biorid-ii head restraint certification test development · 2011. 3. 23. · gus serrano, keith alto...
TRANSCRIPT
BioRID-II Head Restraint
Certification Test Development
Paul Depinet, John Below,
John Arthur, Mike Beebe,
Alex Schmitt, Charlie Steinmetz,
Gus Serrano, Keith Alto
Feb. 28, 2011
Content
►Rationale for a Head Restraint Test
►Development of Pulse
►Safety of Current Test
►Changeover issues
►Where to go from here
Rationale for a Head Restraint Test
►PDB paper at ESV 2009 indicated
that biggest dummy to dummy
reproducibility issues existed during
head contact with headrest
4
Initial Head Restraint Test
►Fixed 70 mm
backset
►Rigid head
restraint
►Same probe and
ETD as without
head restraint
test
5-200
-150
-100
-50
0
50
100
150
-10 40 90 140 190
Time (ms)
(N)
68MM TEST 1.AF.CSV
70MM TEST 1.AF.CSV
72MM TEST 1.AF.CSV
Initial Head Restraint Test
►Very short duration contact time
►Concerns about forcing backset
►Curve shapes totally different than
seat testing
Head Restraint Test Development
►Requested revisions
– Padded head restraint
– Adjustable head restraint
– Tool to determine head restraint position
adjustment from nominal
– Upper and Lower neck forces and moment similar
to car seat testing
Head Restraint Test Development
►Target curves
from JASIC/Japan
– Feb. 2010 GTR
meeting Tokyo
►Experimented with many conditions
– Foam pad thickness
– Foam pad stiffness
– Input pulse amplitude and duration
►Best combination
– 75 mm thick foam
– Pulse proposed by Johann Davidson (16 kph, 10 g)
Head Restraint Test Development
Head Restraint Test – Selected Pulse
►Impact pulse of
16kph to match seat
testing
-20
0
20
40
60
80
100
120
-10 10 30 50 70 90
m/
s2
T ime (msec)
Sled Acceleration
ETD
Target
Target = 98.1 m/s2
-0. 5
0
0. 5
1
1. 5
2
2. 5
3
3. 5
4
4. 5
5
-10 40 90 140 190
m/
s
Time (msec)
Sled Velocity
ETD
Ta rget
Target = 4.44 m/s (16 Kph)
Head Restraint Test vs JASIC & Sport Seat
-100
-50
0
50
100
150
-20 0 20 40 60 80 100 120 140 160 180 200
N
Time (msec)
Upper Neck Force FX
Test 6
Test 1
Test 2
Test 3
Test 4
Test 5
160
-15
-10
-5
0
5
10
15
20
25
30
-20 0 20 40 60 80 100 120 140 160 180 200
Nm
Time (msec)
Upper Neck Moment MY
Test 6
Test 1
Test 2
Test 3
Test 4
Test 5
14
Head Restraint Test vs JASIC & Sport Seat
-200
-100
0
100
200
300
400
500
-20 0 20 40 60 80 100 120 140 160 180 200
N
Time (msec)
Upper Neck Force FZ
Test 6
Test 1
Test 2
Test 3
Test 4
Test 5
Head Restraint Test vs JASIC & Sport Seat
Head Restraint Test vs German Seat
-200
-100
0
100
200
300
400
500
-20 0 20 40 60 80 100 120 140 160 180 200
N
Time ( msec)
Upper Neck Force FZ
Test 6
Test 1
Test 2
Test 3
Test 4
Test 5
0.40
-0.10
0 240
German Car Seats – Upper Fz0.45
-0.10
0.60
-0.10
0.50
-0.10
0.30
-0.10
0.40
-0.10
-20 0
-10 0
0
100
200
300
400
500
- 20 0 20 4 0 60 80 100 120 140 160 180 200
N
T ime ( msec)
Upper Neck Forc e FZ
Test 6
Test 1Test 2
Test 3
Test 4
Test 5
400
-100
German Car Seats – Lower Fz
-0.30
0.10
-0.15
0.25
-0.14
0.10
-0.25
0.10
-0.10
0.20
-400
-300
-200
-100
0
100
200
300
-2 0 0 2 0 40 60 80 1 00 120 140 160 180 200
N
Tim e (msec)
Lower Neck Force FZ (T1 load Cell )
Tes t 6
Tes t 1
Tes t 2
Tes t 3
Tes t 4
Tes t 5
-300
200
Head Restraint Test Development
-Longer, shaped ETD to
get extended pulse
-Heavier probe
necessary for sufficient energy
►Head Rest Certification Test
– Heavier probe with same impact face
� Total probe mass = 118.5 kg +/- 0.1 kg (261.2lb)
– Custom ETD for advanced pulse
– Adjustable foam head rest
� Mass added to sled 6.00 kg +/- 0.02 kg
– Cap contact switch
BioRID Certification with Head Rest
Head Restraint Test Development-Adjust head restraint for 70 mm backset with head level.
-75 mm thick foam pad
Head Restraint Test – Setup Position
70 mm backset
Head Restraint Setup Zeroing Tool
►Tool allows setting nominal
position of scale
►Scale measures adjustment
from nominal position
Head Restraint Test – Setup Position
T1 angle 29.8 deg.
