4. This is a comment from a FT dummy user. Smaller in back of headskin originally, cap skin thinner than spec for CG Need spec change for both drawings

8 2. Head skin top thickness (con t) Cap Skin is also call out to be.5 thick

9 3. Chin location -Align eyes, nose first, then harmonized chin location is different than FT. -Head location on steering wheel will be different. -This is just comment from a FT dummy user. - - Harmonized chin headskin has same thickness as 10 year old

10 4. H head skin lip -FT head has more depth in its lip. Head drop wire drops together with the head. -H head has less depth in its lip. Head drop wire slips out soon, and it may be catching other portion of head skin, and this may create noise in head drop test. -Customer is worrying when they have to wait 3 hours to do another test.

11 UPDATE OF HYBRID III 50 TH LUMBAR SPINE SAE ACTIVITIES April 17, 2010

12 SAE Project to review Lumbar Angle Check 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

13 Draft Minutes from last SAE meeting o Hybrid III 50th Male Lumbar Angle Check Problem Mike Beebe: (see presentation) Current molds made to print. Tolerances are machine tolerances, not mold tolerances. Polyacrylate material was chosen by Don? and Wolanan to ensure stiffness. Probably needs a stiffness test. Early lumbar drawing package had a performance test associated with the spine. A pull test was also part of the spec, but has since been lost. Polyacrylate has a compression set. Polyacrylate is difficult to push through a sprue. Depinet: Nominal & Variation Measurements: presented by Denton Guy Marshall: Presented spread sheet on lumbar measurements (7 each FTSS and 2 each DATD). Guys stated that he believes that FTSS used three molds based on his observation of the sprue hole location. Buehler: Reason for the investigation has to do with variation in dummy kinematics and performance on Toyota tests. Suspects that lumbar plays a meaningful role based on bending stiffness. TEMA will run various tests with soft and stiff lumbar spines. Depinet: Issues have been brought up related to dimensions and stiffness. Do we come up with a realistic measurement that would determine if a lumbar is within spec and would allow the user to have faith that the lumbar is good to use in performance testing? Bastian: the current drawing does not contain enough information to address performance specifications. We need a dimensional spec and stiffness / bending test. Depinet: Proposed a free angle and free height measurement to better characterize the lumbar Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

14 Drawing Issues Polyacrylate does change size from a mold o o o o o o Current drawings if based on machining tolerance not molding tolerances. Current molds made to meet print. Only difference is change in dimension to account for individual shrinkage of materials. Current tolerances will not match the rubber molding process Dimension range larger than current specification tolerance. It was recommended to have total of 4% tolerance for all rubber parts due to changes after molding and variability. Suggest we measure the population of current lumbars in the field with a simple height measurement. Set angle, measure height. Polyacrylate was chosen as the compound, why? o o o To be stiff and hold the upper torso in position during thorax cert test and for lateral stability in a seat. Need to add a stiffness test to control. A performance spec is listed on current drawing, what does this refer to? Add Torso Flexion Test Polyacrylate has compression set o o Need to set position to measure Need to store lumbar out of dummy to minimize variation 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

15 Mold Target to meet part print 5/15/2014

16 Cross Section of mold lumbar 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

17 Comparison of Height and Cable Arc Length measurements & Calculations from Drawing Requirements 5/15/2014

18 Height & Angle Dimension Comparison Toyota Lumbar Dimensional Check Reported to SAE Without Cables With Cables (10 inch-lbs torque) Height (mm) Angle (center) Height (mm) Angle (Left) Angle (Right) DNA1 Denton Denton AC3545 FTSS AB4787 FTSS AB4788 FTSS AC3546 FTSS Calculated Height from drawings with tolerances mm to mm Angle of Mold 45 to 46 Degrees 5/15/2014

19 GM Measurement Reported to SAE Calculated Height from drawings with tolerances mm to mm Angle of Mold 45 to 46 Degrees 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

