Safety Enhanced Innovations For Older Road Users

Ref.
Ares(2017)5285587 - 30/10/2017
SAFETY ENHANCED INNOVATIONS FOR OLDER ROAD USERS
EUROPEAN COMMISSION
EIGHTH FRAMEWORK PROGRAMME
HORIZON 2020
GA No. 636136
Deliverable No. D3.3

Elderly Overweight Dummy certification document (D3.3a) and
Deliverable Title
certification documents for updated pedestrian impactors (D3.3b)
Dissemination level Public
Burleigh, Mark Humanetics
Written by Lemmen, Paul Humanetics
Zander, Oliver BASt
Checked by Fornells, Alba IDIADA 17/10/2017
Hynd, David TRL 17/10/2017
Approved by Wisch, Marcus BASt 30/10/2017
Issue date 30/10/2017
This project has received funding from the European Union's Horizon 2020
research and innovation programme under grant agreement No 636136.
Deliverable 3.3
EXECUTIVE SUMMARY
The SENIORS project aims at reducing the numbers of fatally and seriously injured older
road users considering both car occupants and external road users such as pedestrians. As
part of the activities test tools to better represent elderly in passive safety tests are being
developed.
The elderly as occupant is being addressed by a new Elderly Overweight Dummy

representing older car occupants with a Body Mass Index (BMI) of 28 to 29. The elderly as a
pedestrian / cyclist is addressed by adaptations to existing pedestrian impactors:
• Adding an Upper Body Mass (UBM) to a legform impactor improving the biofidelity in
terms of kinematics and loadings of the lower extremities during impact.
• Adding a neck – mass system to a headform impactor to result in a more realistic
rotational behavior and thus loading of the impactor
This deliverable report presents certification requirements for these tools. For the Elderly
Overweight dummy the certification will likely evolve further as biofidelity improves so initial
certification requirements based on current knowledge are listed for this tool.
In support of the testing in subsequent tasks of SENIORS handling instructions are provided
as well. This includes assemble and dis-assembly instruction, seat positioning details and
after test inspection advice to check for any failures.
Contributions of the partners:

HIS Co-ordination of the deliverable and main contributor to D3.3a and b.
Definition of all certification requirements and handling instructions.
TRL/BASt Contributed to certification requirements and detail review of D3.3a and b.
IDIADA Review of D3.3a and b.
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Deliverable 3.3
CONTENTS
This Deliverable report D3.3 consists of two parts:
• D3.3a describing the certification requirements, handling and seating for the Elderly
Overweight Dummy to represent the elderly as car occupants
• D3.3b describing the certification requirements for the improved pedestrian impactors
to represent the elderly as external road users
Both parts were prepared as separate documents which are included in the sequel of this
report.
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EUROPEAN COMMISSION
HORIZON 2020
GA No. 636136
Deliverable No. D3.3a

Deliverable Title Elderly Overweight Dummy Certification
Written by
Lemmen, Paul Humanetics
Checked by Fornells, Alba IDIADA 17/10/2017
Deliverable 3.3a
EXECUTIVE SUMMARY
This SENIORS deliverable report presents initial certification details for the physical elderly
overweight dummy which is to be sled tested and evaluated in the project. The certification
will likely evolve further as biofidelity improves. When satisfactory biofidelity, durability and
repeatability are established draft certification corridors will be established for component
and full assembly conditions. The dummy was mainly designed by Humanetics in the United
States under the ICAM project.
In cooperation with ICAM the dummy is further refined and utilized in SENIORS as it fitted
well into the protection of the elderly. See SENIORS design specification document 3.1a.
This report also includes assemble and dis-assembly instruction, seat positioning details and
after test inspection advice to check for any failures. These instructions are to assist all
partners testing with the dummy.
The dummy will be baseline certified before testing.

HIS Certification specifications, assembly and dummy preparation
IDIADA/BASt Report review
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Deliverable 3.3a
Contents
Executive summary ...................................................................................................................... 2

1 Introduction ......................................................................................................................... 4
1.1 The EU Project SENIORS................................................................................................ 4
1.2 Background to this Deliverable ..................................................................................... 5
1.3 Objective of this Deliverable ......................................................................................... 5
2 Certification ......................................................................................................................... 6
2.1 Introduction ................................................................................................................. 6
2.2 Head ............................................................................................................................ 6
2.3 Neck ............................................................................................................................ 6
2.4 Upper Thorax ............................................................................................................... 7
2.5 Lower Thorax Qualification ......................................................................................... 10
2.6 Abdomen Qualification............................................................................................... 13
2.7 Lumbar Spine ............................................................................................................. 17
2.8 Knee Certification....................................................................................................... 18
2.9 Foot Certification ....................................................................................................... 18
3 Dummy Assembly ............................................................................................................... 19
3.1 Head and Neck Assembly............................................................................................ 19
3.2 Shoulder Assembly ..................................................................................................... 19
3.3 Thorax Assembly ....................................................................................................... 21
3.4 Abdomen, Lumbar Spine and Pelvis Assembly ............................................................. 26
3.5 Lumbar Spine Assembly.............................................................................................. 29
3.6 Leg Assemblies ........................................................................................................... 29
3.7 Arm Assemblies ......................................................................................................... 30
4 Dummy Damage Check List................................................................................................. 31
5 Seating Procedure .............................................................................................................. 32
6 Spares Provided ................................................................................................................. 33
7 Dummy Lifting.................................................................................................................... 34
8 Summary and Conclusions .................................................................................................. 35
References ................................................................................................................................. 37
Appendix 1 Europe Qualification testing, Thorax ......................................................................... 37
Acknowledgments ...................................................................................................................... 41
Disclaimer .................................................................................................................................. 41
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Deliverable 3.3a
1 INTRODUCTION
1.1 THE EU PROJECT SENIORS
Because society is aging demographically and obesity is becoming more prevalent, the
SENIORS (Safety ENhanced Innovations for Older Road userS) project aims to improve the
safe mobility of the elderly, and overweight/obese persons, using an integrated approach that
covers the main modes of transport as well as the specific requirements of this vulnerable
road user group.
This project primarily investigates and assesses the injury reduction in road traffic crashes
that can be achieved through innovative and suitable tools, test and assessment procedures,
as well as safety systems in the area of passive vehicle safety. The goal is to reduce the
numbers of fatally and seriously injured older road users for both major groups: car
occupants and external road users (pedestrians, cyclists, e-bike riders).
The overall scope for the SENIORS project is shown in the flowchart.
Quantification of needs
• Literature (injury, behaviour, …) IDENTIFICATION
• Accident studies OF NEEDS /
Prioritise
Initial benefit assessment PRIORITIES FOR • Future project activities
• Achievable injury prevention OLDER ROAD
• Analysis of risks USERS
• Derivation of safety strategies
Biomechanical testing
Dummies / impactors IMPROVED Injury risk curves
Test procedures
Numerical models TOOLS Assessment procedures
Injury criteria
CAR OCCUPANT PEDESTRIAN/CYCLIST

• Better older thorax IRC* • Flex-PLI with UBM ‡ Head-neck and pedestrian
* To be confirmed
• Obese occupant • Head-neck thorax will be early-stage
from the accident
analysis
• Active HBM • Pedestrian thorax‡ research
Safety of older road users

• Effectiveness of new tools and
advantages of new procedures BENEFIT AND
• Applied to current and advanced IMPACT Integrated benefit analysis
new safety systems ASSESSMENTS
• Passive
• Active
Figure 1 Flowchart of the SENIORS project
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Deliverable 3.3a
1.2 BACKGROUND TO THIS DELIVERABLE

In the U.S and Europe statistics show older road uses above 65 are taking a larger share of
fatalities. The age and weight identified for the most vulnerable person in the U.S was a 70
year old female 1.61 m in height and 73 Kg in weight. Humanetics initiated the elderly
overweight dummy as a research tool for testing to try and help protect this vulnerable group
and to use 3D printing for most of the dummies manufactured parts. This new technology
would be a platform to help develop crash test dummies for the future and to invoke interest
in the crash industry to this age group. Before SENIORS the dummy was a basic prototype.
During the project the dummy has been updated in the U.S and in SENIORS for improved
biofidelity, durability and anthropometry. However there is still much improvement to be done
and the dummy is very much still a research tool under development.
1.3 OBJECTIVE OF THIS DELIVERABLE

