1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2011 SAE International All rights reserved. No part of this publication m
3、ay be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside U
4、SA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/J2915_201108SURFACEVEHICLEINFORMATIONREPORTJ2915 AUG2011 Issued 2011-08 H-III5F Spine Box Updat
5、e to Eliminate Noise RATIONALE The Hybrid III Dummy Family Task Force has recommended a change to the H-III5F dummy to fix a design defect that causes data artifacts. This report is needed to document the problem and the solution to this problem recommended by the task force. FOREWORD In the late 19
6、80s the Centers for Disease Control (CDC) awarded Ohio State University a grant to develop multi-sized test dummies based on the Hybrid III design. To aid in this endeavor, the Mechanical Human Simulation Subcommittee of the Society of Automotive Engineers (SAE) formed a Task Group to define the spe
7、cifications for an adult size small female dummy which would have, at least, the same level of biofidelity and measurement capacity as the 50th Hybrid III dummy. Throughout the 1990s this Small Female dummy was revised and improved until it was finally fully defined by a drawing package by NHTSA and
8、 adopted in U.S. Federal Regulations as a part of the Code of Federal Regulations Part 572. The 2002 version of this drawing package defines the currently regulated version of this dummy today. At the December 11, 2007 meeting of the SAE Hybrid III Dummy Family Task Force, data was presented showing
9、 that there was a problem with the 2002 version of the design of the spine box for the Small Female dummy which could cause mechanical noise artifacts in sled and crash test data. Possible solutions to this problem were discussed, and it was agreed to develop a new spine box design to eliminate the
10、possibility of this noise being generated. A new design was discussed, prototypes built and tested, and the design revised until, at the January 13, 2009 meeting, it was agreed to document the design in an Information Report so that it can recommended by the Task Force. SAE J2915 Issued AUG2011 Page
11、 2 of 27 TABLE OF CONTENTS 1. SCOPE AND PURPOSE 3 2. REFERENCES 32.1 Applicable Documents 32.1.1 SAE Publications . 32.2 Related Publication . 32.2.1 Federal Publication . 3 3. ABBREVIATIONS . 3 4. TECHNICAL REQUIREMENTS 44.1 2002 Regulation Spine Box 44.1.1 Description of Problem 44.1.2 Tests Demon
12、strating Problem 44.1.3 Interim Measure 64.2 Recommended Spine Box Update 64.2.1 Description of Solution 64.2.2 Drawings . 74.2.3 Tests Demonstrating Acceptability 15 5. NOTES 165.1 Marginal Indicia . 16APPENDIX A - RELEVANT 2002 REGULATION DRAWINGS 21 APPENDIX B - STOP-GAP SCREW TIGHTENING PROCEDUR
13、E . 26 FIGURE 1 - SPINE ROCKING ON SCREWS 4FIGURE 2 SLED DATA DEMONSTRATING PROBLEM 5FIGURE 3 - BARRIER CRASH DATA DEMONSTRATING THE PROBLEM 6FIGURE 4 - DESIGN OF UPGRADED SPINE BOX . 7FIGURE 5 - 880105-1045 SHEET 1 OF 3 8FIGURE 6 - 880105-1045 SHEET 2 OF 3 9FIGURE 7 - 880105-1045 SHEET 3 OF 3 10FIG
14、URE 8 - 880105-1047 . 11FIGURE 9 - SID-070-6 12FIGURE 10 - 880105-1045-MOD 13FIGURE 11 - 880105-1048 . 14FIGURE 12 - 880105-1049 . 15FIGURE 13 - EVALUATION SERIES TEST PLAN . 17FIGURE 14 - EVALUATION SERIES RESULTS SUMMARY 18FIGURE 15 - EVALUATION SERIES GRAPHS . 19FIGURE 16 - EVALUATION SERIES KINE