20 Cable Hole Arc Length vs Cable length Cable Hole Arc Length Cable hole arc length =135.5 to 138.7mm (includes c bore in top plate) Cable length in hole = to mm Height of both nuts = 20.7 m Cable Lg.-- Nut Hg. Hole Lg. = -3 to mm ( = -6.7 mm) Cable is not long enough by approximately 3 to 7 mm to have both nuts fully engaged on end of cable threads

21 Original SAE/PADI Inspection Found Picture to be incorrect due to actual part drawing specifications This picture is from 1984, we think the cable was too long or lumbar too short. 5/15/2014

22 Next Step: Develop a Performance Spec 5/15/2014

23 Next Step: Proposed Toyota Lumbar Test 5/15/2014

24 Next Steps: Proposed Denton Lumbar Test

25 Issues when part is removed from mold Variation in parts greater than tolerance on drawing. o Rubber can change after molding o Any bending test, storage in dummy, use, etc.. Changes shape of lumbar. This is due to compression set of the rubber. o Need a stiffness test o Agreed upon dimension o Typical Physical Properties of Polymer o Interesting comparison of Polyacrylate and two other types in compressive stress relaxation 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

26 SAE Next Steps Guy Marshall will put a spread sheet together, along with a few instructional points, on how to measure and record this information. Spread sheet is to be distributed to members and returned to Guy for collation. Buehler will measure the dimensions of the lumbar spines that he has with and without the cables to see if the cable makes a difference in the angle or height. Buehler: Presented data on lumbar bending test which included the test setup and procedures. TEMA measured the initial angle and load at 10, 20, and 30 degrees. Fixture uses a quick release and they measure return angle. Depinet: Do we need a component test and a system (torso flexion) test at this time for the lumbar? Need to determine if this part is repeatable. Also need to measure the pelvis to see if it is moving during the pull test. Buehler volunteered to check this. Pietsch: would prefer to look at the lumbar first before we add tests to the portfolio of tests already required. Beebe: develop and run a quasi-static test before investigating other tests. Run the Toyota test for now as a baseline. Supported by Pietsch, but eliminate the pelvis from the test. Bastian: For now, let s go ahead and use the hardware specified by Toyota since everyone has most of the hardware in their lab now. Bastian needs to check on the neck bracket to see if there is a drawing. If so, make it available. Buehler: volunteered to run additional tests to lock down the test details. TEMA has a procedure written by FTSS (translated from Japanese) that can be made available. It will be distributed so that others can try it and provide feedback. Beebe: Recommended that DATD and FTSS work with Toyota to nail down the procedure and get a round robin test going with FTSS and Denton lumbar spines Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

27 Next Steps: Proposed Measurements for Inspection, currently under development 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

28 Please Fill in the measurements of your lumbars and send back Hybrid III 50% Male Lumbar Static Measurements Date Measured: Name / Company: Note: the lumbar cable is not installed for these measurements. Manufacture Serial No. Max. Height (mm) Angle of Top Surface (deg.) Notes Denton Example

29 GM Measurement Reported to Dummy Testing Committee of SAE Calculated Height from drawings with tolerances mm to mm Angle of Mold 45 to 46 Degrees 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

30 Proposals for Lumbar Testing under review SAE Reviewing SAE Proposal for inspection tests Dynamic testing of lumbar on neck pendulum 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

31 Background Toyota Lumbar Test Lumbar bend test was created to provide a force vs angle requirement to the existing durometer requirement. 5/15/2014

32 SAE evaluation of Lumbar Pull Test Jesse Buehler of TEMA/Toyota will write J document A procedure comparison was completed between Humanetics US, TEMA, Toyota Japan, and Humanetics Japan A round robin has begun using three new lumbars, and the testing equipment at TEMA, Plymouth, and Huron. An initial review of the data has been completed 5/15/2014

33 Force (N) Initial Data Review 10 and 20 degree lumbar bend angles o Similar results between labs and test equipment. 30 degrees of lumbar angle o Differences were found Current corridor is not linear as expected o The theory is that the corridors were created including the interference between pot bracket and lumbar TTC, Huron Lumbar Flexion Averages Degrees Huron TTC 5/15/2014

