dts-2026Presentation/technical_standards_specifications.md

Technical Standards and Specifications for Crash Testing

SAE, ISO, and Other Engineering Standards

Data Acquisition, Instrumentation, Injury Criteria, and Test Methods

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OVERVIEW

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.

Key Standards Organizations:

• SAE International - Society of Automotive Engineers (US-based, global influence)
• ISO - International Organization for Standardization (global)
• UN/ECE - United Nations Economic Commission for Europe
• NHTSA - Defines injury criteria referenced by FMVSS

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SAE J211: INSTRUMENTATION FOR IMPACT TEST

SAE J211-1: Instrumentation for Impact Test - Electronic Instrumentation

First Published: 1971 Current Version: SAE J211-1 (Rev. 2014) Scope: Defines requirements for electronic instrumentation used in vehicle crash testing

Purpose

SAE J211-1 ensures that crash test data is:

• Accurate - Measurements reflect actual physical events
• Repeatable - Same test produces same data across labs
• Comparable - Data from different facilities can be compared
• Filtered appropriately - High-frequency noise removed without distorting signal

Channel Frequency Classes (CFC)

The most important concept in J211 is Channel Frequency Class - the bandwidth of the measurement system.

CFC	-3dB Frequency	Primary Use	Why This Bandwidth
CFC 1000	1000 Hz (1650 Hz)	Head acceleration	Head impacts are high-frequency events
CFC 600	600 Hz (1000 Hz)	Chest, pelvis acceleration	Torso response is lower frequency
CFC 180	180 Hz (300 Hz)	Structural measurements	Vehicle deformation
CFC 60	60 Hz (100 Hz)	Sled displacement	Gross motion

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.

Filter Characteristics

SAE J211 specifies a 4th-order Butterworth low-pass filter with specific characteristics:

Parameter	Specification
Filter type	Butterworth (maximally flat)
Filter order	4th order (24 dB/octave rolloff)
Phase	Zero phase shift (bi-directional filtering)
Passband	Flat to -0.5 dB at CFC frequency
Stopband	-24 dB at 1.67 × CFC frequency

Sampling Requirements

CFC	Minimum Sample Rate	Recommended Rate
CFC 1000	8,000 Hz	10,000+ Hz
CFC 600	4,800 Hz	6,000+ Hz
CFC 180	1,440 Hz	2,000+ Hz
CFC 60	480 Hz	1,000+ Hz

Rule of thumb: Sample at 8-10× the CFC frequency for adequate resolution.

Transducer Requirements

Parameter	Specification
Amplitude linearity	±1% of full scale
Cross-axis sensitivity	<5% of primary axis
Zero shift (post-impact)	<2% of full scale
Frequency response	Flat to at least CFC frequency

Data Channel Designation

J211 defines a naming convention for data channels:

[Location][Direction][Type][Filter]

Example: 11HEAD0000ACXC (Head X-acceleration, CFC 1000)

Code	Meaning
11	Driver position
12	Front passenger
13	Rear passenger
HEAD	Head
CHST	Chest
PELV	Pelvis
FEMR	Femur
AC	Acceleration
FO	Force
MO	Moment
X, Y, Z	Direction

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SAE J211-2: Instrumentation for Impact Test - Photographic Instrumentation

Current Version: SAE J211-2 (Rev. 2001) Scope: Requirements for high-speed photography and video in crash testing

Frame Rate Requirements

Application	Minimum Rate	Typical Rate
Occupant kinematics	500 fps	1,000 fps
Structural deformation	1,000 fps	2,000-4,000 fps
Airbag deployment	2,000 fps	5,000-10,000 fps
Detail analysis	5,000+ fps	10,000-40,000 fps

Camera Positioning

• Minimum 3 views: front, side (left or right), overhead
• Additional views as needed for specific analysis
• Reference markers (targets) for photogrammetric analysis
• Lighting requirements for adequate exposure at high speed

Timing Synchronization

• All cameras synchronized to common time base
• Synchronization with electronic data acquisition
• Timing marks visible in frame or recorded electronically
• Time zero defined as first contact

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ISO 6487: ROAD VEHICLES - MEASUREMENT TECHNIQUES IN IMPACT TESTS

Equivalent to: SAE J211-1 Current Version: ISO 6487:2015 Scope: International standard for crash test instrumentation

Relationship to SAE J211

ISO 6487 and SAE J211-1 are technically equivalent and mutually referenced. Key correspondences:

SAE J211 CFC	ISO 6487 CFC	Application
CFC 1000	CFC 1000	Head
CFC 600	CFC 600	Chest, pelvis
CFC 180	CFC 180	Structure
CFC 60	CFC 60	Gross motion

Filter Specification (ISO 6487)

ISO 6487 defines the same 4th-order Butterworth filter with identical characteristics:

H(f) = \frac{1}{\sqrt{1 + (f/f_c)^{2n}}}

Where:

• H(f) = filter transfer function
• f = frequency
• f_c = cutoff frequency (CFC)
• n = filter order (4 for 4th order)

Calibration Requirements

Parameter	Accuracy
Acceleration	±1.5% of full scale
Force	±1% of full scale
Displacement	±1% of full scale
Time	±0.01 ms

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ISO 13232: MOTORCYCLES - TEST AND ANALYSIS PROCEDURES FOR RESEARCH EVALUATION OF RIDER PROTECTIVE DEVICES