The objective of this deliverable is to show certification/qualification procedures to ensure the
dummy is in a repeatable condition before each test series by testing component parts and
the fully assembled dummy using various laboratory test methods to established draft
corridors. As the dummy is new where there is no established corridor a comparison will be
made with the initial baseline qualification performance to ensure the dummy maintains the
same response throughout the test program. This deliverable will also include information for
assembly/dis-assembly, handling, seat positioning and part condition checks after testing.
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Deliverable 3.3a
2 CERTIFICATION
2.1 INTRODUCTION
Certification should be carried out after every 10 to 15 tests. If low speed tests are carried out
certification can be longer but should be done before a new test lab starts testing. Particular
attention should be applied to the thorax and abdomen tests.
2.2 HEAD
The head used on the elderly dummy is the WorldSID small female (WorldSID-5F). Head
drop equipment, certification procedures and corridors can be found in the WorldSID-5F User
manual (Humanetics, 2015a). Figure 2 shows the frontal head drop certification test set up.
Figure 2 Head Drop Test setup WorldSID-5F
2.3 NECK
The neck on the elderly dummy is also a standard WorldSID-5F part. Frontal, lateral and rear
pendulum tests are to be carried out. Procedures, equipment and corridors can be found in
the user’s manual (Humanetics, 2015a).
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Deliverable 3.3a
2.4 UPPER THORAX
The upper thorax qualification test is a blunt impact to the center of the ribcage and follows
the THOR-50M Upper Thorax test procedure. See (Humanetics, 2017). In this test an
impactor with mass 23.36 ±0.02 Kg with a 152.4 ±0.25 mm diameter impact face (same as
used on Hybrid III 50th percentile male ATD) contacts the chest at mid-sternum level at 4.3
m/s ±0.05 m/s.
The primary response specifications for the upper thorax test are the X axis deflection of the
left and right upper ribs in the local spine co-ordinate system, as measured by the Infra-Red
Telescopic Rod for Assessment of Chest Compression (IR-TRACC) and the reaction force,
as measured using the pendulum acceleration times its mass. The X-axis deflections of the
left and right IR-TRACC are assessed individually to ensure proper functionality while
facilitating diagnosis should the response not meet the qualification requirement.
Test Instrumentation
o Instrumentation to measure impact force (accelerometer on impactor or load
cell/accelerometer combination if using a linear impactor)
o Instrumentation to measure impact velocity
o A dual axis tilt sensor on the thoracic spine to measure X and Y-axis
o A dual axis tilt sensor attached to the pelvis to measure initial angle about X and Y-
axis
o 3D IR-TRACC assemblies in the upper left and upper right thorax ribs
Pre-Test Procedure
o Lower the jacket to waist level, if installed and inspect the rib flesh, bib and ribs for
any damage. Some damage to the flesh is acceptable as long as the geometry is
intact and stable. The ribs should be examined to determine if they have been
permanently deformed. If necessary take action to refurbish deformed or damaged
ribs.
o Soak the ATD in a controlled environment with a temperature of 20.6 to 22.2 °C with
relative humidity from 10 to 70% for at least 4 hours prior to a test. The test
environment should have the same temperature and humidity as the soak.
Test Procedure
o Seat the dummy on a horizontal surface (±0.5⁰) with no back support, with limbs
extended horizontally, legs slightly apart and forward parallel to the midsagittal plane.
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Deliverable 3.3a
The midsagittal plane shall be vertical within ±1⁰. Support the arms on the legs. See
figure 3.
Figure 3 Dummy Position for Upper Thorax Certification Test
o Set the pelvis so that the angle measured by the pelvis tilt sensor or H point tool is 0 ±
5⁰ in the X-axis and 15 ± 1⁰ in the Y-axis.
o The shoulder tilt sensor or angle should be 0⁰ ± 1 in the X and Y-axis.
o Adjust the table height or the impactor so that the center of the impactor face is at the
vertical level of the third rib anteriorly and central between the IRTRACC attachment
screws, as indicated by the attachment bolts of the left and right upper thorax IR-
TRACC assemblies. See figure 4.
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Deliverable 3.3a
Figure 4 Upper Thorax Pendulum Impact Points
o Carefully reinstall the dummy suit zipping up at the rear

o The motion of the impactor should be constrained so that there is no significant
lateral, vertical or rotational movement.
o Record the as measured (AM) channels in accordance with SAE-J211. Determine
the time of first contact between the impactor and the ATD using a contact strip,
light trap, instrumentation level trigger or equivalent and ensure at least 20
milliseconds of data are recorded before contact.
o Conduct the test at an impact speed of 4.3 ± 0.5 m/s.
Data Processing
o Remove data channel offset but do not zero the IR-TRACC and potentiometer
channels; per SAE J211 section 8.4.3, bring the normalized value of a stable pre-test
section of data to the proper initial value for the transducer.
o Filter the channels using a 180 CFC filter class. Do not filter the raw IR-TRACC
voltage as this will be filtered after it is linearized and scaled during the upper right X
and Z axis deflections below.
o Calculate time history of impact force at the contact interface.
o Calculate the upper right X-, and Z- axis thorax deflections in the local spine co-
ordinate system (upper thoracic spine (UTS)) (See THOR User’s manual).
o Calculate the absolute value of the difference between the peak left and right X-axis
deflections in the local co-ordinate system (UTS).
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Deliverable 3.3a
o Calculate the absolute value of the difference between the peak left and right Z-axis
deflections in the local co-ordinate system (UTS).
o Record results. No corridor is currently available. An example of the force deflection is
shown in figure 5 below and will be used as a baseline for certification.
Figure 5 Expected Upper Thorax Force deflection Response
2.5 LOWER THORAX QUALIFICATION
Description
The lower ribcage impact qualification test uses the same impactor as the upper ribcage
central impact test (23.36 ±0.02 kg). The speed is also the same at 4.3 ±0.05 m/s. In these
tests the impactor is centered directly over the lower left or right thorax IR-TRACC
attachment to the bib with the line of impact horizontal and parallel to the dummies sagittal
plane.
The X-axis deflections are calculated in the local spine co-ordinate system for both the left
and right IR-TRACCs to examine the force-deflection response of the lower ribcage. The X-
axis deflections of the left and right IR-TRACCs are assessed individually to ensure that both
of the lower thorax IR-TRACCs are functioning properly, while facilitating diagnosis should
the force-deflection response not meet the qualification requirement.
Instrumentation
o Instrumentation to measure impact force (accelerometer on impactor or load
cell/accelerometer combination if using linear impactor)
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Deliverable 3.3a
o Instrumentation to measure impact velocity

o A dual axis sensor on the thoracic spine to measure x and y axis
o A dual axis tilt sensor attached to the pelvis to measure initial angle about X and Y
axes
o 3D IR-TRACC assemblies (472-3570) installation as shown in figure 15.
Pre-Test Procedures
o Pull down the jacket and inspect the ribcage, bib and jacket for wear, tears or other
damage. Prior to assembly the profiles of the ribs should be examined to determine if
they have been permanently deformed and if necessary take appropriate action to
refurbish any part.
o Soak the dummy in a controlled environment with a temperature of 20.6 to 22.2 ⁰C
with a relative humidity from 10 to 70% for at least 4 hours prior to the test. The test
environment should have the same temperature and humidity as the soak
environment.
Test Procedure
1. Seat the dummy on a horizontal surface (±0.5⁰) with no back support, with limbs
extended horizontally (arms propped) and forward parallel to the midsagittal plane.
The midsagittal plane shall be vertical within ±1⁰.
2. If the jacket is fitted unzip from the back and pull the jacket down to expose the
ribcage. Support the hands over the knee as shown in figure 3 above.
3. Set the pelvis so that the angle measured by the pelvis tilt sensor or H point tool is 0
±0.5⁰ in the X-axis and 15 ±1 in the Y-axis.
4. Position the thorax so that the T6 tilt sensor reads -4 ±1⁰ (forward tilt about the Y-axis)
and 0 ± 0.5⁰laterally (about the X-axis). If the T6 tilt sensor is not fitted set the
shoulder to 0º ±1.
5. Adjust the table height or impactor height so that the center of the impact is at the
vertical level of the center of the sixth rib anteriorly, as indicated by the attachment
bolt of the lower left or right thorax IR-TRACC assembly. See figure 6.
6. Align the impact face with the center of the left or right lower thorax IR-TRACC bolt. A
removable pointer (threaded into the centerline of the pendulum with approximately
30 mm protruding) will aid this process. Remove the pointer tool when this step has
been completed.
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Deliverable 3.3a
7. Ensure that at least 30 minutes have passed since the last upper, lower thorax or
abdomen test.
8. Conduct the test at an impact velocity of 4.3 ±0.05 m/s.
Figure 6 Location Points for Elderly Dummy Lower Thorax Impact Test
Data Processing
o Remove data channel offset but do not zero the IR-TRACC and potentiometer
channels; per SAE J211 Section 8.4.3, bring the normalized value of a stable pre-test
section of data to the proper initial value for the transducer.
o Filter channels using a 180 CFC filter class for left and right impacts. Do not filter the
raw IR-TRACC voltage as this will be filtered after it is linearized and scaled during X
axis deflection calculations below.
o Calculate time-history of impact force at the contact interface.
o Calculate the lower left or lower right X-axis deflections in the local spine co-ordinate
system (Lower Thoracic Spine (LTS). See THOR User’s manual.
o Record results, no corridors are available at this time. See example of expected
results in figures 7 and 8 below.
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Deliverable 3.3a
Figure 7 Expected Force / Deflection Liver Side
Figure 8 Expected Force / Deflection Spleen Side
2.6 ABDOMEN QUALIFICATION
Description
The lower abdomen impact qualification test utilizes a rectangular, horizontally-orientated
rigid bar attached to an impactor (total mass 32 ± 0.02 kg) to impact the lower abdomen. The
impact speed is 3.3 ± 0.05 m/s and is centered at the level of the 1D IR-TRACC link
attachments to the anterior surface of the abdomen.
The X-axis abdomen deflections are calculated in the local spine co-ordinate system for both
left and right IR-TRACCs to examine the force-deflection response of the lower abdomen.
The X-axis deflections of the left and right abdomen IR-TRACCs are assessed individually to
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Deliverable 3.3a
ensure that both of the lower abdomen IR-TRACCs are functioning properly. This also
facilitates diagnosis should the force deflection response not meet the qualification
requirement.
Figure 9 Abdomen Qualification Set-up
Impactor
32.00 ±0.02 kg in mass, including rectangular impact face, instrumentation, rigid attachments
and the mass of the lower 1/3 suspension cables. The standard THOR 152.4 ±0.25 mm
diameter rigid cylinder test probe is used with a 177.8 x 50.8 mm rectangular impact face
attached. See figure 10. The rectangular impact surface attached to the probe (DL472-3000)
has a flat, right angle face with an edge radius of 6 ±0.3 mm.
Figure 10 Rectangular Impactor Face used in Lower Abdomen Test
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Deliverable 3.3a
Figure 11 Elderly Dummy Abdomen Qualification Test Setup
Instrumentation
o Instrumentation to measure impact force (accelerometer on impact or load cell /

