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033-9900 User Manual Q6 (Advanced 6 year old) Rev. M
©2016 Humanetics Innovative Solutions Inc.

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Page 14 of 96

3. Instrumentation

3.1   General
The  dummy  accepts  both  accelerometers  and  load  cells  as  standard
instrumentation.  Angular  velocity  sensors  (DTS-ARS  and  Applied  Technologies
Associates type ARS-01 or ARS-06 (flanged version)) can be fitted to the head,
which  requires  an  alternative  head  accelerometer  mount.  The  dummy  can  be
equipped with uni-axial accelerometers for all locations. Tri-axial accelerometers
can  be  used  on  the  pelvis  and  thorax  location.  The  standard  dummy  will  be
delivered including mounting blocks for uni-axial accelerometers.

The load cells or their structural replacements are a part of the dummy structure;
the structural replacements have to be used in absence of the actual transducer.
A 6-channel load cell (Humanetics model IF-217 or IF-218) can be placed in the
upper neck, lower neck and lumbar spine location.

Tilt sensor mounts are also available for head, thorax and pelvis to suit 2 axis
sensor type IES1402. Part Numbers are 033-1110 head, 033-4110 thorax, and
033-7110 pelvis.

3.2 Transducers

The Q6 dummy can be fitted to measure any or all of the following parameters
(see also notes below):

Head
Standard - 3 uni-axial accelerometers in head (Ax, Ay, Az)
Optional - 3 angular velocity sensors:

Applied Technologies Associates type ARS-01 or ARS-06 (flanged
version) or DTS-ARS.

Neck
Standard - Upper neck 6 channel load cell, 3 forces, 3 moments (Fx, Fy, Fz, Mx,

My, Mz). Humanetics Model IF-217 (350 Ohm) or IF-218 (120 Ohm).

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Summary of Contents for Q6

Page 1: ...Q6 Advanced 6 year old child User Manual ...

Page 2: ...cs Innovative Solutions Copyright 2016 Humanetics Innovative Solutions All rights reserved The information in this manual is furnished for informational use only and is subject to change without notice Humanetics Innovative Solutions assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual Notice This product may contain lead A list of components that ma...

Page 3: ...ns 12 2 5 Main Dimensions 12 2 6 Mass Distribution 13 2 7 Standard Dummy 13 3 Instrumentation 14 3 1 General 14 3 2 Transducers 14 3 3 Accelerometer Mounts 17 3 4 Angular Velocity Sensor Mounting 19 3 5 Abdomen Pressure Twin Sensor ATPS 21 3 6 Cable Routing and Protection 23 4 Assembly Disassembly 24 4 1 General Overview 24 4 2 Head 25 4 3 Neck 28 4 4 Torso 32 4 5 Lumbar Spine and Abdomen 40 4 6 P...

Page 4: ... Dummy Parts List and Recommended Spare Parts 57 6 1 Dummy Parts 57 6 2 Recommended Spare Parts 60 7 Certification Equipment 61 7 1 Requirements 61 7 2 Equipment 62 7 3 Equipment Parts List 67 8 Certification Tests 68 8 1 Head Certification 68 8 2 Certification of the Neck 72 8 3 Certification of the Lumbar Spine 78 8 4 Certification of the Abdomen 84 8 5 Certification of the Thorax 85 9 Markers L...

Page 5: ...de bottom 37 Figure 15 IR TRACC should swing freely 38 Figure 16 Q6 side impact IR TRACC arrangement 39 Figure 17 Lumbar spine assembly and abdomen 43 Figure 18 Pelvis and hip joint assembly 45 Figure 19 Leg Assemblies 47 Figure 20 Arm Assemblies 49 Figure 21 Neck Shield Installed Left Rear view Right Front view 52 Figure 22 Hip insert fitted on Q6 sitting position left straight legs right 53 Figu...

Page 6: ...6 Table 10 IR RTRACC attachment part list frontal impact configuration 39 Table 11 Spine and abdomen assembly parts 41 Table 12 Pelvis assembly parts 44 Table 13 Legs assembly parts 46 Table 14 Arm assembly parts 49 Table 15 Dummy parts list 57 Table 16 Recommended spare parts 60 Table 17 Q6 full body pendulum specifications 65 Table 18 Q Dummy certification equipment parts list 67 Table 19 Marker...

Page 7: ...ving child safety in cars As of December 2011 the series is available in five age groups representing a Newborn 1 year 1 year 3 year 6 year and 10 year old child Nowadays members of this Q family are applied in UNECE Regulation R129 which became effective per January 2013 Also various consumer rating programs world wide apply Q dummies Humanetics reserves the right to make improvements or implemen...

Page 8: ... program of the Q series in 2004 A full report on a possible recommendation for use of the dummies in ECE R44 tests is expected in 2005 Results of the first evaluations have been published at the 19th Enhanced Safety of Vehicles conference in 20055 In 2006 the New Programme for the Assessment of Child restraint Systems NPACS adopted the Q dummies for their test protocols 2 2 Applications The Q6 du...

