893 lines
24 KiB
Markdown
893 lines
24 KiB
Markdown
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# Technical Standards and Specifications for Crash Testing
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## SAE, ISO, and Other Engineering Standards
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### Data Acquisition, Instrumentation, Injury Criteria, and Test Methods
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---
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# OVERVIEW
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This document covers the technical standards that govern HOW crash testing is performed - the instrumentation, data acquisition, filtering, injury calculations, and dummy specifications that underlie FMVSS and IIHS testing.
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**Key Standards Organizations:**
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- **SAE International** - Society of Automotive Engineers (US-based, global influence)
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- **ISO** - International Organization for Standardization (global)
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- **UN/ECE** - United Nations Economic Commission for Europe
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- **NHTSA** - Defines injury criteria referenced by FMVSS
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---
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# SAE J211: INSTRUMENTATION FOR IMPACT TEST
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## SAE J211-1: Instrumentation for Impact Test - Electronic Instrumentation
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**First Published:** 1971
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**Current Version:** SAE J211-1 (Rev. 2014)
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**Scope:** Defines requirements for electronic instrumentation used in vehicle crash testing
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### Purpose
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SAE J211-1 ensures that crash test data is:
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- **Accurate** - Measurements reflect actual physical events
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- **Repeatable** - Same test produces same data across labs
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- **Comparable** - Data from different facilities can be compared
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- **Filtered appropriately** - High-frequency noise removed without distorting signal
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### Channel Frequency Classes (CFC)
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The most important concept in J211 is **Channel Frequency Class** - the bandwidth of the measurement system.
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| CFC | -3dB Frequency | Primary Use | Why This Bandwidth |
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|-----|----------------|-------------|-------------------|
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| **CFC 1000** | 1000 Hz (1650 Hz) | Head acceleration | Head impacts are high-frequency events |
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| **CFC 600** | 600 Hz (1000 Hz) | Chest, pelvis acceleration | Torso response is lower frequency |
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| **CFC 180** | 180 Hz (300 Hz) | Structural measurements | Vehicle deformation |
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| **CFC 60** | 60 Hz (100 Hz) | Sled displacement | Gross motion |
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**Note:** The -3dB point is where signal is attenuated by 3dB (70.7%). The values in parentheses are the frequency at which attenuation reaches -40dB.
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### Filter Characteristics
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SAE J211 specifies a **4th-order Butterworth low-pass filter** with specific characteristics:
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| Parameter | Specification |
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|-----------|---------------|
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| Filter type | Butterworth (maximally flat) |
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| Filter order | 4th order (24 dB/octave rolloff) |
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| Phase | Zero phase shift (bi-directional filtering) |
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| Passband | Flat to -0.5 dB at CFC frequency |
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| Stopband | -24 dB at 1.67 × CFC frequency |
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### Sampling Requirements
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| CFC | Minimum Sample Rate | Recommended Rate |
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|-----|---------------------|------------------|
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| CFC 1000 | 8,000 Hz | 10,000+ Hz |
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| CFC 600 | 4,800 Hz | 6,000+ Hz |
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| CFC 180 | 1,440 Hz | 2,000+ Hz |
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| CFC 60 | 480 Hz | 1,000+ Hz |
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**Rule of thumb:** Sample at 8-10× the CFC frequency for adequate resolution.
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### Transducer Requirements
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| Parameter | Specification |
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|-----------|---------------|
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| Amplitude linearity | ±1% of full scale |
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| Cross-axis sensitivity | <5% of primary axis |
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| Zero shift (post-impact) | <2% of full scale |
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| Frequency response | Flat to at least CFC frequency |
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### Data Channel Designation
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J211 defines a naming convention for data channels:
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```
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[Location][Direction][Type][Filter]
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Example: 11HEAD0000ACXC (Head X-acceleration, CFC 1000)
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```
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| Code | Meaning |
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|------|---------|
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| 11 | Driver position |
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| 12 | Front passenger |
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| 13 | Rear passenger |
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| HEAD | Head |
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| CHST | Chest |
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| PELV | Pelvis |
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| FEMR | Femur |
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| AC | Acceleration |
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| FO | Force |
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| MO | Moment |
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| X, Y, Z | Direction |
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---
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## SAE J211-2: Instrumentation for Impact Test - Photographic Instrumentation
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**Current Version:** SAE J211-2 (Rev. 2001)