accelerometer combination if using linear impactor)
o Instrumentation to measure the impact speed
o A dual-axis tilt sensor on the thoracic spine (T6 location) to measure initial angle about X
and Y axes
o 2x 1D IR-TRACC assembly 10180-R4 in the lower left and lower right abdomen installed
as shown in figure 17
Pre Test Procedure
o If the jacket is installed unzip at the rear and expose the ribcage and abdomen inserts.
Inspect the lower abdomen flesh for wear and tears or other damage. Some damage is
OK as long as structure is stable. Prior to assembly the abdomen should be inspected for
any permanent set and if necessary take appropriate action to replace or refurbish.
o Soak the dummy in a controlled environment with temperature of 20.6 to 22.2 ⁰C and with
a relative humidity between 10 and 70% for at least 4 hours prior to the test. The test
environment should have the same temperature as the soak environment.
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Deliverable 3.3a
Test Procedure
o Seat the dummy on a horizontal surface ±0.5⁰ with no back stop, with limbs extended
horizontally and forward parallel to the midsagittal plane. The midsagittal plane shall be
vertical within ±1⁰.
o Support the forearms in the fully extended orientation with props, see figures 9 and 11.
o Position the pelvis so that the pelvis tilt sensor or H point tool reads 10 ±1⁰ (rearward tilt
about the Y-axis) and 0 to 0.5⁰ laterally (about the X-axis).
o Align the vertical centreline of the probe with the midsagittal plane of the dummy. Using a
straight edge with an inclinometer or using a laser level. Confirm that the tilt sensor
measurement from above are still OK.
o Adjust the table height or impactor height so that the bottom edge of the impactor face is
aligned with the top of the pelvis flesh see figure 12.
o Position the impactor face adjacent to the abdomen. The probe centre must be aligned
with the mid sagittal plane within ±5 mm. If the difference is greater gently manipulate the
dummy and re-measure until the measurement in less than 5 mm difference.
Figure 12 Lower Abdomen Probe Alignment Definition
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Deliverable 3.3a
Data Processing
o Remove data channel offset but do not zero the IR-TRACC and potentiometer channels;
per SAE J211 section 8.4.3, bring the normalized value of a stable pre-test section of
data to the proper initial value for the transducer.
o Filter channels using a 180 CFC filter class. Do not filter the raw IR-TRACC voltage as
this will be filtered after it is linearized and scaled during the X-axis deflection calculations
o Calculate time history of impact force at the contact interface.
o Calculate the left and right X-axis abdomen deflections in the local spine co- ordinate
system (see THOR User’s manual).
o Calculate the absolute value of the difference between the peak left and right X-axis
deflections in the local co-ordinate system. See example of expected results in figure 13
below.
Figure 13 Lower Abdomen Typical Test Result
2.7 LUMBAR SPINE

Currently there is no lumbar spine certification, only a biofidelity test has been carried out for
the lumbar and abdomen region. The details of this are to be reported in a supporting
document to D3.4a Demonstrator, Validated Elderly Overweight Dummy.
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Deliverable 3.3a
2.8 KNEE CERTIFICATION
The knee certification will be identical to the procedure for the HIII 5F dummy (Hybrid III 5th
female) see user manual section 9.4 page 61 on Humanetics website. (Humanetics, 2015b)
http://www.humaneticsatd.com/crash-test-dummies/frontal-impact/hiii-5f
The knees are new and certified.
2.9 FOOT CERTIFICATION
The feet are standard Hybrid 5th female parts which require a compression test and an ankle
motion test. Details can be found in the Humanetics 5th female user manual sections 10.3
and 10.4 pages 72 to 78. The website link and ref is the same as shown in 2.8 above. The
feet are new and certified.
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Deliverable 3.3a
3 DUMMY ASSEMBLY
3.1 HEAD AND NECK ASSEMBLY
The current WorldSid small female head and neck are used on the elderly dummy. The head
provides frontal and lateral responses.
For head and neck assembly refer to WorldSID-5F user manual (Humanetics, 2015a).
3.2 SHOULDER ASSEMBLY
There are 2x clavicles attaching to the sternum at one end and to a soft rubber like bush
above the arm shoulder socket housing. There is a scapular that connects to the shoulder
socket housing and to a rubber bush connecting to the side of a metal upper spine. The top
rib (rib 1) also connects to the central spine. Under the central spine there is a flexible rubber
element to provide flexibility to the upper spine. Cables pass through these rubber elements
to provide durability. At the rear a flexi-cord pulls the two scapulars together. This cord is
tensioned to square the weight of the arms. The scapulars should be vertical when this is
done. For the flesh there are 2x protectors to the front of the rib and a shoulder cover slots
over the assembly. To remove the arms, which is necessary when fitting the ribs, remove the
2x M6x 20 long SHCS item 21 in figure 14.
Table 1: Shoulder Assembly Parts List

ITEM QTY PART No DESCRIPTION
1 1 164-3540 T4/NECK BRACKET
2 1 164-3550 SCAPULA LEFT
3 1 164-3560 SCAPULAR RIGHT
4 2 164-3541 SCAPULA FLEXION INSERT
5 4 047-2200 Q0 NECK CABLE
6 1 164-3051-01 RIB NO 1
7 2 910420-019-H ISOLATION DAMPER, SHOULDER
8 4 5000566 M5 FLAT WASHER PLAIN ZINC
9 4 5000522 M5 X 0.8 HEX LOCK NUT ZINC
10 1 164-3530 T4 FLEX JOINT
11 2 472-3645 UPPER THORACIC SPINE FLEX JOINT ASSEMBLY
12 2 5000466 M5 X 0.8 X 25 LG BHCS
13 1 164-3571 CLAVICLE LEFT
14 4 5000133 M6 X 1 X 25 LG BHCS
15 1 164-3572 CLAVICLE RIGHT
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Deliverable 3.3a
16 2 9000121 ¼-20 X ½ LG SHCS

17 4 164-3573 BUNGEE CORD RETAINER
18 1 175-3574 175-3015-FT TRIMMED 150 mm LG
19 2 9003938 ½ SAE FLAT WASHER TYPE-B ZINC
20 1 164-7011 SHOULDER LEFT
21 4 5000001 M6 X 1 X 20 LG SHCS
22 1 164-3570 SHOULDER CAP
23 1 164-7021 SHOULDER RIGHT
24 2 472-3747 M12 X 1.75 LOCK NUT, MODIFIED
25 2 79051-33-DN WASHER COMPRESSION
26 2 9002412 5/16” X 2” LG SHSS
27 4 5001041 M6 X 1 X 12 LHCS
28 1 164-3052-01 RIB FLESH LEFT
29 1 164-3053-01 RIB FLESH RIGHT
Figure 14 Shoulder Assembly Exploded View
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Deliverable 3.3a
3.3 THORAX ASSEMBLY
The thoracic spine consists of a 3D printed metal upper spine and a lumbar load cell
structural replacement. These are bolted together, 6x M8 bolts attach the load cell to the
spine. A ballast weight attaches to the front of the spine using 4x M6 screws. There are 4x
3D IR-TRACC assemblies that attach to the side of the spine and are attached with 2x M4
SHCS screws. The flesh rib covers slide over the ribs and are attached to the back of the
spine. Each rib is different so must be assembled in order rib 6 to 2. Each rib is marked with
its number. The IR-TRACCs are then connected as the ribs are assembled, so start with rib 6
which has 2x IRTRACCs. There is a small dowel pin on the IR-TRACC assembly that locates
into the inside of the rib. See figure 15. Detail A. The breast plate is attached using 12x M5
button head screws with washers. Attach the breast plate one rib at a time while assembling
the ribs from the bottom. Note, the 4x breast screws that attach the IRTRACCs must be
restrained internally with the prototype at the outer universal joint to avoid twisting the
IRTRACC wire as the pin does not prevent the IRTRACC rotating. This also applies to
disassembly. The IRTRACC wire will spin around the ITRACC and break if not
prevented from rotating.
Table 2: Thorax Assembly Parts List