Page 9: ...ren and scaled adult biomechanical response curves has been used to define the dummy response The anthropometry of the dummy is based on CANDAT7 data The dummies can be equipped with accelerometers angular velocity sensors load cells and displacement sensors This allows evaluation of the injury risk under various circumstances Special attention has been paid to the handling characteristics of the ...

Page 10: ... failure A six channel load cell can be mounted at the neck head and neck torso interface Thorax The thorax of the child is represented by a single rib cage The deformation can be measured with an IR TRACC Infra Red Telescoping Rod for Assessment of Chest Compression sensor The shoulders are connected with a flexible joint to the thorax allowing deformation forward Accelerometers can be mounted on...

Page 11: ...n be mounted in the pelvis Special hip joints are available that allow the dummy to be position in a standing posture Legs The knee joints can be locked in any position This feature can be used to facilitate positioning the dummy in a standing position Note that the dummy does not have the ability to stand without support It must be placed against some object such as the dashboard ...

Page 12: ... linear acceleration upper and lower side Abdomen Pressure Lower Lumbar Spine Fx Fy Fz forces and Mx My Mz moments Pelvic Ax Ay Az linear acceleration 2 5 Main Dimensions The main dimensions of the Q6 dummy are provided below Table 1 Main dimensions Description Q6 Dimension mm Tolerance mm Seating height head tilted forward 601 9 Shoulder height sitting 362 7 Stature 1143 9 Chest depth 141 5 Shoul...

Page 13: ...s and fasteners Table 2 Mass distribution Component Q6 Mass kg Tolerance kg Head Neck incl acc mount 3 94 0 10 Torso incl acc mounts IR TRACC 9 07 0 40 Legs left right 6 90 0 10 Arms left right 2 49 0 10 Suit 0 55 0 10 Total 22 95 0 80 2 7 Standard Dummy The standard Q dummy is delivered with the following items One piece of clothing a yellow suit Structural replacements in the location of the loa...

Page 14: ...r their structural replacements are a part of the dummy structure the structural replacements have to be used in absence of the actual transducer A 6 channel load cell Humanetics model IF 217 or IF 218 can be placed in the upper neck lower neck and lumbar spine location Tilt sensor mounts are also available for head thorax and pelvis to suit 2 axis sensor type IES1402 Part Numbers are 033 1110 hea...

Page 15: ...e pelvis interface Fx Fy Fz Mx My Mz Humanetics Model IF 217 350 Ohm or IF 218 120 Ohm Abdomen Optional Twin pressure sensor Pelvis Standard 3 uni axial accelerometers or tri axial accelerometer on pelvis skeletal structure Ax Ay Az Optional Asis Load cell left and right Fx My Prototype Notes 1 IR TRACC sensor may be mounted in two ways either to measure frontal or lateral deformations The IR TRAC...

Page 16: ...ure that the accelerometers are not located on positions that may contact other parts of the dummy as a result of deformation To process and combine the data first filter both signals at CFC1000 according to SAE J211 Subtract the signals and integrate the result This results in the deformation velocity Numerical integration of the calculated velocity signal gives the deformation itself Note that t...

Page 17: ...i axial accelerometers Note Thorax and Pelvis locations will ONLY accept tri axial transducers with a side entry cable The uni axial accelerometers and mounts that can be used for the Q6 dummy are listed Table 3 The mounts and their orientation are depicted in figure 2 to 5 Tri axial accelerometers and mounts are listed in Table 4 Table 3 Uni axial accelerometers and mounts for thorax and pelvis A...

Page 18: ...s Inc Page 18 of 96 Figure 2 Accelerometer mounts for Q6 Figure 3 Thorax uni axial acceleration mounts I AO left and I AN right Figure 4 Pelvis uni axial acceleration mounts I AO left and I AN right Figure 5 Head uni axial acceleration mounts I AD left and I AM right Up Down Front Rear ...

Page 19: ...re 6 with special mount block 020 1014 The mount block 020 1014 consists of a base and three ATA ARS sensor blanks of similar weight and size Any of these ARS sensor blanks can be replaced with an ATA ARS 01 or ARS 06 flanged version sensor The 020 2014 mounting block will accept the same mount block as the standard accelerometer mounting for the head I AD or I AM see Figure 2 Note that the arrang...

Page 20: ...meter ARS mount DTS drawing TRIAX M2D 1168 on the standard bracket 020 1013A The sensor and the mount are shown in Figure 3 Figure 7 DTS ARS s on the special mount DTS drawing TRIAX M2D 1168 Figure 8 Q6 Head instrumentation Note Both accelerometer bracket arrangements 020 1013A standard and 020 1014 optional for ATA ARS version are shown in overlay ...

