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4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J2921_201301 SURFACE VEHICLE INFORMATION REPORT J292 JAN2013 1Issued 2013-01 H-II
5、I5F Chest Jacket Harmonization RATIONALE The Hybrid III Small Female Jacket harmonization project was established to revise both existing chest jackets from the dummy manufacturers to match as close as possible to the existing NHTSA jacket drawing. FOREWORD In the late 1980s the Center for Disease C
6、ontrol (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 specifications for an adult size
7、 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 adopted in U.S. Federal Regu
8、lations 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 April 20, 2006 meeting of the Hybrid III Dummy Family Task Force information was brought in showing that there was a difference
9、between small female chest jackets between different dummy manufacturers. A petition was submitted to NHTSA on January 31, 2006 requesting corrections to the drawings of the small female dummy because these differences could affect the results in restraint system tests. Possible solutions to this pr
10、oblem were discussed, and it was agreed to develop a new harmonized design using the NHTSA drawing as guide. TABLE OF CONTENTS 1. SCOPE AND PURPOSE . 2 2. REFERENCES 2 2.1 Applicable Documents 2 2.2 Related Publication . 3 3. ABREVIATIONS 3 4. TECHNICAL REQUIREMENTS 3 4.1 General Jacket Requirements
11、. 3 4.2 Recommended Chest Jacket Updates . 5 5. NOTES 18 5.1 Marginal Indicia . 18 SAE J2921 Issued JAN2013 Page 2 of 18 FIGURE 1 COMPARISON OF TWO TYPES OF SMALL FEMALE CHEST JACKETS 4 FIGURE 2 COMPARISON OF TWO JACKETS USING SAME DUMMY FOR STANDARD THORAX IMPACT TEST 5 FIGURE 3 3D SHAPE OF THE HAR
12、MONIZED SMALL FEMALE JACKET 6 FIGURE 4 FRONT VIEW CHEST JACKET DRAWING . 7 FIGURE 5 SIDE VIEW OF CHEST JACKET . 8 FIGURE 6 REVISED CHEST JACKET PAD DRAWING . 9 FIGURE 7 3D SHAPE OF INSIDE JACKET MANDREL 10 FIGURE 8 MANDREL DRAWING 10 FIGURE 9 COMPARISON OF STERNUM DISPLACEMENT OF AN OLD AND NEW JACK
13、ET ON SAME DUMMY 11 FIGURE 10 COMPARISON OF PENDULUM FORCE OF AN OLD AND NEW JACKET ON THE SAME DUMMY . 12 FIGURE 11 COMPARISON OF FORCE VS DEFLECTION OF AN OLD AND NEW JACKET ON THE SAME DUMMY . 13 FIGURE 12 SCAN OVERLAY OF THE DATD AND FTSS REVISED SMALL FEMALE JACKETS 17 TABLE 1 LOW SPEED TEST RE
14、SULTS . 14 TABLE 2 TORSO FLEXION RESULTS . 15 TABLE 3 UPPER TORSO WEIGHT SUMMARY . 16 TABLE 4 JACKET WEIGHT AND TORSO ASSEMBLY WEIGHT AND CG COMPARISONS . 16 1. SCOPE AND PURPOSE The Hybrid III Small Female Jacket harmonization project was established to revise both existing chest jackets from the d
15、ummy manufacturers to match as closely as possible to the existing NHTSA jacket drawing. This Information Report documents the new harmonized jacket that resulted from that project. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent spec
16、ified 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 (outside USA), www.sae.org. SAE EA-25 User
17、s Manual for the Small Adult Female Hybrid III Test Dummy SAE J2921 Issued JAN2013 Page 3 of 18 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 Superin
18、tendent of Documents, U.S. Government Printing Office, Mail Stop: SSOP, Washington, DC 20402-9320. Motor Vehicle Regulation No. 572 Test Dummies Specifications - Anthropomorphic Test Dummy for Applicable Test Procedures Available from Leet-Melbrook, Division of New RT, 18810, Woodfield Road, Gaither
19、sburg, MD 20879, (301) 670-0090, 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. ABREVIATIONS H-III5F Hybrid III 5th Percentile Smal
20、l Female Crash Test Dummy, FTSS First Technology Safety Systems, Inc. DATD Denton ATD, Inc. NHTSA National Highway Traffic Safety Administration 4. TECHNICAL REQUIREMENTS 4.1 General Jacket Requirements Current NHTSA jacket specification package Breast Location Symmetrical Design Overall width, dept
21、h, height, and circumference Arm opening location and shape Weight specification Upper Torso Assembly CG Requirements SAE J2921 Issued JAN2013 Page 4 of 18 4.1.1 Description of Problem This issue was first raised on April 20, 2006 during a meeting of the SAE Hybrid III Dummy Family Task Force. Both