1 1 164-3040 SPINEBOX
2 1 472-3720 THORACIC SPINE LC STRUCTURAL REPLACEMENT
3 12 5000210 M5 X 0.8 X 20 LG BHCS
4 4 5000438 M6 X 1 X 20 LG BHCS
5 4 5000285 M6 X 1 X 18 LG SHCS
6 6 5001091 M8 X 1.26 X 16 LG FHCS
7 1 164-3051-02 RIB No 2
8 1 164-3051-3 RIB No 3
9 1 164-3051-4 RIB No 4
10 1 164-3051-5 RIB No 5
11 1 164-3051-6 RIB No 6
12 12 9000054 WASHER FLAT No 10 X .500 X .049
13 1 164-3070 UPPER TORSO BALLAST
14 4 5000390 M6 X 1 X 25 LG BHCS
15 10 5000466 M5 X 0.5 X 25 LG BHCS
16 1 164-3052-02 RIB No 2 FLESH LEFT
17 1 164-3053-02 RIB No 2 FLESH RIGHT
18 1 164-3052-03 RIB No 3 FLESH LEFT
20 1 164-3052-04 RIB No 4 FLESH LEFT
22 1 164-3052-05 RIB No 5 FLESH LEFT
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Deliverable 3.3a

24 1 164-3052-06 RIB No 6 FLESH LEFT
26 1 164-3265 BREAST PLATE
27 1 164-3500 SHOULDER ASSEMBLY
28 8 5000151 M4 X 0.7 X 10 LG SHCS
29 1 RIB 3 IRTRACC RIB No 3 IRTRACC LEFT
30 1 IRTRACC_RIB3R RIB No 3 IRTRACC RIGHT
31 1 IRTRACC_RIB6 RIB No 6 IRTRACC LEFT
32 1 IRTRACC_RIB6R RIB No 6 IRTRACC RIGHT
Figure 15 Thorax Assembly Exploded View
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Deliverable 3.3a
Figure 16 Pictures of Thorax Assembly
UPPER TORSO ASSEMBLY SUPPLEMENT
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Deliverable 3.3a
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Deliverable 3.3a
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Deliverable 3.3a
3.4 ABDOMEN, LUMBAR SPINE AND PELVIS ASSEMBLY
The pelvis bone is a standard Hybrid III 5th female assembly, refer to Humanetics manual for
assembly and dis-assembly instructions. The flesh system is all new along with the lumbar
spine and IR-TRACC instrumentation. The IR-TRACCs mount to a bracket at the rear that
fixes to the pelvis bone. The front IR-TRACC attachment is to a vertical hinged rib. See figure
17. The pelvis bone assembly slots into the pelvis flesh then the femur assemblies are
installed. A ballast weight attaches to the top of the pelvis bone with two screws. The lumbar
spine has two plates each end to attach to the pelvis bone at the bottom and the thoracic
spine lumbar load cell structural replacement at the top. The rear two part abdomen flesh
slots around the lumbar spine and the front abdomen flesh fits centrally at the front behind
the front lip of the pelvis flesh. The three organs fit into their designated recesses.
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Deliverable 3.3a
Table 3: Pelvis Assembly Parts List

1 1 164-4050 PELVIS FLESH
2 1 880105-432-1-DN LEFT LOAD CELL SIMULATOR
3 1 880105-438-FT FEMUR ASSEMBLY. MACHINED LEFT
4 1 880105-432-2-DN RIGHT LOAD CELL SIMULATOR
5 4 9000476 5/16-18 X 7/8 LONG SHCS
6 4 9000750 3/8-24 X ¾ LONG SHCS
7 6 9000624 10-24 X ½ LONG SHCS
8 2 1200051-FT PELVIC PLUNGER ASSEMBLY
9 2 880105-1101-FT MODIFIED SCREW
10 4 5000864 M5 X 14 LONG FHCS
11 4 5000001 M6 X 20 LONG SHCS
12 1 164-4550 ORGAN SAC
13 1 880105-431-FT PELVIS ASSEMBLY
14 1 880105-439-FT FEMUR ASSEMBLE MACHINED, RIGHT
15 4 5000391 M3 X 18 LONG DOWEL PIN SS
16 1 164-3010 LUMBER T12 ADAPTOR
17 1 164-4555 PELVIS ABDOMINAL BALLAST
18 2 5000416 M5 X 16 LONG BHCS
19 1 164-4517 VERTICAL RIB ASSEMBLY, RIGHT
20 2 10180-R4 VERTICAL RIB IRTRACC
21 1 164-4516 VERTICAL RIB ASSEMBLY LEFT
22 1 164-4510 LUMBER SPINE
23 1 164-4554 SPLEEN
24 1 164-4552 LIVER LOBE No1
25 1 164-4553 LIVER LOBE No2
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Deliverable 3.3a
Figure 17 Pelvis Assembly Exploded View
Figure 17 Assembled Pelvis without Abdomen
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Deliverable 3.3a
3.5 LUMBAR SPINE ASSEMBLY
The lumbar spine is a stacked elliptical assembly with rigid and flexible segments as shown
in figure 19 with two steel cables running through the center. To dismantle unscrew the two
nuts at the top, remove the two bushes then pull out the two wires. The stacked parts can
then be lifted away. It is best to maintain the same position if parts are structurally OK, so
should be laid out in order on the bench. If replacing parts just remove the damaged part and
replace with new keeping the rest of the parts in the same position. The parts are identical
apart from the top segment. On re-assembly the nuts are tightened to 1.24 ±0.1 Nm.
Table 4: Lumbar Spine Assembly

Item Qty Part Number Description
1 2 78051-301-FT CABLE - NECK
2 2 180-2004 BUSHING, UPPER NECK
3 1 164-4510 LUMBAR BASE
4 3 164-4510-2 VERTEBRAL DISC
5 3 164-4510-5 VERTEBRAL DISC, INNER
6 2 164-4510-3 VERTEBRA
7 1 164-4510-4 VERTEBRA, TOP
8 2 180-2005 BUSHING, NECK LOWER
9 2 9000018-DN NUT, JAM – ½-20
Figure 18 Lumbar Spine Assembly
3.6 LEG ASSEMBLIES
The leg design is basically Hybrid 3 small female (HIII 5F) but with a longer femur and a
longer tibia. Therefore the thigh flesh and the lower leg flesh are new parts along with the
ankle. Structural replacement load cells are fitted to the top and the bottom of the tibia for
replacement with actual load cells. Knee and foot are standard Hybrid III small female. For
leg assembly instructions see HIII 5F manual (Humanetics 2015b) Section 8 page 43 on the
Humanetics website. http://www.humaneticsatd.com/crash-test-dummies/frontal-impact/hiii-5f
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Deliverable 3.3a
3.7 ARM ASSEMBLIES
The upper Arm consists of four parts. A bone assembly with build in ball socket, an upper
flesh, lower flesh and a shoulder screw for the lower arm connection. Only a light friction is to
be applied to the shoulder ball. This is applied by tightening the shoulder bolt running inside
the shoulder ball. The lower arm is standard HIII 5F so for lower arm assembly refer to HIII
5F manual Section 7 page 41 on Humanetics website see web link and ref above.
Particularly note requirement for elbow friction.
Table 5: Upper Arm Parts List

ITEM QTY PART NUMBER DESCRIPTION
1 1 164-7001 HUMERUS
2 1 164-7004 UPPER ARM FLESH
3 1 9000248 5/16 X 1 ¼ LG SHSS
4 1 8005111 VELCRO LOOP COVER
5 1 164-7003 UPPER ARM CAP
Figure 19 Upper Arm Assembly
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Deliverable 3.3a
4 DUMMY DAMAGE CHECK LIST

Below is a table of items to be checked before certification. As most parts are 3D printed and
this process of manufacture is new close attention should be paid to these items.
Table 6: Dummy Check List