34 Force (N) A further investigation was completed on November 12, 2012 Four items were discovered during the investigation o o o o The pot bracket structure comes in contact with the lumbar spine at approximately 29 deg, effected by initial angle Weight of spine boxes were found to be different (.4 lbs) One of the test equipment max pull angle is only 29 degrees Pull angle similar but test equipment set up is different TTC, Huron Lumbar Flexion Averages Degrees Contact could occur sooner depending on initial angle 5/15/2014 Huron TTC

35 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

36 Longer Term for SAE J Document (6 months) Update Procedure o Replace spine box with special design pull device to prevent spine interaction. Update Corridors o Update, as necessary, corridors after round robin is complete 5/15/2014

37 Lumbar Test Background: An force vs. angle test for the 50 th lumbar was created by Toyota Problem Definition: SAE took on the project to explore reproducibility of current test and, if necessary, develop a SAE test recommended practice. Current Status: o o o o o SAE is creating a new J document Jessie Buehler from TEMA will by the Author Test procedures have been reviewed and updated SAE will perform a round robin test series to check updated procedure Humanetics will supply lumbars and analysis support Initial round robin test will include Toyota headquarters, TEMA, Humanetics Japan, Humanetics US 54 different test at three labs currently in progress between Huron, Plymouth, and TEMA Labs, Due Fall Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

38 Conclusion Humanetics to draft Lumbar test for SAE and will send out for vote 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

39 Will re-issue SAE J2949 Document First ballot did not receive enough votes Will need to re-issue 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

40 TNO-10 Replaced material in early 2013 Continued work to look for a superior material We believe we are close to having a new replacement material New samples are close to harmonized brown color 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

41 Head Form Issue raised No new updated information Problem Identified: o Head skin slipping off during testing, both in chin and skull back areas. Possible solutions were identified: o o o Next Step o Create a skin over the chin area to prevent the skin from releasing Glue parts of the head skin to the skull. Either solution is not prohibited by NHTSA spec because this part does not appear in the Part 572 on in reference in a standard. Head skins were created with an additional chin flap to prevent skin from coming off the chin during testing. One skin was provided to Germany for testing, another to NHTSA. NHTSA did not have time to test it, however Daimler did Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

42 Daimler Report 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

43 Daimler Report 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

44 IR-TRACC Workshop 3 rd Quarter 2014 HISTORY IR-TRACC FEATURES TYPES PRINCIPLES OF OPERATION SPECIFICATIONS DATA PROCESSING CALIBRATION

45 Hybrid III 5 th /50 th Euro NCAP Dummies ATDs optimized for Euro NCAP BKS-H BKS-H BKS-H BKS-H Standard Features, All BKS-H: High and low speed rib certification High and low speed ball slider certification Zippered Leg Flesh Additional Features, -1-BKS-H : NCAP Accel Mount Feet 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

46 H Standard 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

47 Certification Test Repeatability using Humanetics H Standard Set Up Procedures Documentation Equipment Dummies Lab, H Std. Lab inspection Gage R&R Sensors DAS Data Collection process

48 DRAFT H STANDARD

49 H Standard Comparison of Neck D-plane certification error between various standards 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

50 WS50 SINGLE RIB CERTIFICATION Oct 2013

51 23.Oct WS50 Thorax Certification ISO/TC22/SC12/WG5 Leonhard Ferdinand 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

52 Option List Static tests of individual ribs o (Force vs Deflection) Drop tower of individual ribs o (Force vs Deflection) Single rib pendulum on dummy (2 m/s) o (Force vs Deflection) Single rib Stiffness of all three ribs at the same time with pendulum o Weight? (5 th or SID IIs pendulum and add weight) 25 kg probe o Speed?- standard cert test speed Need enough deflection of ribs Currently Humanetics is building testing rig for rib testing, lower priority to small female worldsid update, different stiffness ribs has been completed 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