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**Scope:** Requirements for high-speed photography and video in crash testing
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### Frame Rate Requirements
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| Application | Minimum Rate | Typical Rate |
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|-------------|--------------|--------------|
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| Occupant kinematics | 500 fps | 1,000 fps |
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| Structural deformation | 1,000 fps | 2,000-4,000 fps |
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| Airbag deployment | 2,000 fps | 5,000-10,000 fps |
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| Detail analysis | 5,000+ fps | 10,000-40,000 fps |
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### Camera Positioning
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- Minimum 3 views: front, side (left or right), overhead
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- Additional views as needed for specific analysis
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- Reference markers (targets) for photogrammetric analysis
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- Lighting requirements for adequate exposure at high speed
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### Timing Synchronization
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- All cameras synchronized to common time base
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- Synchronization with electronic data acquisition
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- Timing marks visible in frame or recorded electronically
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- Time zero defined as first contact
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---
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# ISO 6487: ROAD VEHICLES - MEASUREMENT TECHNIQUES IN IMPACT TESTS
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**Equivalent to:** SAE J211-1
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**Current Version:** ISO 6487:2015
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**Scope:** International standard for crash test instrumentation
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### Relationship to SAE J211
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ISO 6487 and SAE J211-1 are technically equivalent and mutually referenced. Key correspondences:
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| SAE J211 CFC | ISO 6487 CFC | Application |
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|--------------|--------------|-------------|
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| CFC 1000 | CFC 1000 | Head |
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| CFC 600 | CFC 600 | Chest, pelvis |
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| CFC 180 | CFC 180 | Structure |
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| CFC 60 | CFC 60 | Gross motion |
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### Filter Specification (ISO 6487)
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ISO 6487 defines the same 4th-order Butterworth filter with identical characteristics:
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$$H(f) = \frac{1}{\sqrt{1 + (f/f_c)^{2n}}}$$
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Where:
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- H(f) = filter transfer function
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- f = frequency
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- f_c = cutoff frequency (CFC)
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- n = filter order (4 for 4th order)
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### Calibration Requirements
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| Parameter | Accuracy |
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|-----------|----------|
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| Acceleration | ±1.5% of full scale |
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| Force | ±1% of full scale |
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| Displacement | ±1% of full scale |
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| Time | ±0.01 ms |
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---
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# ISO 13232: MOTORCYCLES - TEST AND ANALYSIS PROCEDURES FOR RESEARCH EVALUATION OF RIDER PROTECTIVE DEVICES
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**Current Version:** ISO 13232:2005 (Parts 1-8)
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**Scope:** Motorcycle crash testing with rider dummies
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### Key Differences from Automotive
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| Parameter | Automotive | Motorcycle (ISO 13232) |
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|-----------|------------|------------------------|
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| Dummy | Hybrid III, THOR | Motorcyclist ATD |
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| Positions | Seated upright | Various riding positions |
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| Impact modes | Frontal, side, rear | Multiple approach angles |
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| Ejection | Prevented (restraints) | Expected and measured |
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---
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# INJURY CRITERIA DEFINITIONS
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## Head Injury Criterion (HIC)
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**Defined in:** FMVSS 208, SAE J885, NHTSA regulations
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**First Used:** 1972 (FMVSS 208)
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### Formula
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$$HIC = \left[ \frac{1}{t_2 - t_1} \int_{t_1}^{t_2} a(t) \, dt \right]^{2.5} (t_2 - t_1)$$
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Where:
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- a(t) = resultant head acceleration (g)
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- t₁, t₂ = time interval (seconds)
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- (t₂ - t₁) = time interval maximized to find worst case
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### HIC Versions
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| Version | Time Window | Limit | Application |
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|---------|-------------|-------|-------------|
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| HIC₃₆ | 36 ms max | 1000 | FMVSS 208 (airbag) |
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| HIC₁₅ | 15 ms max | 700 | FMVSS 208 (current) |
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| HIC unlimited | No limit | 1000 | Historical |
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### Interpretation
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| HIC Value | Injury Risk |
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|-----------|-------------|
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| < 500 | Low risk |
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| 500-700 | Moderate risk |
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| 700-1000 | Significant risk |
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| > 1000 | High risk of serious injury |
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**Basis:** Wayne State Tolerance Curve (WSTC) derived from cadaver and volunteer testing.