DUMMY ITEM INSPECT FOR
Head outer skin Gashes, rips, cracks
Neck Broken or cracked rubber
Neck brackets firmly attached
Buffer blocks are in position
Shoulder ball Cracks or breaks
Clavicles Cracks distortion or breaks
Shoulder flesh Tears
Ribs, Thorax and abdomen Broken, bent or cracked
Rib flesh Tears and cracks
Spine Broken or cracked
Upper spine element Tears or delamination
Sternum Tears and cracks
Sternum flesh Tears and cracks
Rib IR-TRACs Loose end fittings or bent. Free articulation
Transducer leads Torn cables
Accelerometer mounts Mounting secure
Lumbar spine Cracks or tears in flexible and rigid elements
Abdomen flesh Tears, cracks and distortion
Abdomen vertical ribs Cracked or broken
Abdomen IR-TRACCs Loose end fittings or bent. Free articulation
Pelvis flesh Tears, cracks and distortion
If upon visual examination, damage is apparent in any of these areas, the appropriate
engineering technician is to be consulted for a decision on repair or replacement.
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Deliverable 3.3a
5 SEATING PROCEDURE
No defined positioning has been finalized for the elderly dummy as it is still very new and
limited testing has been carried out. There will be different seating positioning for generic and
actual car seating. For generic test rig seating the following procedure can be used.
1. Position the dummy on the seat to the THOR reference H-point (check bilaterally).
2. Adjust pelvis angle to 20° (+/-2°)
3. Adjust foot rest position so that lower extremity angles are matching to THOR
references (femur angle about 13 deg, tibia angle about 45 deg) ?? please check
reference angles from your THOR tests
4. Adjust cable back tension so that:
a. Sternum angle matches THOR reference: about 55° ?? please check
reference value from your THOR tests
b. Alternatively use THOR thoracic spine Tilt-sensors reference values from your
THOR tests, if they are transferable to elderly dummy?
5. Adjust head position to keep constant the following relationship:
6. Adjust the head angle to 0° (+/-2°)
The seating procedure for both generic and vehicle testing is to be fully defined in Task 4.1.
The seating should be consistent between partners and setup details should be passed on
after testing from each lab.
The H point or center of hip ball location is shown in Figure 21 relative to the pelvis below. A
tool is provided with the dummy to set the pelvis angle which is inserted into the square peg
in the pelvis.
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Deliverable 3.3a
Figure 20 H-Point Location
6 SPARES PROVIDED
Due to the unknown durability of the 3D printed parts spares are to be provided. These items
listed below where considered as potential areas of failure. Generally parts will be available
at short notice due to the quick manufacture of 3D parts.
1x clavicle set
1x shoulder flesh cover
1x abdominal flesh
1x Ribs 5 and 6 with flesh covers
1x Sternum flesh
2x abdominal ribs
1x IRTRACC attachment mount
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Deliverable 3.3a
7 DUMMY LIFTING
If needed a lifting harness has been provided with the dummy, see figure 22. A leaflet has
also been provided on how to fit.
Figure 22 Dummy with lifting harness attached
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Deliverable 3.3a
8 SUMMARY AND CONCLUSIONS

The present deliverable proposes certification procedures for the Elderly Overweight dummy
to ensure the dummy is in a repeatable condition before each test series. Like for other
ATD’s the tests consists of component and fully assembled dummy configurations.
Testing follows standard type of tests and laboratory equipment as used for existing ATD’s.
For all tests a description of the procedure and equipment is provided. However, as it
concerns a dummy consisting of new parts combined with existing parts from other dummies,
some corridors are not established yet for all tests. In such cases it is proposed to compare
against initial baseline performance to ensure that the dummy maintains the same response
throughout the test program.
In addition to the dummy certification procedures information for assembly/dis-assembly,

handling, seat positioning and part condition checks after testing has been provided in this
Deliverable. This information is needed for partners to run tests in SENIORS.
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Deliverable 3.3a
Glossary
Term Definition
ATD Anthropometric test device; sometimes known as a crash test dummy

ICAM International Centre Automotive Medicine
BASt Bundesanstalt für Straßenwesen
CAE Computer Aided Engineering
BMI Body Mass Index
ISO International Organization for Standardization
PMHS Post Mortem Human Subject
SENIORS Safety ENhanced Innovations for Older Road userS
IRTRACC InfraRed Telescoping Rod for Assessment of Chest Compression
WorldSID-5F World Side Impact Dummy 5th percentile female version
THOR-50M Test device for Human Occupant Restraint 50 percentile male version
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Deliverable 3.3a
REFERENCES
Humanetics. (2015a). User manual WorldSid Small Female. W5-9900 WorldSid 5th
User Manual, Rev E.
Humanetics. (2015b). User Manual Hybrid III 5th Female. 880105-9900 User Manual
Rev F.
Humanetics. (2017). User Manual THOR-50M. 472-9900 THOR User Manual Rev D.
APPENDIX 1 EUROPE QUALIFICATION TESTING, THORAX

As a THOR dummy template was used to record results a fail result is shown in red
in the qualification reports. This can be ignored for the elderly dummy as corridors
have not yet been assigned. The software assumed a THOR dummy was being
tested. The upper right hand IRTRACC was not present on the dummy so could not
be reported. Comparison to U.S qualification testing showed the results to be very
similar.
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Deliverable 3.3a
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Deliverable 3.3a
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Deliverable 3.3a
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Deliverable 3.3a
ACKNOWLEDGMENTS
This project has received funding from the European Union's

Horizon 2020 research and innovation programme under grant
agreement No 636136.
DISCLAIMER
This publication has been produced by the SENIORS project, which is funded under the
Horizon 2020 Programme of the European Commission. The present document is a draft
and has not been approved. The content of this report does not reflect the official opinion of
the European Union. Responsibility for the information and views expressed therein lies
entirely with the authors.
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EUROPEAN COMMISSION
HORIZON 2020
GA No. 636136
Deliverable No. D3.3b

Deliverable Title Updated Pedestrian Impactor Certification
Written by
Lemmen, Paul Humanetics
Zander, Oliver BASt 20/10/2017
Checked by Hynd, David TRL 16/10/2017
Alba Fornells IDIADA 16/10/2017
Deliverable 3.3b
EXECUTIVE SUMMARY
This SENIORS deliverable report presents certification instructions and results for the
physical Flexible Pedestrian Leg form Impactor (Flex PLI) which is to be tested and
evaluated with two versions of an Upper Body Mass (UBM) to produce realistic kinematics
and loading to the test tool. The second dynamic certification of the new assembly with an
UBM will be needed and will evolve once both designs have been tested and the best
performing tool has been chosen. When satisfactory kinematics, durability and repeatability
are established draft certification procedures and corridors would be produced for component
parts and the full assembly. Injury criteria already exist for the tibia and knee ligaments but
femur injury criteria will need to be established. One leg has been supplied by Humanetics
for this testing and its certification details are reported in this deliverable.
The Thorax Injury Prediction Tool (TIPT) has not yet been physically tested. So far this has
only been simulated. This tool is based on the European Side Impact Dummy (ES-2) which is
a standard regulated dummy. As such standard certification requirements already exist. A
new full assembly linear guided impact test certification procedure is to be adopted.
For the Head Neck Impactor (HNI) it has been decided not to test with this tool due to results
in simulation. The potential benefit that would be gained from using such a tool has not yet
been sufficiently illustrated at this time. Further research is needed with this design. Details
are reported in deliverable D3.2b.

HIS Certification
TRL/BASt Report review
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Deliverable 3.3b
Contents
Executive summary ...................................................................................................................... 2
1.1 The EU Project SENIORS................................................................................................ 4
1.2 Background to this Deliverable ..................................................................................... 5
1.3 Objective of this Deliverable ......................................................................................... 5
2 Certification ......................................................................................................................... 6
2.1 Introduction ................................................................................................................. 6
2.2 Flex PLI Leg .................................................................................................................. 6
2.3 Static Tests, Femur and Tibia ........................................................................................ 8
2.4 Results Static Tests Femur and Tibia ............................................................................. 8
2.5 Knee Certification......................................................................................................... 8
2.6 Results Knee Certification ............................................................................................. 9
2.7 Pendulum Dynamic Certification................................................................................... 9
2.8 Inverse Dynamic Certification ..................................................................................... 10
2.9 Results Inverse Test .................................................................................................... 11
2.10 Upper Body Mass Flexible Element Certification ......................................................... 11
2.11 Upper Body Mass Full assembly Certification .............................................................. 13
2.12 UBM Launch Requirements ........................................................................................ 14
2.13 UBM Rigid Launch Requirements ................................................................................ 14
2.14 UBM Flexible Element Launch Requirements .............................................................. 15
3 UBM Assembly ................................................................................................................... 17
3.1 Rigid Upper Body Mass Assembly ............................................................................... 17
3.2 Flexible Upper Body Mass Assembly ........................................................................... 18
4 Damage Check List ............................................................................................................. 21
5 Spares Provided ................................................................................................................. 22
6 TIPT (Thorax Injury Prediction Tool) .................................................................................... 23
6.1 Ribs ........................................................................................................................... 23
6.2 Full TIPT Assembly Certification .................................................................................. 25
7 Summary and Conclusions .................................................................................................. 26
References ................................................................................................................................. 28
Appendices ................................................................................................................................ 29
Acknowledgments ...................................................................................................................... 57
Disclaimer .................................................................................................................................. 57
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Deliverable 3.3b
1.1 THE EU PROJECT SENIORS