53 Small Female World-SID Current Project List o Shoulder interaction with neck bracket o Interaction of pelvis bone and lumbar spine/ S-I load cell (long term redesign req d) o Lower rib interaction with top portion of pelvis flesh, under investigation First prototype due end of October, Cert and Bio testing to be completed in November by Humanetics 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

54 WORLDSID 5 TH DESIGN UPDATES PRESENTED TO GTR TEG 5/6/14 prepared by: Paul Depinet & Ashwin Mathews

55 Shoulder Status Neck bracket fit o Carefully re-examined tolerance stackup o Redid drawings with GD&T callouts Guarantee parts will always fit if to tolerance Evaluating supplier capable of checking accurately enough o Neck brackets are on order Timing o As soon as one set is in and fits correctly, dynamic testing will begin o Once we get remainder of sets, strength validation testing will be completed 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

56 Pelvis Testing current status Have cables to collect all load cell channels Pelvis process o Developed material & process that should be reproducible Testing o Completed matrix of varying stiffness parts o Completed testing with 2 of 3 new pelvises o Looked at contacts using chalk with softest parts o Testing up to this point with original setup o Using scaled corridor from B. Donnelly 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

57 Pelvis Testing Next Steps Test 3 rd pelvis Pick set of parts for next steps o Can predict response as soon as we have 3 rd pelvis o Will shoot for middle of corridor Try new setup suggested at last meeting o Torso upright as possible o Maintain relationship between torso and pelvis Don t come so far forward that probe contacts table (allow 1 cm) o Run 6 tests to compare to original setup 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

58 Pelvis Testing Next Steps Run tests over widest velocity range we can achieve o 4.5 up to 7.0 m/s, will attempt up to 10 m/s o Use contact switches and chalk to look for contacts Reassess selection of parts o Did contact occur at high velocity o How did biofidelity look at high velocity o Possible try lower or higher stiffness parts 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

59 Pelvis Testing Next Steps Run certification pendulum o Use contact switches & collect all pelvis channels and T12 acceleration & rotation o Use bench method 6.7 m/s o Run tests at velocities as high as we can achieve Try to get 5, 6, 6.7, 7, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0 Use velocity range to look for if/when contacts start to occur Run 25 repeat tests at 7.5 m/s if contact occurs above this to look for durability (25% increase in energy) Run 10 repeat tests at 8.2 m/s if contact occurs above this to look for durability (50% increase in energy) o Repeat 6.7 m/s tests to see if performance has changed 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

60 THOR ATD HUMANETICS INNOVATIVE SOLUTIONS, INC.

61 Dummy Development In 2011 NHTSA contracted Humanetics to develop a mod kit add-on package intended to improve biofidelity, anthropometry, durability, and usability of existing THOR-NT ATDs. The project included: 1. Development of a mod kit add-on package for existing THOR-NT dummies 2. Development and fabrication of a new fully updated THOR- NT (also known as THOR-M) 3. Fabrication and installation of mod kits on existing NHTSA THOR-NT dummies Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

62 THOR-NT Mod Kit The Mod Kits are available to existing THOR-NT owners Mod Kit updates Head Neck Thorax Lower Abdomen Pelvis And Upper Leg 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

63 THOR-NT Mod Kit Delivery Total current orders (1) Nissan Total delivered (4) VRTC/NHTSA (3) Renault Toyota 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

64 THOR-M THOR-M dummy is configured with SD3 shoulder and THOR-LX legs Typical order includes 136 channels of instrumentation Options available for ARS sensors mounts in Head, Chest, and Pelvis 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

65 THOR-M Delivery Total current orders (14) GM TEMA Toyota (2) Mazda (2) Nissan Honda (3) Ford (2) PDB Daimler Total delivered (4) VRTC/NHTSA (3) BAST 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

66 SD3 Shoulder Included in standard THOR-M Offered as optional equipment on THOR Mod Kit 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

67 THOR-LX Lower Leg Included in standard THOR-M Offering kit that will allow the use of existing inch load cells when upgrading to the THOR-LX metric leg design 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

68 THOR-LX Leg Upgrade Shown is the assembly of the THOR-LX metric leg with the imperial load cells and imperial knee clevis. This configuration can be used on THOR-NT/THOR-K, and will allow the customer to use their existing imperial load cells when upgrading to the THOR-LX metric leg design. First upgrade delivered to Toyota this month.