Page 21: ...by IFSTARR and is sold by Transpolis SAS The bladders come in three sizes 30 40 and 50 mm diameter The 40 mm diameter is used on Q6 Figure 9 40 mm APTS sensor The ATPS are mounted inside a special abdomen assembly part number 033 5005 This part has two blind holes for the sensors parallel to the lumbar spine The ATPS are inserted aluminium cap down and the sensor cables come out through small hole...

Page 22: ...sensors and with foam plugs for certification For information on biofidelity sensitivity performance repeatability reproducibility and injury criteria development refer to EEVC document number 661 to be submitted summer 2016 The assembly and component part numbers for the abdomens that can engage the APTS sensors are summarized in Table 5 Table 5 Assembly and component part numbers for abdomens th...

Page 23: ... transducer cables have been defined The general guideline is that all cables should be routed towards the thoracic spine of the dummy Cables should run from the top to the base of the thoracic spine At the lumbar spine thorax interface the cables go either towards the left or the right side The abdomen has been formed to allow the routing of the cables in such a way that they lie recessed between...

Page 24: ... following main components Head Neck Thorax Lumbar spine Abdomen Pelvis Arms Legs The dummy is dressed in a tight fitting suit This suit is an integral part of the dummy and should be worn during all tests A full description of the instrumentation capabilities is given in section 3 The tools needed for assembly and disassembly of the Q6 dummy are Screwdrivers Metric hex keys ...

Page 25: ...mounting base 020 1013 1 Screw SHCS M3 x 40 5000649 1 Screw SHCS M3 x 10 5000119 2 The head consists of two parts the front assembly skull and skin and a rear assembly skull cap The rear assembly may be removed by unscrewing the four M5 x 12 button head cap screws located at the rear of the head The head skin and skull are molded together and cannot be separated Inside the head is a large cavity w...

Page 26: ...033 9900 User Manual Q6 Advanced 6 year old Rev M 2016 Humanetics Innovative Solutions Inc Page 26 of 96 Figure 11 Q6 Head assembly standard and optional instrumentation brackets shown ...

Page 27: ...hrough the top of the head 4 Remove the head and upper neck load cell or structural replacement from the neck 5 Turn the head upside down and remove the FHCS screws at the base of the head Assembly The head can be assembled to the dummy by reversing the order of the disassembly Instrumentation Standard Instrumentation 1 To install the accelerometers first remove the head rear assembly by unscrewin...

Page 28: ...erometer mounting base 020 1013A the application of DTS ARS sensors is possible For additional information on the mounting of these sensors see Section 3 Instrumentation and Figure 5 4 3 Neck Construction Table 7 Neck assembly parts Description Part No Qty in Assembly Neck Assembly Tested and Certified 033 2300 1 Neck Molded pre tested 033 2301 1 Neck cable assembly pre tested 033 2200 1 Nut 020 2...

Page 29: ...ains high yield strength low stretch synthetic fiber cord This neck cable assembly is tested and pre stretched to ensure the correct length and the performance of the neck assembly The cable assembly should not be disassembled by the user The neck cable will act as a safety measure in case of rubber failure Figure 12 Q6 Neck assembly ...

Page 30: ...the bottom of the clamping plates on the neck cable assembly The neck cable is pre stretched and clamped down at manufacturing and should not be disassembled In case of cable damage customers are recommended to replace the complete neck cable assembly 020 2200 There is no adjustable pretension in the cable The nut 020 2204 can be tightened firmly Assembly Head neck Perform the steps described unde...

Page 31: ...0 countersunk head cap screws 5 Assemble head and load cell onto the top of the neck using the four M5 x 12 SHCS screws 6 Mount the head instrumentation in the head and close the head with the skull cap Note Always mount the upper neck load cell on to the neck BEFORE the head accelerometers as the accelerometer array will block the top access to the screws through the head ...

Page 32: ...my 033 4000 1 Rib Cage Assembly Tested and Certified 033 4100 1 Clavicle Retainer 033 4200 1 Clavicle 033 3200 1 Neck Torso interface plate 020 2308 1 Load cell Structural replacement 020 2007 1 Shoulder spine interface RH 033 3011 1 Shoulder spine interface LH 033 3015 1 Shoulder ball 033 3004 2 Shoulder Ball Retainer Ring 033 3003 2 Thoracic Spine Frontal Impact 033 4401 1 IR TRACC attachment ha...

Page 33: ...033 9900 User Manual Q6 Advanced 6 year old Rev M 2016 Humanetics Innovative Solutions Inc Page 33 of 96 Figure 13 Q6 Thorax assembly ...

Page 34: ...moving components or installing instrumentation it is convenient first to remove the head and neck see the paragraphs above for the procedure how to do this and then divide the dummy in two parts by removing the thorax lumbar spine screws This gives easy access to the internals of the upper torso and to the various bolts and screws Note to prevent unnecessary wear the rib cage and shoulders should...