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---
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## Chest Injury Criteria
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### Chest Acceleration (3ms Clip)
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**Defined in:** FMVSS 208
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**Formula:** Maximum resultant chest acceleration sustained for 3 ms
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**Limit:** ≤ 60g
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### Chest Deflection
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**Defined in:** FMVSS 208
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**Measurement:** Compression of sternum relative to spine
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**Limits:**
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| Dummy | Deflection Limit |
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|-------|-----------------|
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| Hybrid III 50th Male | 63 mm |
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| Hybrid III 5th Female | 52 mm |
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| THOR 50th Male | 63 mm |
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### Viscous Criterion (V*C)
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**Defined in:** European regulations, soft tissue injury
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**Formula:**
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$$V \cdot C = V(t) \times C(t)$$
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Where:
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- V(t) = velocity of chest compression
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- C(t) = compression as fraction of chest depth
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- Limit: ≤ 1.0 m/s
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**Purpose:** Captures rate-dependent soft tissue injury (heart, liver, spleen)
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### Combined Thoracic Index (CTI)
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**Defined in:** FMVSS 208 (advanced airbag rule)
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**Formula:**
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$$CTI = \frac{A_{max}}{A_{int}} + \frac{D_{max}}{D_{int}}$$
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Where:
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- A_max = maximum chest acceleration
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- D_max = maximum chest deflection
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- A_int, D_int = intercept values (dummy-specific)
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**Limit:** CTI ≤ 1.0
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---
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## Neck Injury Criteria (Nij)
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**Defined in:** FMVSS 208
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**Purpose:** Combined neck axial load and bending moment
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### Formula
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$$N_{ij} = \frac{F_z}{F_{zc}} + \frac{M_{oy}}{M_{yc}}$$
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Where:
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- F_z = axial neck force (tension or compression)
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- M_oy = neck bending moment (flexion or extension)
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- F_zc, M_yc = critical intercept values
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### Critical Values (Hybrid III 50th Male)
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| Direction | Force (N) | Moment (Nm) |
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|-----------|-----------|-------------|
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| Tension-Extension | 6,806 | 135 |
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| Tension-Flexion | 6,806 | 310 |
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| Compression-Extension | 6,160 | 135 |
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| Compression-Flexion | 6,160 | 310 |
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**Limit:** Nij ≤ 1.0 for any combination
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---
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## Femur Load Criterion
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**Defined in:** FMVSS 208
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**Measurement:** Axial compressive force in femur
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**Limit:** ≤ 10,000 N (10 kN)
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**Duration:** Peak force in any 10 ms window
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### Femur Force Measurement
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| Dummy | Measurement Location |
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|-------|---------------------|