22、an FTSS and DATD jacket were passed around for inspection by the task force members. The task force members decided to begin a project to review the drawing specifications and add detail such that both dummy manufacturers would be able to make the same jacket. Figure 1 depicts the differences discov
23、ered comparing two small female jackets: FIGURE 1 - COMPARISON OF TWO TYPES OF SMALL FEMALE CHEST JACKETS Gaps in the drawings and specification packages for the small female chest jacket were required to be filled in to complete the specification to complete the harmonization process. They were as
24、follows: 3D model of jacket to fit dummy Additional contour information for both breast shape and location and overall jacket shape Determine which dimensions take precedent due to the fact that the Front View of the NHTSA drawing does not match side view. EX: Breast location in front view is 0.5 in
25、ch lower then side view Move clavicle bolt access holes to correct position Lack of complete zipper attachment information Lack of shoulder fit information to arm hole in jacket SAE J2921 Issued JAN2013 Page 5 of 18 4.1.2 Tests Demonstrating Problem It was demonstrated that the two manufacturers jac
26、kets were different enough that different chest deflections resulted with the same dummy was subjected to the same test condition with each jacket. Figure 2 is an example of this difference using a standard small female dummy in a standard thorax impact. FIGURE 2 - COMPARISON OF TWO JACKETS USING SA
27、ME DUMMY FOR STANDARD THORAX IMPACT TEST The Task Force also reviewed and examined the results from a 2006 study presented at the 50thSTAPP conference: “The Effect of Breast Anthropometry On The Hybrid III 5thFemale Chest Response” by Suzanne Tylko and Dominique Charlebois from Transport Canada and
28、Alain Bussieres and Dainiaus Dalmotas from PMG Technologies. This study documented the dimensional differences as well as the performance differences of jackets in certification and crash tests. This clearly showed the need for harmonization. 4.2 Recommended Chest Jacket Updates 4.2.1 Technical Requ
29、irements The following is the list of requirements that were used by the committee to direct DATD and FTSS to design and construct the harmonized jacket: Develop 3D model of jacket to fit dummy Additional contour information for both breast shape and location and overall jacket shape Revise NHTSA dr
30、awing so it is complete with front and side view matching Determine which dimensions take precedent due to the fact that the Front View of the NHTSA drawing does not match side view. EX: Breast location in front view is 0.5 inch lower then side view Move clavicle bolt access holes to correct positio
31、n Add complete zipper attachment information Add shoulder fit information to arm hole in jacket in 3D model One piece jacket design (breast molded on) Nipple marking (no hole) Manufacturing tolerances (include shrinkage) -70-60-50-40-30-20-100101 27 53 79 105 131 157 183 209 235 261 287 313 339 365
32、391 417 443 469 495 521 547 573 599 625 651 677 703 729 755 781 807 833 859 8855 to 6 mm peak deflection differences noted SAE J2921 Issued JAN2013 Page 6 of 18 Design fit check fixture (mandrel) Compare Rib Circumferences Perform thorax impact tests with jacket zipped and upzipped 3D mandrel to che
33、ck fit of jacket over time for shrinkage Material hardness, a nominal 40 Durometer Shore A. Common wall thickness 0.38 to 0.50 inch thick with foam 0.18inch thick skin for breast w/o foam Common Opening for Zipper Placement (.75 inch per drawing) Scaled Shoulder Lip on Jacket, remove ledge 4.2.2 3D
34、Shape of Chest Jacket The 3D shape was developed by DATD and FTSS which was used to manufacture the molds at both facilities. This CAD model comes as close to the NHTSA drawing as could be achieved. The model is mirrored about the midsagittal plane to achieve symmetry. See Figure 3 for example of 3D
35、 shape. FIGURE 3 - 3D SHAPE OF THE HARMONIZED SMALL FEMALE JACKETSAE J2921 Issued JAN2013 Page7 of18 4.2.3 2D Drawing ofChestJacketThe 2D drawing wasdeveloped byDATDand FTSS which wasused to manufacture the moldsat both facilities.Thisdrawing isan update ofthe NHTSA drawing to correct errorsand lack