Page 35: ...be removed by unscrewing the three M4 x 12 button head cap screws of each shoulder spine interface Assembly To assemble the thorax perform the operation described above in reverse order Note The shoulder should be set to the 1 2 g friction setting This can be done by tightening or loosening the three M3 button head screws See section 4 8 of this manual Instrumentation Standard Instrumentation Acce...

Page 36: ...rso interface plate 033 2308 from the load cell structural replacement by unscrewing the four M5 x 10 countersunk screws 4 Install the load cell by reversing the procedure described above First attach the neck torso interface plate 033 2308 to the load cell with the four countersunk screws 5 Place the load cell on top of the thoracic spine 033 4401 The base plate should be facing upward and the ca...

Page 37: ...20 4402 2 Gimbal Shaft 020 4403 1 E clip RS 209 8839 2 Shaft Locking Boss 020 4404 1 Gimbal Ring 020 4405 1 Screw SSCP M5 x 5 5000406 1 Attachment IR TRACC 033 4402 1 Spacer IR TRACC Attachment 020 4407 2 Screw SHCS 5 40 x 5 8 9002975 1 Screw FHCS M5 x 8 5000662 1 Figure 14 IR TRACC attachment hardware spine frontal top left and right and rib cage side bottom ...

Page 38: ... TRACC 4 Now center the gimbal shaft and tighten the set screw 5 The two gimbal pivot pins can be inserted into the thoracic spine Screw in until they will just appear on the inside of the thoracic spine 6 Hold the gimbal ring before the pin and screw in further until it holds 7 Attach the hardware at the other side of the IR TRACC as shown in Figure 14 8 Insert M5 screw in the rib cage hole and s...

Page 39: ... 5000662 1 3 IR TRACC Bracket Q6 033 4505 1 4 IR TRACC Bracket arm Q6 033 4502 1 5 Screw BHCS M5 x 22 5000571 2 6 Screw BHCS M4 x 20 5000007 2 7 Cone Spacer IR TRACC attachment 020 4407 4 8 Screw FHCS 5 40x5 8 9002975 2 9 Rod end mount base end 3620 44 1 10 Screw SHCS M2 x 6 5000082 1 Figure 16 Q6 side impact IR TRACC arrangement 1 To use the IR TRACC IF 362 for side impacts the IR TRACC should fi...

Page 40: ...with the three M5 x 22 screws 8 Attach the top end of the IR TRACC to the rib cage with the M5 countersunk screw 4 5 Lumbar Spine and Abdomen Construction The lumbar spine assembly consists of a rubber column with metal interfaces bonded to the top and bottom The top interface is U shaped vertical elements at the front and back The thoracic spine fits into this bracket and is secured using the two...

Page 41: ...escription Part No Qty in Assembly Lumbar Spine Assembly tested and certified 033 6000 1 Lumbar Spine central molding pre tested 033 6001 1 Lumbar Cable 033 6100 1 M6 nut self locking 5000093 1 M6 Plain Washer 5000094 1 Load cell structural replacement 020 2007 1 Screw SHCS M5 x 12 5000002 4 Screw FHCS M5 x 10 5000084 4 Abdomen foam part 033 5000 1 ...

Page 42: ...ll or load cell structural replacement from the lumbar spine by removing the four M5 x 12 socket head cap screws 5 The cable assembly should not need to be removed under normal circumstances If it becomes necessary use a screwdriver in the slot at the top of the cable to prevent the cable from turning and unscrew the self locking nut with a spanner In the steel cable there is no pretension require...

Page 43: ... x 12 counter sunk head screws attaching the structural replacement to the pelvis Remove the lumbar spine structural replacement assembly from the pelvis casting 3 Unscrew the four M5 x 12 screws to remove the structural replacement from the lumbar spine 4 Now replace the structural replacement with the actual load cell and install the four M5 x 12 cap head screws The base plate of the load cell s...

Page 44: ...ew SHCS M5 x 12 5000002 4 Screw BHCS M4 x 12 5000005 4 Assembly and Disassembly Disassembly 1 If necessary remove the dummy s upper part by removing the M6 x 43 bolts 020 9902 at the lumbar spine thorax interface 2 Remove the lumbar spine and load cell or load cell structural replacement as described in section 4 5 Legs 3 Remove the left and right legs To do so put the dummy on its back or front a...

Page 45: ... the leg at the hip Skin 6 When the legs are removed the pelvis flesh can be removed from the pelvis casting by pulling it downward Assembly Perform steps 1 to 6 under Disassembly in reverse order Figure 18 Pelvis and hip joint assembly Instrumentation Accelerometers The pelvis can be equipped with a mounting block accepting three uni axial accelerometers or a single tri axial accelerometer In ord...

Page 46: ... and lower leg connected to each other with a knee joint At the hip side a ball and socket joint is used This joint should not be taken apart under normal operating circumstances In the knee joint a limited range of motion has been built in At the end of this range rubber stops are used to smoothly decelerate the motion and thereby prevent spikes on the measurement signals The parts of the legs ar...