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| Hybrid III | Femur load cell |
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| THOR | Upper, middle, lower femur |
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---
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## Tibia Injury Criteria
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### Tibia Index (TI)
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**Defined in:** European regulations
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**Formula:**
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$$TI = \frac{M_R}{M_C} + \frac{F_Z}{F_C}$$
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Where:
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- M_R = resultant bending moment
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- F_Z = axial force
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- M_C, F_C = critical values
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**Limit:** TI ≤ 1.0
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### Tibia Compressive Force
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**Limit:** ≤ 8,000 N (8 kN)
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---
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## Pelvis Acceleration
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**Defined in:** FMVSS 214
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**Measurement:** Resultant pelvis acceleration
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**Limit:** Varies by test mode and dummy
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---
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## Severity Index (SI) - Helmets
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**Defined in:** NOCSAE, FMVSS 218
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**Formula:**
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$$SI = \int a^{2.5} \, dt$$
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Where:
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- a = head acceleration (g)
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- t = time (seconds)
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**Limits:**
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| Standard | SI Limit |
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|----------|----------|
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| NOCSAE Football | < 1200 |
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| FMVSS 218 Motorcycle | N/A (uses peak g) |
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**Relationship to HIC:** SI is the time-weighted integral; HIC normalizes by time interval.
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---
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# DUMMY (ATD) SPECIFICATIONS
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## SAE J963: Anthropomorphic Test Dummy Family
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**Scope:** Defines the Hybrid III dummy family specifications
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|||
|
|
|
|||
|
|
### Hybrid III Family
|
|||
|
|
|
|||
|
|
| Model | Height | Weight | Primary Use |
|
|||
|
|
|-------|--------|--------|-------------|
|
|||
|
|
| 95th Male | 188 cm (6'2") | 101 kg (223 lb) | Large adult male |
|
|||
|
|
| 50th Male | 175 cm (5'9") | 78 kg (172 lb) | Average adult male |
|
|||
|
|
| 5th Female | 152 cm (5'0") | 49 kg (108 lb) | Small adult female |
|
|||
|
|
| 10-year-old | 138 cm (4'6") | 36 kg (79 lb) | Child |
|
|||
|
|
| 6-year-old | 117 cm (3'10") | 23 kg (51 lb) | Child |
|
|||
|
|
| 3-year-old | 99 cm (3'3") | 15 kg (33 lb) | Child |
|
|||
|
|
|
|||
|
|
### Hybrid III 50th Male Instrumentation
|
|||
|
|
|
|||
|
|
| Location | Measurements | Channels |
|
|||
|
|
|----------|--------------|----------|
|
|||
|
|
| Head | Triaxial acceleration | 3 |
|
|||
|
|
| Head | Angular acceleration (optional) | 3 |
|
|||
|
|
| Upper neck | 6-axis load cell | 6 |
|
|||
|
|
| Lower neck | 6-axis load cell | 6 |
|
|||
|
|
| Chest | Triaxial acceleration | 3 |
|
|||
|
|
| Chest | Deflection (potentiometer) | 1 |
|
|||
|
|
| Lumbar spine | 6-axis load cell | 6 |
|
|||
|
|
| Pelvis | Triaxial acceleration | 3 |
|
|||
|
|
| Femur (L) | Axial force | 1 |
|
|||
|
|
| Femur (R) | Axial force | 1 |
|
|||
|
|
| Knee (L) | Displacement | 1 |
|
|||
|
|
| Knee (R) | Displacement | 1 |
|
|||
|
|
| Tibia (L) | 6-axis load cell | 6 |
|
|||
|
|
| Tibia (R) | 6-axis load cell | 6 |
|
|||
|
|
| **TOTAL** | | **~47 channels** |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## ISO 13232-3: Motorcyclist Anthropomorphic Test Device
|
|||
|
|
|
|||
|
|
**Scope:** Dummy for motorcycle crash testing
|
|||
|
|
|
|||
|
|
### Differences from Hybrid III
|
|||
|
|
|
|||
|
|
| Feature | Hybrid III | Motorcyclist ATD |
|
|||
|
|
|---------|------------|------------------|
|
|||
|
|
| Neck | Limited ROM | Full range of motion |
|
|||
|
|
| Shoulder | Automotive seated | Riding position |
|
|||
|
|
| Hip | Seated | Straddling |
|
|||
|
|
| Limbs | Fixed joints | Articulated |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## THOR (Test Device for Human Occupant Restraint)