69 THOR-LX Shoe development Humanetics is currently working on an engineering development project to redesign the THOR-LX molded shoe. Develop THOR-LX molded shoe design that will meet performance requirements as defined by NHTSA The response of the THOR-LX with molded shoe in 1) heel impact and 2) ball-of-foot impact certification tests is expected to match the response of the existing THOR-LX foot with the MIL-spec shoe installed Final delivery to NHTSA will be (2) pair of molded shoes that meet testing criteria no later than December 31, 2014

70 THOR iliac wing redesign Pelvic bone failures reported during THORAX test program, NHTSA UVA test program Coordinated with NHTSA to develop load limit requirements for analysis Speculations: thin area around the h-point hole boss caused the failure

71 THOR iliac wing redesign Recent activity involves fabrication of sample wings and creating fixtures to perform destructive testing Estimate months of effort to perform evaluation and complete the redesign

72 THOR-M Certification Heavy engineering focus on dummy certification, the Humanetics test team is currently working to: o Establish preliminary certification corridors o Finalize certification test processes o Train additional test technicians o Develop certification test software o Develop certification test equipment

73 Q3s Update

74 Q3s Regulatory Status 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary

75 Q3s Certification Status NPRM Proposed Corridors based on four prototype Q3s dummies owned by VRTC. In some instances, Humanetics has been unable to duplicate the NPRM Corridors with current production dummies: Neck Flexion Timing Issue Head Lateral Response close to upper end of corridor Humanetics is shipping dummies and is looking for certification data from customers to support adjustments to the NPRM corridors Humanetics Innovative Solutions Inc. Confidential & Proprietary

76 Obese ATD 272 lb. ATD using the skeleton of the existing THOR 50M dummy Duplicate the kinematic response of obese PMHS s which have been tested previously Additional weight and size will be added to the lower torso, upper legs, and upper torso flesh University of Virginia to evaluate the ATD kinematics using a seat mounted on a sled The ATD will also be provided to third parties for evaluation 2013 Humanetics Innovative Solutions Inc. Confidential & Proprietary 5-

77 Scaling THOR to Obese 165 lbs. 273 lbs.

78 Anthropometry (35BMI subject)

79 Kinematic Obese subject s H point translates further forward on the seat as compared to a non-obese person The knee impacts into the restraint much farther than a non-obese person Working with the University of Virginia to preform Sled testing comparing to their PMHS testing 5/15/2014

80 Anthropometry Belt Positioning is an issue for persons with higher BMI. Belts are positioned above the ASIS point on the pelvis bone. 5/15/2014

81 Humanetics Advanced Dummy Organs (HADO) The ability to have the correct regional abdominal stiffness, intrusion measurement of the abdominal organs, and loading patterns in the thorax in motor vehicle crash conditions is important for assessing head-neck loads, brain, thorax, and abdominal injuries. Current ATD s do not have all the components necessary to measure regional abdominal organ loadings necessary in new types of crash test procedures such as offsets. A proper thorax regional stiffness using the proper shaped and stiffness organs in the abdominal cavity covered with a muscle and fat layer are the items described in this presentation. As part of the development for these new platforms, the development of new biofidelity corridors and injury criterion will be completed.

82 Thank You for your attention ATD Technical Advisory Group May 15, 2014

83 2014 Humanetics Innovative Solutions, Inc. This presentation is the proprietary property of Humanetics Innovative Solutions, Inc; a registered company in Plymouth, Michigan, USA. The report includes confidential information. Disclosure, use, copying, or distribution of this information without the written authorization of Humanetics Innovative Solutions is prohibited.