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?