|
|||
|
|
|
|||
|
|
### THOR-50M Specifications
|
|||
|
|
|
|||
|
|
| Parameter | Specification |
|
|||
|
|
|-----------|---------------|
|
|||
|
|
| Height | 175 cm (5'9") |
|
|||
|
|
| Weight | 78 kg (172 lb) |
|
|||
|
|
| Channels | 150+ |
|
|||
|
|
|
|||
|
|
### THOR Improvements Over Hybrid III
|
|||
|
|
|
|||
|
|
| Feature | Hybrid III | THOR |
|
|||
|
|
|---------|------------|------|
|
|||
|
|
| Chest | Single deflection point | Multi-point (4 locations) |
|
|||
|
|
| Abdomen | Not instrumented | Instrumented |
|
|||
|
|
| Face | Basic | Deformable, instrumented |
|
|||
|
|
| Shoulder | Simple | Complex clavicle |
|
|||
|
|
| Pelvis | Basic | Instrumented iliac wings |
|
|||
|
|
| Spine | Rigid | Flexible |
|
|||
|
|
|
|||
|
|
### THOR-5F (Female)
|
|||
|
|
|
|||
|
|
**Released:** 2023
|
|||
|
|
**Significance:** First true female dummy (not scaled male)
|
|||
|
|
|
|||
|
|
| Feature | Hybrid III 5th Female | THOR-5F |
|
|||
|
|
|---------|----------------------|---------|
|
|||
|
|
| Design basis | Scaled 50th male | Female anatomy |
|
|||
|
|
| Hip structure | Male-derived | Female pelvis |
|
|||
|
|
| Breast | Not represented | Represented |
|
|||
|
|
| Organ placement | Male-based | Female-based |
|
|||
|
|
| Height | 152 cm | 161 cm |
|
|||
|
|
| Weight | 49 kg | 49 kg |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## BioRID II (Rear Impact Dummy)
|
|||
|
|
|
|||
|
|
**Purpose:** Whiplash assessment in rear impacts
|
|||
|
|
|
|||
|
|
| Feature | Specification |
|
|||
|
|
|---------|---------------|
|
|||
|
|
| Spine | Highly articulated (24 vertebrae) |
|
|||
|
|
| Head/neck response | Biofidelic in rear impact |
|
|||
|
|
| Certification | Dynamic corridor matching |
|
|||
|
|
| Primary use | IIHS head restraint test |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## WorldSID (World Side Impact Dummy)
|
|||
|
|
|
|||
|
|
**Purpose:** International harmonized side impact dummy
|
|||
|
|
|
|||
|
|
### Versions
|
|||
|
|
|
|||
|
|
| Model | Percentile | Primary Use |
|
|||
|
|
|-------|------------|-------------|
|
|||
|
|
| WorldSID 50th | 50th male | Side impact |
|
|||
|
|
| WorldSID 5th | 5th female | Side impact |
|
|||
|
|
|
|||
|
|
### Instrumentation
|
|||
|
|
|
|||
|
|
| Location | Measurements |
|
|||
|
|
|----------|--------------|
|
|||
|
|
| Head | Triaxial acceleration, angular velocity |
|
|||
|
|
| Neck | 6-axis load cell |
|
|||
|
|
| Thorax | Rib deflections (3 levels, multiple points) |
|
|||
|
|
| Abdomen | Forces |
|
|||
|
|
| Pelvis | Acceleration, pubic force |
|
|||
|
|
| Spine | T1, T12 acceleration |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## SID-IIs (Side Impact Dummy - Second Generation)
|
|||
|
|
|
|||
|
|
**Purpose:** Small female side impact (IIHS side test)
|
|||
|
|
|
|||
|
|
| Parameter | Specification |
|
|||
|
|
|-----------|---------------|
|
|||
|
|
| Percentile | 5th female |
|
|||
|
|
| Height | 152 cm (5'0") |
|
|||
|
|
| Weight | 45 kg (99 lb) |
|
|||
|
|
| Primary use | IIHS side impact test |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## ES-2re (European Side Impact Dummy - Rib Extension)
|
|||
|
|
|
|||
|
|
**Purpose:** FMVSS 214 side impact
|
|||
|
|
|
|||
|
|
| Parameter | Specification |
|
|||
|
|
|-----------|---------------|
|
|||
|
|
| Percentile | 50th male |
|
|||
|
|
| Rib design | Extended measurement range |
|
|||
|
|
| Primary use | FMVSS 214, NCAP side |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## Q-Series (Child Dummies)
|
|||
|
|
|
|||
|
|
**Purpose:** Child occupant protection
|
|||
|
|
|
|||
|
|
| Model | Age Represented | Weight |
|
|||
|
|
|-------|-----------------|--------|
|
|||
|
|
| Q0 | Newborn | 3.4 kg |
|
|||
|
|
| Q1 | 1-year-old | 9.8 kg |
|
|||
|
|
| Q1.5 | 1.5-year-old | 11 kg |
|
|||
|
|
| Q3 | 3-year-old | 14.5 kg |
|
|||
|
|
| Q6 | 6-year-old | 23 kg |
|
|||
|
|
| Q10 | 10-year-old | 36 kg |
|
|||
|
|
|
|||
|
|
### Q-Dummy Features
|
|||
|
|
- Biofidelic child response
|
|||
|
|
- Appropriate injury criteria
|
|||
|
|
- Used in Euro NCAP, i-Size testing
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## CRABI (Child Restraint Air Bag Interaction)
|
|||
|
|
|
|||
|
|
**Purpose:** Infant dummy for airbag interaction testing
|
|||
|
|
|
|||
|
|
| Model | Age | Weight | Use |
|
|||
|
|
|-------|-----|--------|-----|
|
|||
|
|
| CRABI 6-month | 6 months | 7.8 kg | Out-of-position testing |
|
|||
|
|
| CRABI 12-month | 12 months | 10 kg | Child seat testing |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## WIAMan (Warrior Injury Assessment Manikin)
|
|||
|
|
|
|||
|
|
**Purpose:** Military underbody blast testing
|
|||
|
|
|
|||
|
|
| Feature | Specification |
|
|||
|
|
|---------|---------------|
|
|||
|
|
| Developer | US Army + DTS |
|
|||
|
|
| Primary threat | IED underbody blast |
|
|||
|
|
| Key measurements | Lumbar spine, pelvis |
|
|||
|
|
| Position | Seated (military vehicle) |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
# COORDINATE SYSTEMS
|
|||
|
|
|
|||
|
|
## SAE J1733: Sign Convention for Vehicle Crash Testing
|
|||
|
|
|
|||
|
|
**Purpose:** Standardized coordinate system for crash data
|
|||
|
|
|
|||
|
|
### Vehicle Coordinate System
|