Current Version: ISO 13232:2005 (Parts 1-8) Scope: Motorcycle crash testing with rider dummies

Key Differences from Automotive

Parameter	Automotive	Motorcycle (ISO 13232)
Dummy	Hybrid III, THOR	Motorcyclist ATD
Positions	Seated upright	Various riding positions
Impact modes	Frontal, side, rear	Multiple approach angles
Ejection	Prevented (restraints)	Expected and measured

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INJURY CRITERIA DEFINITIONS

Head Injury Criterion (HIC)

Defined in: FMVSS 208, SAE J885, NHTSA regulations First Used: 1972 (FMVSS 208)

Formula

HIC = \left[ \frac{1}{t_2 - t_1} \int_{t_1}^{t_2} a(t) \, dt \right]^{2.5} (t_2 - t_1)

Where:

• a(t) = resultant head acceleration (g)
• t₁, t₂ = time interval (seconds)
• (t₂ - t₁) = time interval maximized to find worst case

HIC Versions

Version	Time Window	Limit	Application
HIC₃₆	36 ms max	1000	FMVSS 208 (airbag)
HIC₁₅	15 ms max	700	FMVSS 208 (current)
HIC unlimited	No limit	1000	Historical

Interpretation

HIC Value	Injury Risk
< 500	Low risk
500-700	Moderate risk
700-1000	Significant risk
> 1000	High risk of serious injury

Basis: Wayne State Tolerance Curve (WSTC) derived from cadaver and volunteer testing.

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Chest Injury Criteria

Chest Acceleration (3ms Clip)

Defined in: FMVSS 208 Formula: Maximum resultant chest acceleration sustained for 3 ms Limit: ≤ 60g

Chest Deflection

Defined in: FMVSS 208 Measurement: Compression of sternum relative to spine Limits:

Dummy	Deflection Limit
Hybrid III 50th Male	63 mm
Hybrid III 5th Female	52 mm
THOR 50th Male	63 mm

Viscous Criterion (V*C)

Defined in: European regulations, soft tissue injury Formula:

V \cdot C = V(t) \times C(t)

Where:

• V(t) = velocity of chest compression
• C(t) = compression as fraction of chest depth
• Limit: ≤ 1.0 m/s

Purpose: Captures rate-dependent soft tissue injury (heart, liver, spleen)

Combined Thoracic Index (CTI)

Defined in: FMVSS 208 (advanced airbag rule) Formula:

CTI = \frac{A_{max}}{A_{int}} + \frac{D_{max}}{D_{int}}

Where:

• A_max = maximum chest acceleration
• D_max = maximum chest deflection
• A_int, D_int = intercept values (dummy-specific)

Limit: CTI ≤ 1.0

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Neck Injury Criteria (Nij)

Defined in: FMVSS 208 Purpose: Combined neck axial load and bending moment

Formula

N_{ij} = \frac{F_z}{F_{zc}} + \frac{M_{oy}}{M_{yc}}

Where:

• F_z = axial neck force (tension or compression)
• M_oy = neck bending moment (flexion or extension)
• F_zc, M_yc = critical intercept values

Critical Values (Hybrid III 50th Male)

Direction	Force (N)	Moment (Nm)
Tension-Extension	6,806	135
Tension-Flexion	6,806	310
Compression-Extension	6,160	135
Compression-Flexion	6,160	310

Limit: Nij ≤ 1.0 for any combination

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Femur Load Criterion

Defined in: FMVSS 208 Measurement: Axial compressive force in femur Limit: ≤ 10,000 N (10 kN) Duration: Peak force in any 10 ms window

Femur Force Measurement

Dummy	Measurement Location
Hybrid III	Femur load cell
THOR	Upper, middle, lower femur

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Tibia Injury Criteria

Tibia Index (TI)

Defined in: European regulations Formula:

TI = \frac{M_R}{M_C} + \frac{F_Z}{F_C}

Where:

• M_R = resultant bending moment
• F_Z = axial force
• M_C, F_C = critical values

Limit: TI ≤ 1.0

Tibia Compressive Force

Limit: ≤ 8,000 N (8 kN)

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Pelvis Acceleration

Defined in: FMVSS 214 Measurement: Resultant pelvis acceleration Limit: Varies by test mode and dummy

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Severity Index (SI) - Helmets

Defined in: NOCSAE, FMVSS 218 Formula:

SI = \int a^{2.5} \, dt

Where:

• a = head acceleration (g)
• t = time (seconds)

Limits:

Standard	SI Limit
NOCSAE Football	< 1200
FMVSS 218 Motorcycle	N/A (uses peak g)

Relationship to HIC: SI is the time-weighted integral; HIC normalizes by time interval.

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DUMMY (ATD) SPECIFICATIONS

SAE J963: Anthropomorphic Test Dummy Family

Scope: Defines the Hybrid III dummy family specifications

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

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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

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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

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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

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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

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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

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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

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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

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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

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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)

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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

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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

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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

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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"

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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

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SAE J1733: Sign Convention

Already covered above - defines positive/negative directions for all measurements.

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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.

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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%

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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

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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.

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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

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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

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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

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Document prepared as technical reference for DTS safety testing Standards current as of February 2026 Last updated: February 13, 2026