452
572
87
79
272
303
Center of dummy support
Safety of Current Test
►Is 37.61 kg safer than 118.5 kg?
– Getting hit by either probe would cause serious or
fatal injuries
– GREAT care must be exercised around either
probe
►Can 118.5 kg probe be handled safely?
Changeover Issues
►Heavier cables
►Stronger winch
►Strengthened attachments
►Lift cart for installing and removing probes
– No lifting by hand is necessary!
Changeover Issues
►Cart for– Probe handling
– Storage
– Installation
►No hand lifting of
probes is necessary!
Probe installation and removal
videos.
Where to go from here
►Do we need so many test?
– Takes far more time to certify dummy
�Cost
�Delays in testing
– What is goal of project?
�Reduce dummy to dummy variation?
�Make certification testing faster and cheaper?
►Do we need two probes/ETD?
Where to go from here
►Is this a reasonable number of tests for a dummy?
SID-IIS H-III50M BioRID-II
Head drop Head Drop Sled w/o head restraint certification
Neck pendulum Neck Flexion Dummy w/o head restraint
shoulder Neck Extension Head restraint foam certification
Thorax without arm Thorax low speed Sled with head restraint certification
Thorax with arm Thorax high speed Dummy with head restraint certification
Abdomen Hip ROM left Jacket certification
Acetabulum Hip ROM right
Iliac Knee impact left
Knee impact right
Knee slider left, low speed
Knee slider left, high speed
Knee slider, right low speed
Knee slider, right high speed
Do we need two probes/ETD?
►Heavy probe / long ETD needed to get pulse
shape
►Would it be acceptable to use same probe
and ETD as “without Head Restraint” test?
HEAVY
VS
STANDARD
CERTIFICATION PROBE
COMPARISON
Pendulum Force
-2000
0
2000
4000
6000
8000
10000
12000
-10 10 30 50 70 90 110 130
N
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Sled Acceleration
-50
-30
-10
10
30
50
70
90
110
130
150
-25 25 75 125 175
m/s
^2
time (milliseconds)
Sled Acceleration
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Sled Velocity
-1
0
1
2
3
4
5
-25 25 75 125 175
m/s
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Upper Neck Force FX
-100
-50
0
50
100
150
200
-25 25 75 125 175
N
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Upper Neck Moment MY
-10
-5
0
5
10
15
20
25
30
-25 25 75 125 175
Nm
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Upper Neck Force FZ
-300
-200
-100
0
100
200
300
400
-25 25 75 125 175
N
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Lower Neck Force FX (T1 load Cell)
-350
-300
-250
-200
-150
-100
-50
0
50
100
150
-25 25 75 125 175
N
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Lower Neck Moment MY (T1 Load Cell)
-15
-10
-5
0
5
10
-25 25 75 125 175
Nm
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Lower Neck Force
-600
-500
-400
-300
-200
-100
0
100
200
-25 25 75 125 175
N
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Pot A - Head Pot
-15
-10
-5
0
5
10
15
-25 25 75 125 175
deg
rees
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Pot B - Neck Link Pot
-20
-15
-10
-5
0
5
10
-25 25 75 125 175
deg
rees
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Pot C - T1 Pot
-20
-15
-10
-5
0
5
10
-25 25 75 125 175
deg
rees
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Total Head Rotation
-20
-15
-10
-5
0
5
10
-25 25 75 125 175
deg
rees
time (milliseconds)
Large Probe-1
Normal Probe-1
Contact Time Normal Probe
Contact Time Large Probe
Comparison Kinematics
Light Probe Video
Heavy Probe Video
Comparison Kinematics
Light Probe T0Heavy Probe T0
Comparison Kinematics
Light Probe 25 msHeavy Probe 25 ms
Comparison Kinematics
Light Probe 50 msHeavy Probe 50 ms
Comparison Kinematics
Light Probe 75 msHeavy Probe 75 ms
Comparison Kinematics
Light Probe 100 msHeavy Probe 100 ms
Comparison Kinematics
Light Probe 125 msHeavy Probe 125 ms
Heavy VS Standard Probe Comparison
►Force and moment curve shapes
– Heavy probe
� with range of car seat testing
� Closest to Sports Seat from PDB R&R study
– Standard Probe
� Does not match any seat data
� Quite different than heavy probe/car seat data
►Is it necessary to duplicate car seat loading regime?
►Using standard probe saves time in certification lab
Decision Time!
►Continue with heavy probe?
►Continue using light probe?
►Continue testing using both probes?
►Do testing with both probes before making
decision?
WHERE DO
WE GO
FROM HERE?
Where to go from here
►Ship head restraint systems to all existing labs
– HumaneticsHuron, Heidelberg, Nagoya
– Ford, IIHS
►Need to collect data
– Multiple dummies which pass without headrest test
– Multiple labs
– Establish corridors on population of dummies that meets
all other requirements
� Find areas of curves that will exclude outlier dummies
– GR&R study at least 3 labs
� Make sure corridors widths ok with GR&R
QUESTIONS?