Because society is aging demographically and obesity is becoming more prevalent, the
SENIORS (Safety ENhanced Innovations for Older Road userS) project aims to improve the
safe mobility of the elderly, and obese persons, using an integrated approach that covers the
main modes of transport as well as the specific requirements of this vulnerable road user
group.
This project will primarily investigate and assess the injury reduction in road traffic crashes
that can be achieved through innovative and suitable tools, test and assessment procedures,
as well as safety systems in the area of passive vehicle safety. The goal is to reduce, the
numbers of fatally and seriously injured older road users for both major groups: car
occupants and external road users (pedestrians, cyclists, e-bike riders).
The overall scope for the SENIORS project is shown in the flowchart.
Quantification of needs
• Literature (injury, behaviour, …) IDENTIFICATION
• Accident studies OF NEEDS /
Prioritise
Initial benefit assessment PRIORITIES FOR • Future project activities
• Achievable injury prevention OLDER ROAD
• Analysis of risks USERS
• Derivation of safety strategies
Biomechanical testing
Dummies / impactors IMPROVED Injury risk curves
Test procedures
Numerical models TOOLS Assessment procedures
Injury criteria
CAR OCCUPANT PEDESTRIAN/CYCLIST

• Better older thorax IRC* • Flex-PLI with UBM ‡ Head-neck and pedestrian
* To be confirmed
• Obese occupant • Head-neck thorax will be early-stage
from the accident
analysis
• Active HBM • Pedestrian thorax‡ research
Safety of older road users

• Effectiveness of new tools and
advantages of new procedures BENEFIT AND
• Applied to current and advanced IMPACT Integrated benefit analysis
new safety systems ASSESSMENTS
• Passive
• Active
Figure 1 . Flowchart of the SENIORS project
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Deliverable 3.3b
1.2 BACKGROUND TO THIS DELIVERABLE

After the introduction of the Flexible Pedestrian Leg Impactor (Flex PLI) into regulation (22
January 2015) it was reported that on higher bumper cars such as Sports Utility Vehicles
(SUVs) the leg had shown some short comings in predicting injury. This was due to the leg
not having an upper body like a human to load the upper part of the leg as the leg was not
bending when impacting the high flat bumper profile of an SUV. The mass of the body flies
over the top of the leading edge of the bonnet and bends the femur and in the case of the
Flex PLI allows sensors in the leg to predict injury. The addition of this mass has shown in
simulation to have more realistic kinematics like a human. Therefore by adding a mass to the
top of the Flex PLI, improved injury prediction will be achieved.
It has been shown from real life data, see e.g. (Wisch, 2017), and from simulation that one of
most injured areas in pedestrian collisions with vehicles is the thorax along with the head.
There are head impactors to test the ability of car bonnets for potential injury but nothing for
the thorax. SENIORS are proposing a test tool ‘The Thorax Injury Prediction Tool’ (TIPT) to
test the ability of car bonnets against thorax injury.
1.3 OBJECTIVE OF THIS DELIVERABLE

The objective of this deliverable is to develop certification procedures to ensure the test tools
are in a repeatable condition before each test series by testing component parts and the fully
assembled tools using various laboratory test methods. Along with standard certification for
the Flex PLI with Upper Body Mass (UBM) and the TIPT, new full assembly certification tests
are to be defined. Draft corridors are to be proposed later in the project. The methods for
these tests are reported in this report. Assembly and condition checks for the leg and flexible
UBM have also been included in this document.
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Deliverable 3.3b
2 CERTIFICATION
2.1 INTRODUCTION
In SENIORS the Flex PLI is being modified to include an upper body mass representing the
influence of pedestrian’s torso on the impact response. Two design variants are proposed:
1) A mass rigidly connected to the top of the Flex PLI as previously proposed in
European funded project APROSYS (Advanced PROtection SYStems) report
D3.3.3H. (J Bovenkerk et al., 2009)
2) A mass connected with a flexible rubber element
As indicated in the Design Specification deliverable report (Burleigh M et al., 2016) the
certification of the Flex PLI with UBM will largely follow existing certification procedures for
the Flex PLI (GRSP, 2013). For the design variants with the UBM an additional inverse test
should be considered due to the different loading conditions to the leg, potentially with a
different impact height loading the femur rather than the knee. The main reason for the UBM
is to load the femur in high bumper vehicle impacts like SUVs as the standard Flex PLI does
not bend the femur due to the vertical face of the high bumper. By adding a mass to the top
of the leg representing the lower torso, this creates a bending force in the femur due to the
mass going over the leading edge of the bonnet. Thus the additional inverse test is meant to
create a humanlike response in the leg as in real accidents.
Certification should be carried out after every 10 vehicle tests. If low speed tests are carried
out the certification interval can be longer but should be done before a new test lab starts
testing. All certification tests shall be conducted in a temperature controlled test environment
with a stabilized temperature of 20 ±2 °C and the temperature shall be recorded.
2.2 FLEX PLI LEG
The Flex PLI leg is used to evaluate pedestrian protection against passenger vehicles in the
event of a collision. Its name Flex is due to the flexible nature of the design where each leg
segment is hinged and the knee is a floating design on springs and wires. The leg has been
biofidelically designed to be struck from the side as if the person was struck walking
perpendicularly across the road. Development started in 2000 and the leg went through four
development stages before regulation in January 2015.
The leg has a number of calibration stages before certification (see Table 1, Steps 0a to 1b).
This table also includes recommended calibration maintenance intervals (Table 1,
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Deliverable 3.3b
Steps 2-4). After calibration of the sensors there are three quasi static component tests on
the femur, knee and tibia. The aim of the static tests is to try and ensure the component parts
are in a condition to pass the full assembly tests. For consumer rating applications these are
followed with a dynamic test consisting of an 8.1 kg linearly guided aluminium honeycomb
faced impactor striking the leg while free hanging in the knee. It is called an inverse test as it
is the opposite of the test tool being fired at a car bumper as in the vehicle assessment
requirement. In regulation ECE R127 there is also a pendulum test which has a lower impact
speed striking the same impact location as the inverse test but generating the same bending
moments. Certification instructions can be taken from (E/ECE, 22 January 2015) and for full
certification details see Humanetics user manual (Humanetcs, 2017a).
Table 1. Flex PLI calibration and certification steps

Step Description When Required Pass-Fail Requirement
Femur Gauge 1. Annually, recommended 1. ±1.0% linearity full scale
0a
Calibration 2. After exceeding injury thresholds 2. ±2.0% hysteresis full
Tibia Gauge +10% for FLEX-GTR in an application scale
0b
Calibration test, recommended all gauges
String Potentiometer 1. Annually ±1.0% (VRCI-P-100A)
0c
Calibration
Accelerometer 1. Annually 1. ±1.0% linearity full scale
0d
Calibration
Femur Assembly 1. Annually recommended 1. Femur centre bending
1a
Bending Test 2. After exceeding injury thresholds moment-deflection corridor
+10%, recommended 2. Tibia centre bending
Tibia Assembly
1b 3. After maintenance and/or component moment-deflection corridor
Bending Test
exchange, recommended
1. Annually recommended 1. MCL moment -
2. After exceeding injury thresholds elongation corridor
Knee Assembly
2 +10%, recommended 2. ACL and PCL moment -
Bending Test
3. After maintenance and/or component elongation corridors
exchange, recommended
1. Annually 1. Peak bending moment
2. After 10 vehicle tests max tibia 1, tibia 2, tibia 3 and
Dynamic Pendulum 3. After exceeding injury thresholds tibia 4
3
Impact +10% 2. peak elongation MCL,
4. After maintenance and/or component PCL and ACL
exchange
1. Annually 1. Peak bending moment
2. After 30 vehicle tests tibia 1, tibia 2, tibia 3 and
Dynamic Linear 3. After exceeding injury thresholds tibia 4
4
Guided Impact +10% 2. Peak elongation MCL,
4. After maintenance and/or component PCL and ACL
exchange
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Deliverable 3.3b
2.3 STATIC TESTS, FEMUR AND TIBIA
This operation requires the use of a materials testing load frame machine with high definition
load cell and the regulated certification fixture, see Figure 2 for a picture of the femur under
loading. All details for the femur and tibia assembly static tests including required corridors
can be found in the Humanetics user manual. (Humanetics, 2017a).
Figure 2 . Bone Assembly Fixture (femur shown under bending)
2.4 RESULTS STATIC TESTS FEMUR AND TIBIA
See Appendix 1 for initial static leg bone tests results of leg used in SENIORS testing.
Sensor sensitivities are included in Appendix 5 for input into test laboratory Data Acquisition
System for accurate performance of sensors.
2.5 KNEE CERTIFICATION
This operation requires the use of a materials testing machine with high definition load cell
and some parts from the regulated test fixture, see Figure 3 setup prior to loading. For test
details refer to Humanetics manual. (Humanetics, 2017a)
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Deliverable 3.3b
Figure 3 . Knee Certification Fixture
2.6 RESULTS KNEE CERTIFICATION