Page 47: ...ve the motion stop screw 020 9901 located on the inside of the knee joint 2 Remove the M6 x 35 socket head shoulder screw 033 9907 connecting the two parts of the leg Assembly 1 Check that the rubber end stops are in the correct positions inside the upper knee joint before assembly of the lower leg 2 Align upper and lower leg at shoulder screw holes and screw in shoulder screw 3 Before inserting t...

Page 48: ... the knee joint in the legs The legs are fully supported and positioned by the child restraint system Instrumentation No instrumentation is used in the legs 4 8 Arms Construction The arms consist of an upper and lower section connected at the elbow with a joint At the upper end a shoulder joint allows a number of degrees of freedom The main joint is of the ball and socket type with a limited range...

Page 49: ...ght Qty in each Assembly Arm Assembly L or R 033 9300 033 9400 1 Upper Arm Assembly L or R 033 9301 033 9401 1 Lower Arm Assembly L or R 033 9302 033 9402 1 Rubber end stop 020 9903 2 Shoulder Screw SHSS M5 x 20 5000626 1 Stop Screw 020 9901 1 Click Stop screw 5000328 1 Screw BHCS M4 x 12 5000005 3 Washer 033 3008 3 Friction washer 033 3007 3 Figure 20 Arm Assemblies ...

Page 50: ...d NOT to undo the shoulder ball 2 Remove the spring plunger 5000328 and motion stop screw 020 9901 3 Remove the shoulder screw connecting the upper and lower arm Assembly 1 Perform steps 1 3 under assembly in reverse order 2 Check that the rubber end stops are in the correct positions inside the elbow joint before assembly of the lower arm 3 Align upper and lower arm at the shoulder screw hole and...

Page 51: ...ee procedure under lumbar spine and or thorax paragraphs by removing the two M6 x 43 screws from the lumbar spine thorax interface 2 The abdomen can then easily be taken from the dummy Note It is not advised to remove the abdomen from the assembled dummy as this places forces and strains upon the material which can in time result in wear and tear Assembly 1 The dummy should be divided into the upp...

Page 52: ...ect the neck and provide a soft flesh covering The part is soft and light so as not to effect neck performance Assembly and Disassembly Disassembly Tilt the head back and pull the neck shield upwards Assembly Tilt the head back and insert the shield into the cavity between the clavicle and neck locating it inside the top of the ribcage See Figure 21 Ensure the shield is central and aligned with th...

Page 53: ... pelvis flesh thus potentially restraining the dummy from submarining The insert is made from a soft polyurethane to maintain dummy range of motion There is some free range of motion for adduction for positioning There is also an overlap at the top of the insert to help prevent the lap belt going under the abdomen The insert is fitted to the dummy before fitting the suit see Figure 22 below The in...

Page 54: ...o visible damage to the cord Shoulders Periodically examine the shoulder to spine interface for damage Clavicle Inspect the clavicle for cracks in the material Rib Cage Check the rib cage for tears and cracks in the material Deform the rib by hand as this will show cracks if present Cracks can be hidden by PVC skin that covers the outside of the rib cage To find significant damage pay special atte...

Page 55: ...nag behind some other object in the test set up which can result in damage of the head instrumentation Dummy Certification Besides the inspections to be performed before each test as described above the dummy should be regularly certified to check its performance It is advised to certify the dummy regularly as described in chapter 8 5 2 Click Stops and Arm Adjustment Arm adjustment The correct arm...

Page 56: ...ut of the click stop position If the click stops are screwed in too far the friction between them and the arm will be too large and the arm will not rotate under gravitation 5 3 Time Interval between Tests When conducting tests with the dummy or with dummy components a time interval of at least 30 minutes should be observed between consecutive tests Except for the head assembly this also applies w...

Page 57: ... head 5000119 2 Loadcell Structural Replacement 020 2007 1 Neck Assembly Test Cert 033 2100 1 Neck Moulding Pre tested 033 2301 1 Neck Cord Assembly 033 2200 1 Screw FHCS M3 x 0 5 x 8 neck cable neck 5000116 2 Neck Shield Frontal 033 2017 1 Torso Assembly Frontal Dummy 033 4000 1 Neck Torso Interface Plate 033 2308 1 Loadcell Structural Replacement 020 2007 2 Thoracic Spine Frontal Impact 033 4401...

Page 58: ...00096 9 Screw SHCS M5 x 0 8 x 12 structural replacement spine 5000002 8 Screw BHCS M5 x 0 7 x 12 Shoulder interface spine 5000005 8 Screw FHCS M5 x 0 8 x 10 Clavicle shoulder interface 5000084 6 Screw BHCS M5 x 0 8 x 14 shoulder ball clavicle 5000684 2 Screw BHCS M5 x 0 8 x 16 rib cage spine 5000416 6 Lumbar Spine Mounting Screw 020 9902 2 Screw FHCS M4 x 0 7 x 16 cable guide spine 5000447 2 Screw...