15、MATICS 20 SAE J2915 Issued AUG2011 Page 3 of 27 1. SCOPE AND PURPOSE This Information Report documents the problems with the 2002 regulated version of the spine box, and defines a recommended solution to resolve the problem. 2. REFERENCES 2.1 Applicable Documents The following publications form a pa
16、rt of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970
17、 (outside USA), www.sae.org.SAE EA-25 Users Manual for the Small Adult Female Hybrid III Test Dummy 2.2 Related Publication The following publications are provided for information purposes only and are not a required part of this SAE Technical Report.2.2.1 Federal Publication Available from the Supe
18、rintendent of Documents, U.S. Government Printing Office, Mail Stop: SSOP, Washington, DC 20402-9320. Code of Federal Regulations Part 572 Test Dummies Specifications - Anthropomorphic Test Dummy for Applicable Test Procedures Available from Reprographic Technologies, 9107 Gaither Road, Gaithersburg
19、, MD 20877, (301) 4195070 as well as from the Department of Transportation Docket Management System Parts Lists and Drawings Part 572 Subpart O Hybrid III 5thPercentile Small Adult Female Crash Test Dummy (H-III5F Alpha Version) June 2002 3. ABBREVIATIONS H-III5F Hybrid III 5thPercentile Small Femal
20、e Crash Test Dummy Hybrid-III AF05 (in Figure 13) Hybrid III 5thPercentile Small Female Crash Test Dummy SHCS Socket Head Cap Screw FHCS Flat Heat Cap Screw NHTSA National Highway Traffic Safety Administration - of the United States Department of Transportation SAE J2915 Issued AUG2011 Page 4 of 27
21、4. TECHNICAL REQUIREMENTS 4.1 2002 Regulation Spine Box The H-III5F dummy in Federal Regulation was first adopted into CFR Part 572 via 65 FR 10968 on March 1, 2000, and subsequently amended via 67 FR 46413 on July 15, 2002. These regulations define drawings for the construction of the dummy as well
22、 as dynamic performance criteria through certification tests in Part 572 Subpart O. The 2002 version of the H-III5F drawing package defines the current version of the dummy. Drawings 880105-000 (page 3 of 8), 880105-300, 880105-328, 880105-1000 (sheet 3 of 3) from this drawing package are most relev
23、ant to this issue, and are included in Appendix A. 4.1.1 Description of Problem In the thorax region of the H-III5F, the spine box (880105-1000) is attached to the thorax load cell simulator (880105-328)by six 5/16-18 x ” SHCS (item 29 on 880105-300). Since the holes in the spine box are 0.323” diam
24、eter and the screws have a maximum diameter of 0.313”, there is always clearance between the screws and the spine box wall. As the H-III5F is exposed to the accelerations involved in sled or crash testing, the screws can loosen and the spine box will slip under the screw heads until it hits the side
25、s of the screws. This motion produces high amplitude, high frequency mechanical noise on accelerometers within the dummy - which is an artifact of the dummy. A secondary effect of this rocking motion is that the spine box can move approximately +/- 1 degree relative to the thorax load cell structura
26、l replacement (see Figure ). This moves the head position relative to the pelvis fore and aft based on how the spine box is in contact with the screws. FIGURE 1 - SPINE ROCKING ON SCREWS 4.1.2 Tests Demonstrating Problem The data in Figure 2 was presented at the Dec. 11, 2007 meeting showing the noi
27、se spikes that were thought to be produced by the spine rocking during the impact event. This data was produced from a 35 mph belted sled test. Figure 3 shows data that was presented at the same meeting showing noise spikes in 35 mph frontal rigid barrier tests that are hypothesized to be from the s