See Appendix 2 for initial knee static tests results of leg used in SENIORS testing.
2.7 PENDULUM DYNAMIC CERTIFICATION
The dynamic pendulum certification test is carried out on a test rig, diagrammatically shown
in Figure 4. Only seven channels are required and must meet the UN-R requirement
(UNECE, 22 January 2015). The leg should be tested with its on-board Data Acquisition
System (DAS) to obtain complete certification of the tool. As the project is following the
European New Car Assessment Programme (NCAP, 2016) protocols only the high-speed
inverse test is required. However for reference purposes the leg was certified to the
pendulum test before testing.
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Deliverable 3.3b
Figure 4 . Diagram of Dynamic Pendulum Fixture
This test could be carried out at any time if required to check leg function before testing. The
leg assembly is tested with the flesh cover parts fitted and the leg is upside down, so that the
leg pivots from the bottom of the tibia. This is to increase the amount of test energy to have
similar loading level to a vehicle impact; an additional 5.0kg mass was added to the femur
end to achieve this. See Humanetics manual for full details (Humanetcs, 2017a).
2.8 INVERSE DYNAMIC CERTIFICATION
The preparation for the leg and execution of the test is described in the Humanetics manual
(Humanetics, 2017a). The seven injury channels must meet the test corridors as stated in
UN Regulation 127.01 (UNECE, 22 January 2015). The leg should be tested with its on-
board DAS to obtain complete certification of the tool.
The inverse test is a dynamic calibration test where the fully assembled leg is suspended
stationary vertically ±2° from a sprung hook which releases within 10 ms after impact. The
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Deliverable 3.3b
leg is struck with a linear guided impactor of 8.15 ± 0.1 kg mass including the honeycomb
face with an impact velocity of 11.1 ±0.2 m/s (40 km/h). See Figure 5.
Hanging System
Z axis
release the FlexPLI
within 10 ms after the
moving ram impact
Y axis X axis
Hanging Bracket
tilted 15° towards
ram FlexPLI with Flesh
(cross sectional image)
Moving ramram
Moving
Total mass 8.158,1
±0.1 Depth
Total Mass: +/- Kg incl
0.05 kghoneycomb Depth (d)
Impact speed 11.1 ±0.2 m/s
Impact speed: 11,1 +/- 0.2 m/s 6060
+/-±5 2mm
mm
0 +/- 2 mm
at impact
Knee joint center
Impact
Direction
Impact face
Moving ram guide Honeycomb
Width
Width (w)
200+/-± 25mm
200 mm
Depth
Length (l)
160 ± +/-
160 5 mm2 mm
Crash strength: 75 +/- 10% psi
Figure 5 . Diagram of Dynamic Inverse Certification Test set up
2.9 RESULTS INVERSE TEST
See Appendix 4 for initial inverse tests results of leg used in SENIORS testing.
2.10 UPPER BODY MASS FLEXIBLE ELEMENT CERTIFICATION
At the current status of the SENIORS project, no certification of the flexible element is
foreseen prior to testing. This would be done if the design provided good performance during
testing and would be a component pendulum test. Therefore only the rubber hardness was
checked (see Figure 6 below). A hardness of 72.5 Shore A was recorded.
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Deliverable 3.3b
Figure 6 . UBM flexible element hardness recording
The dynamic certification test would be carried out after testing and reported in WP4. A plate
would be made to allow the flexible element to be attached to a 572 subpart E pendulum.
(Federal, 1992). For practical reasons a modified heavier version of Q dummy head form
would be used (Humanetics, User Manual Q3 Advanced 3 year old child Rev G, 2016) for
this test at a speed of 6.05 ±0.1 m/s which is close to the highest practical speed for this
pendulum. The pendulum would impact a honeycomb stop to provide a controlled
deceleration. The flexible element rotations would be measured using 2 potentiometers as
fitted to the head form. See figure 7 for Q3 dummy head form example. The maximum head
flexion angle relative to the pendulum will be recorded along with the deceleration velocity
timing. Refer to Q3 lumbar spine certification for details. (Humanetics, User Manual Q3
Advanced 3 year old child Rev G, 2016). Three flexible elements would be tested and draft
corridors established for angle and deceleration. The rubber element design could also be
refined to improve performance, e.g. harder rubber or repositioned internal wires.
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Deliverable 3.3b
Figure 7 . Head form example (Q3 dummy lumbar spine certification)
2.11 UPPER BODY MASS FULL ASSEMBLY CERTIFICATION
As mentioned in the introduction 2.1 a full assembly test will be needed to establish the full
condition of the leg prior to testing. This applies to both flexible and rigid UBM leg
assemblies. It is proposed to have an additional inverse test to the standard leg by impacting
the center of the femur with the UBM attached. The leg would be hung in a similar way to the
current leg and released on impact. The same 8.15 kg linear guided mass with impact speed
11.1 m/s would be used. This test would then represent high bumper (SUV type) loading to
the leg which the upper body mass was designed to address. See Figure 8.
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Deliverable 3.3b
Figure 8 . Diagram of dynamic inverse test for leg with UBM
2.12 UBM LAUNCH REQUIREMENTS
The UBM adds a significant mass (6.85 kg) to the top of the leg that will require support
when being accelerated from the pusher of the launch platform. Therefore any pusher plate
used for the leg without UBM will need modification along with pusher angle adjustment to
allow for gravity in free flight to meet the intended impact target. Below are additional parts to
adapt the pusher plate at BASt for the rigid and flexible UBM.
2.13 UBM RIGID LAUNCH REQUIREMENTS
An extension has been added to the top of the aluminium pusher with an adjustable pusher
bar to directly push the UBM (see Figure 9). This is the setup reported in the APROSYS
project report (J Bovenkerk et al., 2009).
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Deliverable 3.3b
Figure 9 . Rigid UBM pusher arrangement
2.14 UBM FLEXIBLE ELEMENT LAUNCH REQUIREMENTS
Like with the rigid pusher used on the UBM the flexible element follows the same principle to
support the UBM when accelerating the leg towards the vehicle (see Figure 10). This shows
the supporting bar at the rear of the mass located on its cg and the hanging bar to hold the
leg which passes through the base plate of the UBM assembly.
Figure 10 . Flexible UBM pusher arrangement with mass and without
The pusher bar is positioned on the centre of gravity of the UBM above the flexible element;
see Figure 11 below for dimensions.
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Deliverable 3.3b
Figure 11 . Flexible UBM pusher location dimensions
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Deliverable 3.3b
3 UBM ASSEMBLY
Refer to Humanetics Flex PLI manual starting at section 3 page 47 for the standard Flex PLI
leg assembly (GRSP, 2013). For the two upper body masses, assembly’s details are as
follows.
3.1 RIGID UPPER BODY MASS ASSEMBLY

The rigid UBM consists of four parts: a base plate, a lower slide rail, an upper slide rail and
the mass, see Figure 12 below.
Figure 12 . Rigid UBM (J Bovenkerk, 2009)
The rigid mass can be mounted in four ways by either reversing the way the mass is screwed
to the upper slide rail for height or moving the base plate back for a more rearward position
(see Figure 13). This is to investigate the most effective position of the mass for injury and
kinematics.
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Deliverable 3.3b
Center lower Center upper Offset lower Offset upper
Figure 13 . Rigid mass four positions adjustment (J Bovenkerk et al., 2009)
To assembly the rigid mass remove the top plate on the femur of Flex PLI leg by removing
the 4x M6 button head cap screws. Replace with the base plate (shown as purple part in
Figure 13. Then bolt the lower slide rail to the upper slide rail with 4x M6 socket cap head
screws (two grey parts in figure 13). Fit the slide rail assembly to the base plate noting there
are two position options available, in line with the base plate or set back 20 mm. Position as
required and fix with 4x M8 screws. Finally fit the mass. Note there are two height positions
for the mass as the mass can be inverted. Screw on the mass as required on the M38 mm
thread and tighten using the two holes on the end of the mass.
Dis-assembly can be the reverse of assembly or the 4x M8 screws can be removed.
3.2 FLEXIBLE UPPER BODY MASS ASSEMBLY
The flexible UBM consists of five parts, a stainless steel top plate to maintain Flex mass
specification, an aluminium base plate to connect to the flexible element, the flexible element
assembly, the mass and a urethane cover to represent the pelvis flesh and protect the mass.
See Figure 14 and 15 and parts list Table 2.
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Deliverable 3.3b
Figure 14 . Picture showing upper body mass initial trial setup
Figure 15 . Flexible UBM
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Deliverable 3.3b
Table 2. Parts list for flexible element UBM

1 4 5000270 M6 X 1 X 40 LG SHCS
2 1 133-1506 TOP PLATE
3 1 133-1510 RUBBER ELEMENT ASSY
4 4 5000001 M6 X 1 X 20 LG SHCS
5 8 5000438 M6 X 1 X 20 LG BHCS
6 8 133-1505 WASHER
7 2 5001261 M6 X 1 X 35 LG BHCS
8 2 M6 X 1 X 35 LG FHCS
9 1 133-1503-2 BASE PLATE
10 1 133-1501-2 UPPER BODY MASS
11 1 133-1502-2 UBM COVER
To assemble the flexible element UBM remove the top plate from the femur of the flex PLI by
removing the 4x M6 button head cap screws. Lay over the top plate item 2 and base plate
item 9, align the 4x holes with the leg and fit the 2x M6 x 35 long button head screws and the
2x 35 long flat head screws both 35 mm long. Align the rubber element assembly with the
dowel holes and attach to the base plate with 4x M6 x 20 long socket head cap screws. Align
the dowels of the UBM with the rubber element assembly and secure using 4x M6 x 40 long
socket head cap screws. Finally fit the cover aligning the dowels at the front of the UBM and
secure with the 8 washers and M6 x 20 long button head screws. Dis-assembly would be the
reverse of assembly.
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Deliverable 3.3b
4 DAMAGE CHECK LIST