Page 59: ...mbly 033 9400 1 Upper Left Arm Assembly 033 9401 1 Lower Right Arm Assembly 033 9402 1 Shoulder Bolt SHSS M5 20 5000626 1 Stop Screw 020 9901 1 M8 Spring Plunger 5000328 1 IR TRACC IF 362 Assembly IF 362 1 Suit 033 8000 1 Screw FHCS M5 x 0 8 x 12 head structural replacement 5000096 4 Screw SHCS M5 x 0 8 x 12 structural replacement neck 5000002 4 Screw BHCS M5 x 0 8 x 10 neck torso 5000003 4 Screw ...

Page 60: ...efore each test and certify the dummy regularly as described in chapter 8 To safeguard continuous operation with the Q6 dummy it is recommended to take and maintain the following spare parts in stock are listed in Table 16 Table 16 Recommended spare parts Description Part No Qty in Assembly Rib Cage Assembly Test Cert 033 4100 1 Upper Left Leg Assembly 033 9101 1 Lower Left Leg Assembly 033 9102 1...

Page 61: ...st 4 hours prior to the use in a test The testing laboratory environment should be controlled to have a temperature of 20 2 degrees Celsius a relative humidity of 40 30 When conducting certification tests a time interval of at least 30 minutes should be observed between two consecutive tests This also applies when for example a lateral test is followed by a frontal test using the same dummy or dum...

Page 62: ... 572 Hybrid III head drop test and should have equivalent roughness and size Neck and Lumbar Spine Certification Equipment A pendulum which meets the requirements of CFR 49 part 572 33 c is needed to perform the certifications of the neck and lumbar spine see sections 8 6 and 8 7 The spine or neck is mounted upside down on the pendulum arm using an interface plate which replaces the standard part ...

Page 63: ...nsists of two flat disks connected by an interface which allows certification of both the neck and the lumbar spine The head form has different configurations one for testing the neck and one for testing the lumbar spine For testing the neck the large end of the central block is facing towards the pendulum arm and a steel disk is assembled between the neck and the central block see Figure 23 left ...

Page 64: ...neck and lumbar spine The potentiometer and balance mass are mounted on the sides of the head form with their common centerline perpendicular to the movement of the pendulum This can be seen in Figure 23 and Figure 24 The neck and lumbar spine test fixture can be used for both frontal and lateral testing of the head and lumbar spine For testing in frontal direction the head form discs are parallel...

Page 65: ...robe Probe weight including speed vane accelerometers and hardware 5 30 0 10 kg Probe Diameter 90 mm Round off radius 5 mm Figure 25 Q6 full body impactor accelerometer not shown The impactor is suspended as a guided pendulum by eight 7 x 7 stainless steel wires 2 mm diameter Figure 26 shows a front view of the impactor and four of the suspension wires in the required cross configuration A flat ho...

Page 66: ...ion support block Part number TE 033 9910 and a flat plate The support block shape matches the shape of the inside of the abdomen The support is placed on a horizontal surface and the abdomen is placed on the block with the front outer surface facing up A flat plate should be placed parallel to the horizontal base plate on top of the abdomen The dimensions of this plate are 300 by 250 mm and the m...

Page 67: ...ent parts list Part No Description Test 020 1050 Head Certification Mass Q Dummies Head Drop Test TE 2651 Head Positioning Basket Head Drop Test TE 2650 Head form Q Dummies Neck And Lumbar Spine Test TE 2650 Q6KIT Intermediate Plate TE 2650 15 and screws Neck Test TE 033 9910 Abdomen Certification Support Abdomen Test Q6 TE 033 9920 Full Body Probe Q6 Thorax Test Q6 ...

Page 68: ...move it from the neck The parts list for the head assembly is shown below Description Part No Qty Head front assembly 033 1020 1 Head rear assembly 033 1025 1 Head Accelerometer Mounting Base 020 1013 1 Screw BHCS M5 x 12 5000565 4 Screw SHCS M3 x 10 5000119 1 Screw SHCS M3 x 40 5000649 2 Load cell blank drop test mass block representing half the load cell 020 1050 1 Screw FHCS M5 x 10 5000084 4 N...

Page 69: ...re advised to use a thin wire basket TE 2651 to position the head The net has a piece of steel attached to it which allows the use of a magnet to keep the head in place The net allows easy adjustment of the head in any orientation 2 The z axis of the head should make an angle of 28 2 degrees with the horizontal plane and the medial lateral axis should be horizontal 1 degree When released the head ...

Page 70: ...mum resultant head acceleration response should be between 105 g and 135 g 2 The acceleration in Y direction should be between 10 and 10 g Lateral Impact Head Certification Test Procedure 1 The head is suspended above a rigid heavy metal plate The properties of this plate are described in section 7 2 under the heading Head Drop Table of this manual Users are advised to use a thin wire basket TE 26...