28、pine rocking as well. SAE J2915 Issued AUG2011 Page 5 of 27 FIGURE 2 SLED DATA DEMONSTRATING PROBLEM SAE J2915 Issued AUG2011 Page 6 of 27 FIGURE 3 - BARRIER CRASH DATA DEMONSTRATING THE PROBLEM 4.1.3 Interim Measure An interim stop-gap measure to minimize the problem until the spine box can be perm
29、anently fixed, is to re-tighten the six SHCS before every test. The six screws must be loosened and then re-tightened to the proper torque between every sled or crash test. It has been found that keeping the screws tight in this manner will usually prevent the slippage and mechanical noise from occu
30、rring. A sample tightening procedure that can be followed is included in Appendix B. 4.2 Recommended Spine Box Update 4.2.1 Description of Solution To eliminate the possibility of motion, the screws that attach the spine box to the load cell structural replacement are changed from standard SHCS to 5
31、/16-18 SHCS that have a 90 degree chamfer like a FHCS as seen in Figure 4. These screws are already used in the DOT-SID dummy in Part 572 Subpart F. To have sufficient wall thickness to add the countersink to the spine box, a steel plate is welded on each side. The screw holes have 90 degree counter
32、sinks added. This allows the screws to lock the spine box into a unique position, and lets the chamfer of the screw grip to the countersink in the spine box. The screws are torqued to 28 Nm. SAE J2915 Issued AUG2011 Page 7 of 27 FIGURE 4 - DESIGN OF UPGRADED SPINE BOX 4.2.2 Drawings Drawings are pro
33、vided to construct the spine box either from scratch when building a new dummy or to upgrade an existing dummy by updating the spine box and screws. 4.2.2.1 To Make a New Spine Box To make a new spine box from scratch, drawings 880105-1045, 880105-1047, and SID-076-6 are used as shown in Figure 5 th
34、rough Figure 9 as well as the drawings listed on 880105-1045 that are used directly from the 2002 drawing package. 4.2.2.2 To Upgrade a 2002 Regulation Spine Box An existing spine box can be modified by using drawings 880105-1045-MOD (Figure 10), 880105-1048 (Figure 11), and 880105-1049 (Figure 12)
35、shown in the corresponding figures. STANDARD SID 5/16 18 CHAMFER90 deg. Countersink Added PlateSAE J2915 Issued AUG2011 Page 8 of 27 11223344A AB BC CD DPLATE, THORACIC SPINE UPGRADE880105-1047214LUG BASE880105-311113LUG SPINE FRONT880105-309112LUG CENTER PLATE880105-313111LUG BASE END880105-310210L
36、UG PLATE880105-31219NUT, HEX 10-32900142948SPINE FRONT TOP PLATE880105-100117SPINE LOWER FRONT GUSSET880105-100326SPINE FRONT LOWER PLATE880105-100215SPINE TOP PLATE880105-30814UPPER SPINE BRACKET880105-30513SPINE SIDE PLATE880105-101822SPINE BACK PLATE880105-30411Parts ListDESCRIPTIONPAR T NU MBE R
37、QTYITEMRE V :DRAWING NO.:SH E ETSCALE:SIZE:TITLE:TOLERANCESDO NO T S CAL E DRAWINGFIN IS H :HEAT TREAT:MA TE R IAL :PR O J E CT N O . :CH E CK E D B Y :DRAWN BY: DATE:DATE:OF1 3 C880105-1045HYBRID III 5TH F EMAL ETHORACIC SPINE UPGRADECTMV 8/22/2008E00710Weld ed Aluminum-6 061FRA CTION S DECI MALS A
38、 NGLES.X G.1G1/64 G1T.XX G .01.XXX G.005.XXXX G.005P. D EP I NE T 1 2/2 6/2 00 7N/AELECTROLESS NICKEL PLATE .0003 MAX THK. 1/2UNLESS OTHERWISE SPECIFIED:1. ALL DIMENSIONS ARE IN INCHES.2. BREAK ALL SHARP EDGES.3. ALL MACHINED SURFACES 125 OR BETT ER .INT ERNATIONALR.401.878-.000.002+ 2. 30-.00.01+8.