|||
|
|
|
|||
|
|
```
|
|||
|
|
+Z (up)
|
|||
|
|
|
|
|||
|
|
|
|
|||
|
|
|_______ +Y (right)
|
|||
|
|
/
|
|||
|
|
/
|
|||
|
|
+X (forward)
|
|||
|
|
```
|
|||
|
|
|
|||
|
|
| Axis | Positive Direction |
|
|||
|
|
|------|-------------------|
|
|||
|
|
| X | Forward (direction of travel) |
|
|||
|
|
| Y | Right (passenger side in LHD) |
|
|||
|
|
| Z | Up |
|
|||
|
|
|
|||
|
|
### Dummy Coordinate System
|
|||
|
|
|
|||
|
|
Same convention as vehicle:
|
|||
|
|
- +X: Forward (anterior)
|
|||
|
|
- +Y: Right (lateral)
|
|||
|
|
- +Z: Up (superior)
|
|||
|
|
|
|||
|
|
### Sign Conventions for Loads
|
|||
|
|
|
|||
|
|
| Measurement | Positive | Negative |
|
|||
|
|
|-------------|----------|----------|
|
|||
|
|
| Neck tension | Pulling head away from torso | Compression |
|
|||
|
|
| Neck flexion | Chin toward chest | Extension (head back) |
|
|||
|
|
| Femur compression | Pushing toward hip | Tension |
|
|||
|
|
| Chest deflection | Compression | N/A |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
# CALIBRATION STANDARDS
|
|||
|
|
|
|||
|
|
## SAE J2570: Performance Specifications for Anthropomorphic Test Device Transducers
|
|||
|
|
|
|||
|
|
**Scope:** Transducer specifications for ATDs
|
|||
|
|
|
|||
|
|
### Accelerometer Specifications
|
|||
|
|
|
|||
|
|
| Parameter | Specification |
|
|||
|
|
|-----------|---------------|
|
|||
|
|
| Range | ±50g to ±500g (application dependent) |
|
|||
|
|
| Sensitivity | Typically 0.1-10 mV/g |
|
|||
|
|
| Cross-axis sensitivity | <5% |
|
|||
|
|
| Frequency response | DC to CFC requirement |
|
|||
|
|
| Shock survival | >1000g for head accelerometers |
|
|||
|
|
|
|||
|
|
### Load Cell Specifications
|
|||
|
|
|
|||
|
|
| Parameter | Specification |
|
|||
|
|
|-----------|---------------|
|
|||
|
|
| Accuracy | ±1% full scale |
|
|||
|
|
| Cross-talk | <3% between channels |
|
|||
|
|
| Hysteresis | <1% |
|
|||
|
|
| Zero shift | <2% after impact |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## ISO 6487 Calibration Requirements
|
|||
|
|
|
|||
|
|
### Calibration Intervals
|
|||
|
|
|
|||
|
|
| Component | Calibration Interval |
|
|||
|
|
|-----------|---------------------|
|
|||
|
|
| Accelerometers | Annual or after 50 impacts |
|
|||
|
|
| Load cells | Annual or after impact exceedance |
|
|||
|
|
| Data acquisition | Annual |
|
|||
|
|
| Filters | Verification with each test |
|
|||
|
|
|
|||
|
|
### Calibration Documentation
|
|||
|
|
|
|||
|
|
| Item | Required |
|
|||
|
|
|------|----------|
|
|||
|
|
| Calibration certificate | Yes |
|
|||
|
|
| Traceability to national standards | Yes |
|
|||
|
|
| Environmental conditions | Yes |
|
|||
|
|
| Uncertainty statement | Yes |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
# BARRIER SPECIFICATIONS
|
|||
|
|
|
|||
|
|
## IIHS Deformable Barrier (Moderate Overlap)
|
|||
|
|
|
|||
|
|
| Parameter | Specification |
|
|||
|
|
|-----------|---------------|
|
|||
|
|
| Face | Deformable aluminum honeycomb |
|
|||
|
|
| Width | 1,000 mm |
|
|||
|
|
| Height | 650 mm |
|
|||
|
|
| Crush strength | Progressive, 0.34 MPa face, 1.7 MPa back |
|
|||
|
|
| Mass | N/A (barrier fixed) |
|
|||
|
|
|
|||
|
|
## FMVSS 214 Moving Deformable Barrier (MDB)
|
|||
|
|
|
|||
|
|
| Parameter | Specification |
|
|||
|
|
|-----------|---------------|
|
|||
|
|
| Mass | 1,368 kg (3,015 lb) |
|
|||
|
|
| Face | Deformable aluminum honeycomb |
|
|||
|
|
| Face width | 1,676 mm |
|
|||
|
|
| Face height | 559 mm |
|
|||
|
|
| Ground clearance | 279 mm |
|
|||
|
|
| Impact speed | 33.5 mph (53.9 km/h) |
|
|||
|
|
|
|||
|
|
## IIHS Side Impact Barrier (2021+)
|
|||
|
|
|
|||
|
|
| Parameter | 2003-2020 | 2021+ |
|
|||
|
|
|-----------|-----------|-------|
|
|||
|
|
| Mass | 1,500 kg (3,300 lb) | 1,905 kg (4,200 lb) |
|
|||
|
|
| Speed | 50 km/h (31 mph) | 60 km/h (37 mph) |
|
|||
|
|
| Ground clearance | 300 mm | Higher profile |
|
|||
|
|
| Face height | Standard | Taller |
|
|||
|
|
|
|||
|
|
## IIHS Small Overlap Rigid Barrier
|
|||
|
|
|
|||
|
|
| Parameter | Specification |
|
|||
|
|
|-----------|---------------|
|
|||
|
|
| Type | Rigid (non-deformable) |
|
|||
|
|
| Width | 25% of vehicle width |
|
|||
|
|
| Surface | Flat, rigid |
|
|||
|
|
| Impact speed | 64 km/h (40 mph) |
|
|||
|
|
|
|||
|
|
## Euro NCAP Mobile Progressive Deformable Barrier (MPDB)
|
|||
|
|
|
|||
|
|
| Parameter | Specification |
|
|||
|
|
|-----------|---------------|
|
|||
|
|
| Mass | 1,400 kg |
|
|||
|
|
| Speed | 50 km/h |
|
|||
|
|
| Face | Progressive crush (multi-layer) |
|
|||
|
|
| Measurement | Barrier deformation recorded |
|
|||
|
|
| Purpose | Assess vehicle's "aggressivity" |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
# DATA ANALYSIS STANDARDS
|
|||
|
|
|
|||
|
|
## SAE J2052: Test Method for Determining Center of Gravity
|
|||
|
|
|
|||
|
|
**Purpose:** Locate vehicle CG for crash test setup
|
|||
|
|
|
|||
|
|
### Method
|
|||
|
|
- Three-point weighing
|
|||
|
|
- Tilt table measurement
|
|||
|
|
- Calculate CG location in X, Y, Z
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## SAE J1733: Sign Convention
|
|||
|
|
|
|||
|
|
Already covered above - defines positive/negative directions for all measurements.