Page 71: ...sterior axis is horizontal 1 degree This corresponds to an angle between the horizontal plane and the head base plane of 55 2 degrees see Figure 28 When released the head should impact the surface with the side of its head 3 The lowest point of the head should be 130 1 mm above the impact surface 4 Release the head 5 The minimum time interval to observe between tests on the head is 30 minutes Figu...

Page 72: ... 1 Screw FHCS M5 x 10 5000084 4 Screw SHCS M5 x 10 5000291 4 Load cell or load cell structural replacement IF 217 or 020 2007 1 The neck is attached upside down to this pendulum A head form is used to load the neck This head form consists of two flat discs connected by an interface which allows certification of both the neck and the lumbar spine The head form rotation during the test is measured u...

Page 73: ...late 4 x M5 Place the modified 020 2015 TE 2650 15 intermediate plate between the neck and pendulum interface Align the neck and the interface making sure that longitudinal axis of the neck is in the direction of movement of the pendulum arm see Figure 29 4 Attach the head form neck system to the Part 572 pendulum The front of the head form should point in the direction of motion of the pendulum s...

Page 74: ...ed with the pendulum arm in the vertical position 3 Lift the pendulum up to its pre test height and check that the head form is in the correct initial position symmetrical with respect to neck top yoke Do not leave the head form neck system in this position for more than 1 minute as the neck will start to deform due to the mass of the head form 4 Release the pendulum Data Processing 1 Filter the p...

Page 75: ...s Upper limit m s 10 0 5 1 5 20 1 3 2 5 30 2 0 3 3 To meet the requirements of the frontal neck certification test see note below 3 The maximum head angle first maximum should be between 36 9 and 45 8 degrees The peak moment shall be between 22 6 and 28 0 Nm Lateral Neck Test Set up 1 Assemble the complete neck as described in section 4 3 with interface plate 033 2308 See Figure 12 2 Attach the IF...

Page 76: ... mass for the potentiometer on the other side of the central block This ensures that the inertial properties of the head are symmetrical in the impact direction Figure 30 indicates the proper position and orientation of the potentiometers 6 Insert the rod connecting the axes of the potentiometers and tighten the screw on the bottom most axis to secure the rod to the potentiometer The other end of ...

Page 77: ...the pendulum Lift the pendulum up to its pre test height and check that the head form is in the correct initial position symmetrical with respect to neck top yoke Do not leave the head form neck system Data Processing The data processing procedure of the lateral test is equal to the procedure mentioned in the frontal test Requirements 1 The impact velocity should be between 3 8 and 4 0 m s 2 The p...

Page 78: ... two flat disks connected by an interface which allows certification of both the neck and the lumbar spine The head form rotation during the test is measured using two rotational potentiometers One is installed on the base of the neck pendulum interface the second one is attached to the head form Both potentiometers are linked with a thin shaft see Figure 31 and Figure 32 The sum of the two angles...

Page 79: ... arm see Figure 31 4 Attach the head spine system to the part 572 pendulum The front of the head form should point in the direction of motion of the pendulum see Figure 31 5 Install the potentiometers to the mounting interface and on the head form Mount the balance mass for the potentiometer on the other side of the head form This ensures that the inertial properties of the head are symmetrical in...

Page 80: ...m in the vertical position 3 Lift the pendulum up to its pre test height and check that the head form is in the correct initial position Do not leave the head lumbar spine system in this position for more than 1 minute as the neck will start to deform due to the mass of the head form 4 Release the pendulum Data Processing 1 Filter the pendulum acceleration at CFC180 2 Filter the potentiometer read...

Page 81: ... lumbar spine certification test 3 The maximum head angle first maximum should be between 54 0 and 69 0 degrees This value should occur between 45 and 75 ms from the time zero point 4 The minimum head angle first minimum should be between 33 0 and 23 0 degrees This value should occur between 165 and 195 ms from the time zero point Lateral Lumbar Spine Test Set up 1 Slide the certification head for...

Page 82: ...lock Mount the balance mass for the potentiometer on the other side of the central block This ensures that the inertial properties of the head are symmetrical in the impact direction 6 Insert the rod connecting the axes of the potentiometers and tighten the screw on the bottom most axis to secure the rod to the potentiometer The other end of the rod should be able to slide freely through the upper...

Page 83: ...nute as the neck will start to deform due to the mass of the head form 4 Release the pendulum Data Processing The data processing procedures of the lateral test is equal to the procedure mentioned in the frontal test Requirements 1 The impact velocity should be between 4 3 and 4 5 m s 2 The pendulum velocity decrease should be as indicated in the table below Time ms Lower limit m s Upper limit m s...

Page 84: ...paragraph 7 2 To test the correct performance of the dummy abdomen an Additional mass is placed on the top plate Instrumentation The only instrumentation necessary to perform this test is a tape measure or calipers rule to measure the distance between the two plates Equipment required Description Q6 Top plate mass 2 05 0 025 kg Additional mass 8 05 0 025 kg Total mass 10 10 0 05 kg Abdomen support...