36、ofinformation. See Figures4 - 6. FIGURE 4 - FRONTVIEWCHESTJACKETDRAWINGSAE J2921 Issued JAN2013 Page8 of18 FIGURE 5 - SIDE VIEWOF CHESTJACKETSAE J2921 Issued JAN2013 Page9 of18 FIGURE 6 - REVISED CHESTJACKETPAD DRAWINGSAE J2921 Issued JAN2013 Page 10 of 18 4.2.4 Drawing of Jacket Mandrel The 3D shap
37、e and drawings were developed by DATD and FTSS which was used to manufacture the Mandrels at both facilities. The mandrel was developed to check jacket fit as a jacket becomes older. Due to the fact that some jackets shrink over time, it was determine that a method was required to measure this chang
38、e. The mandrel (Figure 7-8) duplicates the nominal size of thorax, shoulder, and ribs so that it can be determine if a jacket has shrunk to a point that it is too tight to fit properly on the thorax of the dummy. FIGURE 7 - 3D SHAPE OF INSIDE JACKET MANDREL 11223344A AB BREV:DRA WIN G N O. :SHEETSCA
39、LE:SIZE :TITLE :TO LE RAN CESDO NOT SCALE DRAWINGFINISH:HEA T T REA T :MATERIAL:PRO JECT NO .:CHECKED BY:D RAW N B Y: D ATE:DATE:OF1 1 B880105-355-GAGEH-III5F CHEST FLESHCHE CK MANDRILDE CIM ALS ANGL ESX g710.5g71 1g84X.X g710. 1X.XX g710. 05PJD 8/29/2009UNLESS OTHERWISE SPECIFIED:1. ALL DIMENSIONS
40、ARE IN MILLIMETERS.2. BREAK ALL SHARP EDGES.3. ALL MACHINED SURFACES 1.60 OR BETTER.INTERNATIONALRUNLESS OTHERWISE SPECIFIED280 mm 360 mm 438 mm14 mm121 mm245 mm279 mm15.0OUTER SHAPE TAKEN FROMINSIDE SHAPE OF JACKETCUTOUT TO CLEARENSOLITE PAD107 mm283 mm359 mm133 mmFIGURE 8 - MANDREL DRAWING SAE J29
41、21 Issued JAN2013 Page 11 of 18 4.2.5 Thorax Impact Testing Both FTSS and DATD manufactured three harmonized jackets from the molds generated from the specifications developed as part of this investigation. Both high and low speed thorax impact tests were conducted. 4.2.5.1 High Speed Thorax Testing
42、 The results of the high speed thorax test results comparing both jackets on a single dummy tested in a standard thorax impact test in two different labs with two different dummies is shown in Figures 9-11. DATD data is on the top and FTSS data on the bottom for each figure. Denton Test Lab-65-55-45
43、-35-25-15-55-100 102030405060Time (ms)Sternum Deflection (mm)Certif Cor1Certif Cor2DATD OLDFTSS AA0622DATD 13518FTSS AA0631DATD 00293FTSS 1514DATD 08276FIGURE 9 - COMPARISON OF STERNUM DISPLACEMENT OF AN OLD AND NEW JACKET ON SAME DUMMY SAE J2921 Issued JAN2013 Page 12 of 18 Denton Test Lab-5000-400
44、0-3000-2000-10000-10 0 10 20 30 40 50Time (ms)Force in Corridor (N)Certif Cor1Certif Cor2DATD OLDFTSS AA0622DATD 13518FTSS AA0631DATD 00293FTSS 1514DATD 08276FIGURE 10 - COMPARISON OF PENDULUM FORCE OF AN OLD AND NEW JACKET ON THE SAME DUMMY SAE J2921 Issued JAN2013 Page 13 of 18 Denton Test Lab-500
45、0-4500-4000-3500-3000-2500-2000-1500-1000-5000-70 -60 -50 -40 -30 -20 -10 0Sternum Deflection (mm)Force in Corridor (N)Biofidelity UpperBiofidelity LowerCertif Cor1Certif Cor2DATD OLDFTSS AA0622DATD 13518FTSS AA0631DATD 00293FTSS 1514DATD 08276FIGURE 11 - COMPARISON OF FORCE VS DEFLECTION OF AN OLD
46、AND NEW JACKET ON THE SAME DUMMY The results shown in Figures 9-11 indicate that the harmonized jackets are interchangeable on a given dummy. Some dummies currently in use may require an adjustment to the damping material thickness due to the fact that the current rib sets in the field were set up w
47、ith the original jackets and foam pads. SAE J2921 Issued JAN2013 Page 14 of 18 4.2.5.2 Low Speed Thorax Testing For the low speed thorax testing two of the harmonized jackets were chosen and compared to the original jacket type from each manufacturers. The tests were performed in two different labs
48、with two different dummies is shown in Table 1. The results indicate that the displacement and the peak force were changed very little between the different dummies and jackets, with hysteresis changing even less. TABLE 1 - LOW SPEED TEST RESULTS Dummy Jacket # Temperature (deg C) Humidity (%RH) Vel
49、ocity (m/s) Sternum Displacement (mm) Peak Probe Force (kN) Hysteresis (%) 2.95 - 3.05 -21.8 - -17.4 2.07 - 1.78 65 - 72 DATD Original 21.9 42.9 2.98 -20.34 -1.85 66 DATD Original 21.9 42.2 2.98 -19.9 -1.897 66 DATD Original 21.9 42.3 2.99 -20.29 -1.887 66 DATD DATD 08276 21.9 42.4 2.99 -20.16 -1.908 66 DATD DATD 08276 21.9 42.8 2.99 -20.43 -1.923 66 DATD DATD