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
## ISO 13232-5: Injury Indices and Risk/Benefit Analysis
|
|||
|
|
|
|||
|
|
**Scope:** Converting dummy measurements to injury probability
|
|||
|
|
|
|||
|
|
### Injury Probability Functions
|
|||
|
|
|
|||
|
|
Example for head injury:
|
|||
|
|
|
|||
|
|
$$P_{injury} = \frac{1}{1 + e^{-(\alpha + \beta \cdot HIC)}}$$
|
|||
|
|
|
|||
|
|
Where α and β are coefficients derived from real-world injury data.
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
# CRASH TEST FACILITY STANDARDS
|
|||
|
|
|
|||
|
|
## SAE J2432: Performance Requirements for a Photogrammetric Vehicle Test System
|
|||
|
|
|
|||
|
|
**Scope:** Requirements for target tracking systems
|
|||
|
|
|
|||
|
|
### Target Specifications
|
|||
|
|
|
|||
|
|
| Target | Size | Contrast | Placement |
|
|||
|
|
|--------|------|----------|-----------|
|
|||
|
|
| Vehicle reference | 25 mm diameter | Black/white | B-pillar, roof rail |
|
|||
|
|
| Dummy | 10-15 mm | Contrasting | Head, chest, knee |
|
|||
|
|
| Time reference | Frame counter | Visible | In-frame |
|
|||
|
|
|
|||
|
|
### Measurement Accuracy
|
|||
|
|
|
|||
|
|
| Parameter | Accuracy |
|
|||
|
|
|-----------|----------|
|
|||
|
|
| Position | ±5 mm |
|
|||
|
|
| Velocity | ±1% |
|
|||
|
|
| Acceleration | ±2% |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
# SLED TEST STANDARDS
|
|||
|
|
|
|||
|
|
## SAE J2765: HYGE Sled Test Procedure
|
|||
|
|
|
|||
|
|
**Scope:** Sled test setup and execution
|
|||
|
|
|
|||
|
|
### Sled Pulse Reproduction
|
|||
|
|
|
|||
|
|
| Parameter | Tolerance |
|
|||
|
|
|-----------|-----------|
|
|||
|
|
| Peak acceleration | ±5% |
|
|||
|
|
| Pulse duration | ±5% |
|
|||
|
|
| Velocity change | ±2% |
|
|||
|
|
| Time to peak | ±5% |
|
|||
|
|
|
|||
|
|
### Data Acquisition for Sled Tests
|
|||
|
|
|
|||
|
|
Same requirements as full vehicle (SAE J211) plus:
|
|||
|
|
- Sled acceleration
|
|||
|
|
- Sled velocity
|
|||
|
|
- Sled displacement
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
# EURO NCAP TECHNICAL BULLETINS
|
|||
|
|
|
|||
|
|
Euro NCAP publishes detailed technical bulletins specifying:
|
|||
|
|
|
|||
|
|
| Bulletin | Content |
|
|||
|
|
|----------|---------|
|
|||
|
|
| TB 013 | Pedestrian testing protocol |
|
|||
|
|
| TB 024 | AEB test protocol |
|
|||
|
|
| TB 025 | Whiplash test protocol |
|
|||
|
|
| TB 026 | MPDB test protocol |
|
|||
|
|
|
|||
|
|
These reference ISO 6487 for instrumentation requirements.