Page 85: ...d the displacement measurement 5 Remove the mass and top plate 6 Observe an interval of at least 30 minutes between successive tests on the same abdomen Data Processing 1 Subtract the final reading from the initial reading Requirement The deformation of the abdomen should be between 6 and 10 mm 8 5 Certification of the Thorax General A complete standard Q6 dummy without neck shield ATPS sensors or...

Page 86: ...ed using a hardware filter prior to A D conversion according to SAE J211 version March 1995 Figure 34 Neck Shield Installed and Removed See Section 4 10 Neck Shield install removal instructions Frontal Impact Thorax Test Instrumentation The dummy must be equipped with the standard IR TRACC to measure frontal chest deflection Use the 5 30 kg test probe as described in section 7 2 equipped with an a...

Page 87: ...owest position Check that the probe is in a horizontal position that is within 2 degrees The impactor front surface should be directly in front of the dummy sternum within 5 mm The height of the center line of the impactor over the seating surface should be chosen in such a way that the center line of the impactor aligns with the sternum halfway between the upper and lower edge of the rib This ali...

Page 88: ...n cause damage to the IR TRACC Use the 5 30 kg test probe as described in section 7 2 equipped with an accelerometer mounted along the impactor s longitudinal centerline to measure the impact deceleration The impact velocity must be measured and recorded This can be done with the speed vane on the test probe Test procedure 1 Dummy positioning Put the suit on the dummy and roll down the top half of...

Page 89: ...orizontal position by placing a bubble level on the flat top surface of the impactor as necessary Find the mid point between the upper and lower edge of the rib directly above and below the lateral IR TRACC attachment point Adjust table or probe as necessary so that the longitudinal centerline of the impactor is at the same height as this mid point Put the upper half of the suit back on the dummy ...

Page 90: ...or as close as possible 3 Make sure that the IR TRACC is not mounted for frontal impact as the side impact test can cause damage to the IR TRACC when it in its set up position for frontal impacts 4 Measure and record the impact velocity with the speed vane on the probe 5 The minimum time interval to observe between tests on the thorax is 30 minutes Data Processing 1 All data channels should be fil...

Page 91: ...96 3 Calculate the impactor force by multiplying the impactor acceleration in m s2 with the impactor mass Requirement To pass the certification requirements for lateral thoracic impact 1 The impactor velocity should be between 4 2 and 4 4 m s 2 The maximum impact force should be between 1 65 and 1 95 kN ...

Page 92: ...ith a pointer ball radius of 2 mm the ball point centre is specified The different marker characters are Dimple Spherical diameter 3 4 mm and diameter at dummy surface 3 0 to 3 5 mm Anticipated Ball Centre BC 1 0 mm outside dummy contour Hex recess of screw head o Hex 2 5 to 3 mm Anticipated Ball Centre BC 1 0 mm outside screw head top face o Hex 4 Anticipated Ball Centre BC 2 0 mm from bottom of ...

Page 93: ...rew head recess IRTRACC to rib attachment lateral 62 9 78 0 262 3 BC Hex 3 mm Ball centres Hip joints 77 4 53 1 48 9 Table 21 Markers Arms Origin Elbow joint centre Upper arm bone vertical lower arm bone horizontal Point Description X mm Y mm Z mm Remark Screw head recess of Top screw of shoulder joint 0 0 20 3 228 0 BC Hex 2 5 mm Screw head recess Elbow 0 0 16 6 0 0 BC Hex 3 mm Ball centre Should...

Page 94: ...st and pelvis exploded view Pg 37 38 Rev E Jan 2014 Updated Time Interval paragraph Pg 45 Section 5 3 Rev F Mar 2014 In section 8 5 a sentence was added under the General paragraph that the Thorax tests should be done without the neck shield In the Side Impact paragraph the sentence Do not leave IR TRACC in its frontal test position as the side impact test can cause damage is now in bold as a warn...

Page 95: ...BHCS M5 x 12 was M5 x 16 and QTY 5 was 4 added Screw FHCS M5 x 8 5000662 QTY 1 Screw BHCS M5 x 14 5000684 QTY 2 and Screw FHCS M4 x 16 5000447 QTY 2 Figure 7 Q6 Thorax assembly Added missing call out 5000447 5000684 was 5000084 5000662 was 5000096 Figure 9 IR TRACC attachment hardware 5000662 was 5000096 Side Impact IR TRACC mounting bracket assembly table Item No 1 Attachment IR TRACC 033 4403 wa...

Page 96: ...ion 4 12 added weight to hip insert Section 7 2 below figure 24 total head form mass includes instrumentation but not loadcell Section 7 3 equipment list table added part TE 2650 Q6KIT Section 8 5 Lateral Impact Thorax Test revised text Added figure for impact location roll down suit and approx to Teflon sheet dimensions Removed between 40 and 60 for leg stability 2 for impactor alignment and bull...

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