39、157().812-.00.01+3.54()1. 7701. 375.550.5211.0051.3752.60849128326115713.11.25.13.13.13(WELDMENT).06101.170145.03(.377)( .812)Q .005 z AREVI SION HISTORYECO # REV DESCRIPTION DAT E BYE00710 AMADE ALL .323 HOLES THE SAME, CHANGED C SINK TO .47 X 90*, MOVED NOTES, ADDED NOTE 7 FIX PART #S IN PARTS LIS
40、T 7/14/08 PJDE00710 C ADDED ITEM 6 FOR REFERENCE 08/21/08 AMN3 TORQUE SCREWS TO 28 Nm (250 LBF-IN)6CCFIGURE 10 - 880105-1045-MOD SAE J2915 Issued AUG2011 Page 14 of 27 1122A AB BREV:DRAWING NO.:SHEETSCALE:SIZE:TITLE:TOLERANCESDO NOT SCALE DRAWINGFINISH:HEAT TREAT:MA TERIA L:PROJ ECT NO.:CHECKED BY:D
41、R AWN B Y: DA TE:DA TE:OF1 1 A880105-1048H-III5F SMALL FEMALEPLATE, LEFT, SPINE UPGRADEATMV 7/8/2008E007101018 STEELFRACTIONS DECIMALS ANGLES.X G.1G1/64 G1T.XX G.01.XXX G.005.XXXX G.005P. DEPINET 12/26/2007NONENONE 1:1UNLESS OTHERWISE SPECIFIED:1. ALL DIMENSIONS ARE IN INCHES.2. BREAK ALL SHARP EDGE
42、S.3. ALL MACHINED SURFACES 125 OR BETTER.INTERNATIONALR.132.4471.0101.5722.3972.529(10)(10).200.750(3X) .323 _ THRU.47 X 90(2.361)ECO REV DESCRIPTION DATE BYE00710 A.375 WAS .350; ADD (2.361) DIM.; REMOVE THRU HOLE; MAKE CSINK 3X NOT 2X; .200 WAS .1557/5/08 PJDAAA.375AFIGURE 11 - 880105-1048 SAE J29
43、15 Issued AUG2011 Page 15 of 27 1122A AB BREV :DRAWING NO.:SHEETSCALE:SIZE:TITLE:TOLERANCESDO NOT SCALE DRAWINGFINISH:HEAT TREAT:MA TERIAL:PROJECT NO.:CHECKED BY:DRAWN BY: DATE:DATE:OF1 1 A880105-1049H-III5F SMALL FEMALEPLATE, RIGHT, SPINE UPGRADEATMV 7/8/2008E007101018 STEELFRACTIONS DECIMALS ANGLE
44、S.X G.1G1/64 G1T.XX G.01.XXX G.005.XXXX G.005P. DEPINET 12/26/2007NONENONE 1:1UNLESS OTHERWISE SPECIFIED:1. ALL DIMENSIONS ARE IN INCHES.2. BREAK ALL SHARP EDGES.3. ALL MACHINED SURFACES 125 OR BETTER.INTERNATIONALR.1322.5292.397.9581.5202.083.750(10)(10).200(3X) .323 _ THRU.47 X 90ECO REV DE SCRIPT
45、ION DATE BYE00710 AADD (2.361) DIM; REMOVE THRU HOLE; MAKE CSINK 90 DEG AND 3X; .200 WAS .1557/5/08 PJD(2.361)A.375AAFIGURE 12 - 880105-1049 4.2.3 Tests Demonstrating Acceptability 4.2.3.1 Sled Testing A sled test series was undertaken for the Hybrid III Family Task Group to evaluate whether the new
46、 spine box design performed differently from the old spine box and to see if it loosened up over four consecutive tests. Figure through Figure document the test plan and results. This series showed that the new spine box has equivalent performance and did not loosen over four tests. 4.2.3.2 Mass and
47、 Center of Gravity Verification The new spine box causes a small (0.077 kg) increase in upper torso mass from the added side plates. This is a small increase compared to the 0.28 kg mass tolerance for the upper torso mass. Since these plates are located very near the center of gravity of the upper t
48、orso, the effect on the center of gravity of the assembly should be minimal. SAE J2915 Issued AUG2011 Page 16 of 27 5. NOTES 5.1 Marginal Indicia A change bar (l) located in the left margin is for the convenience of the user in locating areas where technical revisions, not editorial changes, have be
49、en made to the previous issue of this document. An (R) symbol to the left of the document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original publications, nor in documents that contain editorial changes only. PREPARED BY THE HYBRID III DUMMY FAMILY TASK FORCE OF T