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
# RELATED STANDARDS SUMMARY
|
|||
|
|
|
|||
|
|
## Instrumentation & Data
|
|||
|
|
|
|||
|
|
| Standard | Title | Key Content |
|
|||
|
|
|----------|-------|-------------|
|
|||
|
|
| SAE J211-1 | Electronic Instrumentation | CFC, filtering, sampling |
|
|||
|
|
| SAE J211-2 | Photographic Instrumentation | High-speed video |
|
|||
|
|
| ISO 6487 | Measurement Techniques | International equivalent of J211 |
|
|||
|
|
| SAE J1733 | Sign Convention | Coordinate systems |
|
|||
|
|
| SAE J2570 | Transducer Specifications | Sensor requirements |
|
|||
|
|
|
|||
|
|
## Injury Criteria
|
|||
|
|
|
|||
|
|
| Standard | Title | Key Content |
|
|||
|
|
|----------|-------|-------------|
|
|||
|
|
| SAE J885 | Human Tolerance to Impact | HIC derivation |
|
|||
|
|
| FMVSS 208 | Injury criteria | HIC, chest, femur limits |
|
|||
|
|
| ISO 13232-5 | Injury Indices | Probability functions |
|
|||
|
|
|
|||
|
|
## Dummy Specifications
|
|||
|
|
|
|||
|
|
| Standard | Title | Key Content |
|
|||
|
|
|----------|-------|-------------|
|
|||
|
|
| SAE J963 | Hybrid III Specifications | Dummy design |
|
|||
|
|
| SAE J2868 | THOR Specifications | Next-gen dummy |
|
|||
|
|
| ISO 13232-3 | Motorcyclist ATD | Rider dummy |
|
|||
|
|
| Various CFR | CRABI, SID, Q-series | Specialized dummies |
|
|||
|
|
|
|||
|
|
## Test Procedures
|
|||
|
|
|
|||
|
|
| Standard | Title | Key Content |
|
|||
|
|
|----------|-------|-------------|
|
|||
|
|
| SAE J2432 | Photogrammetric Systems | Target tracking |
|
|||
|
|
| SAE J2765 | Sled Test Procedure | Sled setup |
|
|||
|
|
| Euro NCAP TB | Various technical bulletins | Test protocols |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
# KEY DEFINITIONS
|
|||
|
|
|
|||
|
|
| Term | Definition |
|
|||
|
|
|------|------------|
|
|||
|
|
| **ATD** | Anthropomorphic Test Device (crash test dummy) |
|
|||
|
|
| **CFC** | Channel Frequency Class (filter bandwidth) |
|
|||
|
|
| **HIC** | Head Injury Criterion |
|
|||
|
|
| **Nij** | Neck Injury Criterion |
|
|||
|
|
| **CTI** | Combined Thoracic Index |
|
|||
|
|
| **V*C** | Viscous Criterion (rate-dependent chest injury) |
|
|||
|
|
| **SI** | Severity Index (helmet testing) |
|
|||
|
|
| **MDB** | Moving Deformable Barrier |
|
|||
|
|
| **MPDB** | Mobile Progressive Deformable Barrier |
|
|||
|
|
| **OOP** | Out-of-Position (airbag testing) |
|
|||
|
|
| **Biofidelity** | How closely dummy response matches human |
|
|||
|
|
| **Zero shift** | Change in sensor zero after impact |
|
|||
|
|
| **Cross-axis sensitivity** | Response to off-axis input |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
# DTS RELEVANCE
|
|||
|
|
|
|||
|
|
## How These Standards Apply to DTS Products
|
|||
|
|
|
|||
|
|
| Standard | DTS Application |
|
|||
|
|
|----------|-----------------|
|
|||
|
|
| SAE J211-1 | SLICE systems meet CFC filtering requirements |
|
|||
|
|
| SAE J2570 | DTS accelerometers meet transducer specifications |
|
|||
|
|
| ISO 6487 | International test facilities use DTS to meet ISO requirements |
|
|||
|
|
| Dummy specs | DTS instrumentation embedded in Hybrid III, THOR, WorldSID |
|
|||
|
|
|
|||
|
|
## Key DTS Capabilities
|
|||
|
|
|
|||
|
|
| Requirement | DTS Solution |
|
|||
|
|
|-------------|--------------|
|
|||
|
|
| CFC 1000 head data | High-frequency accelerometers |
|
|||
|
|
| Multi-channel recording | SLICE NANO, SLICE6 |
|
|||
|
|
| Shock survival | Designed for 1000g+ |
|
|||
|
|
| Zero shift | Minimal drift post-impact |
|
|||
|
|
| Sample rate | Up to 100 kHz |
|
|||
|
|
|
|||
|
|
---
|
|||
|
|
|
|||
|
|
*Document prepared as technical reference for DTS safety testing*
|
|||
|
|
*Standards current as of February 2026*
|
|||
|
|
*Last updated: February 13, 2026*
|