See Table 3 below for items to be checked periodically during testing and before certification.
Table 3. Leg and UBM part check list for damage

ITEM INSPECT FOR
Plastic segments Cracks, excessive play
Links Too lose
Double sided tap No sticky or folded over
Rubber bumper stops In central position and not damaged
Outer Neoprene covers Tears and cuts, zipper damage
End cover Cracks and wear
Shoulder bolts Are tight along with M6 button head screws (3 Nm)
Knee meniscus Worn or broken, bronze bushes are tight
Steel cables Adjusted correctly
Transducer leads Torn cables
Leg bone cores Significant cracking
String potentiometers Strings are tight on assembly
UBM flex element Tears, cracks and distortion
UBM flex element wires Wire not pulled out of end fitting or wire damaged
UBM flex element nuts Nuts are tight and no play in wire, if lose check fittings
UBM flex element cover Tears, cracks and wear
UBM flex element Tears, cracks and distortion
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Deliverable 3.3b
5 SPARES PROVIDED
See Table 4 below for spares provided in case of part failure.
Table 4. Spares list of parts provided by Humanetics
Part Number Quantity Description

133-5301 1 PLATE, MENISCUS W/SHARPSERT
61-503-05-01-00 2 STRING POT ASSY 150MM R, TO 7 PIN MALE
61-507-05-01-00 2 STRING POT ASSY 150MM L, TO 7 PIN MALE
133-5165 2 PCB BONE ASSY, 3 CHANNEL, FEMUR, T/C
133-5565 1 PCB BONE ASSY, 4 CH TIBIA, T/C
133-5350 8 CABLE ASSEMBLY - KNEE ML
133-5360 4 CABLE ASSEMBLY - KNEE AP
133-5515 8 LINK
133-5534 4 SEGMENT ASSEMBLY, INNER
133-5108 1 SEGMENT TOP, FEMUR
133-5535 1 SEGMENT ASSY, INNER - CLOSEST TO KNEE
133-5106 4 SHOULDER BOLT
133-5013 1 COVER, INNER, FEMUR, BATCH CERTIFIED
133-5014 1 COVER, OUTER, FEMUR, BATCH CERTIFIED
133-5015 1 COVER, INNER, TIBIA, BATCH CERTIFIED
133-5016 1 COVER, OUTER, TIBIA, BATCH CERTIFIED
133-5017 1 COVER, FLEX PLI GTR, BATCH CERTIFIED
133-5002 4 SHIM BONE CLAMP (TO -05) OPTIONAL
133-5012 20 SHIM 0.05 OPTIONAL
133-5029 12 SHIM, 0.1 THICK OPTIONAL
133-5030 12 SHIM, 0.2 THICK OPTIONAL
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Deliverable 3.3b
6 TIPT (THORAX INJURY PREDICTION TOOL)

The Thorax Injury Prediction Tool (TIPT) is an ES-2 upper torso including arm, shoulders and
thorax with three ribs (instrumented for deflection). Figure 16 shows the TIPT FE model at
the impact location on a generic vehicle. Additional brackets will be attached to the top and
bottom of the test tool to allow it to be launched at vehicle bonnets. For the standard ES-2
parts only the three rib modules can be certified and these will be certified using the standard
ES-2 certification procedures. For full rib certification details see Humanetics user manual
(Humanetics, 2017b). As there is not a full body other dynamic standard tests like shoulder
and thorax cannot be done. Therefore a new assembly test is proposed.
Figure 16 . TIPT FE simulation example on generic simulated vehicle
6.1 RIBS
Two components of the rib unit determine the performance: the damper and the rib. If the rib
unit fails the test, component inspection tests should be carried out. The certification tests of
the ES-2 thorax as well as the component inspection tests are performed on a drop test rig,
see Figure 18. The procedure for rib certification is shown in Figure 17.
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Deliverable 3.3b
Figure 17 . ES-2 thorax certification flow chart (Humanetics, 2017b)
Figure 18 . ES-2 rib unit certification test set up (Humanetics, 2017b)
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Deliverable 3.3b
6.2 FULL TIPT ASSEMBLY CERTIFICATION
Full assembly certification for the TIPT will require a new certification test performed using a
linear guided impactor. This setup would use the same dynamic test rig as the Flex PLI
inverse certification test. This allows the TIPT to be tested in an unrestrained condition as per
the vehicle test. The impactor could have the same 8.15 mass but will have a 20 degree
impact angle to reflect the same conditions as the physical vehicle test. The configuration is
shown in Figure 19. The impactor speed will likely be less than the 40 kph used on Flex PLI
as the TIPT impact is not normally more than 20 kph due to the secondary impact speed of
the torso after leg impact. With a lower speed a higher mass could be used.
The TIPT would be suspended vertically over its cg using 3 or 4 wires so that the TIPT is
stable. The assembly would be released on impact so there would be no restrictive effect
from the supporting structure. Accelerometers could be fitted to either T1 or T12 to review
test repeatability as well as the rib deflections. A suit cover will be fitted and the arm is to be
sown into the Neoprene suit to restrain the arm for repeatability as per in the vehicle test.
The arm should reduce potential damage to the ribs, acting as a loaded buffer.
If the test above does not show repeatable results, the arm could be removed and the TIPT
retested to see if this improves repeatability. In this case the arm would be removed from the
TIPT vehicle tests. TIPT Updates to this test, if any, will be reported in D4.1.
Figure 19 . TIPT full assembly dynamic certification (suit not shown)
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Deliverable 3.3b
7 SUMMARY AND CONCLUSIONS

The present deliverable shows certification requirements for the Flex PLI and TIPT to ensure
the test tools are in a repeatable condition before each test series. Like for other ATD’s the
tests consist of component and fully assembled test tool configurations. For the Flex PLI with
UBM a new additional dynamic inverse test has been proposed, using the same 8.15 kg
linear guided mass impacting the center of the femur at 11.1 m/s. A new component
pendulum certification test of the UBM flexible element has also been proposed.
For the TIPT a new dynamic certification test is proposed with a sloping impactor to
represent a bonnet profile. This rib assembly test with a straight arm assembled on the
impact side is loading the ribs through the arm.
The HNI is not to be physically tested in the project as the performed simulations did not
reveal the benefit as previously expected, according to the APROSYS project results (Brüll et
al., 2008). See report D3.2b for details.
Testing generally follows standard certification testing and uses existing laboratory
equipment. For all tests carried out before testing, references to the procedures and
equipment is provided. For the new proposed full certification assembly tests for the Flex PLI
with UBM and TIPT further refinement could be necessary to verify the setups and establish
draft corridors. For Flex PLI with UBM it is not yet possible as the selection of rigid and
flexible element designs are still to be analyzed in terms of performance. Also for the TIPT
the physical hardware to hang and impact the assembly has not yet been manufactured. Any
updates to the draft certification procedures will be provided in the SENIORS Deliverable 4.1.
In addition to the test tool certification requirements assembly/dis-assembly, handling and

part condition checks after testing has been provided for the new test tools in this deliverable.
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Deliverable 3.3b
Glossary
Term Definition
APROSYS Advanced Protection Systems; Large scale EU FP5 project

ACL Anterior Cruciate Ligament; part of the structure of the knee
ATD Anthropometric test device; sometimes known as a crash test dummy
BASt Bundesanstalt für Straßenwesen
CAE Computer Aided Engineering
ES-2 European Side Impact Dummy (EuroSid 2)
CoG Center of Gravity
FE Finite Element; a type of numerical modelling
FlexPLI Flexible Pedestrian Legform Impactor
HBM Human Body Model
HNI Head-neck impactor
ISO International Organization for Standardization
MCL Medial Collateral Ligament
PCL Posterior Cruciate Ligament; part of the structure of the knee
PMHS Post Mortem Human Subject
UBM Upper Body Mass
SENIORS Safety ENhanced Innovations for Older Road userS
TIPT Thorax Injury Prediction Tool
TRL Transport Research Laboratory
UBM Upper Body Mass
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Deliverable 3.3b
REFERENCES
Brull.et.al. (2009). Brull S, Brvenkerk J. 2009. New and improved test methods to
address head Impacts. APROSYS (D3.3.3C) AP-SP33-021R. APROSYS.
Burleigh M, L. P. (2016). Design Specifications for improved pedestrian test tools.

Burleigh M, Lemmen P, Zander O. (2016). Design specifications for improved
pedestrian tools (D3.1b) SENIORS Deliverable Report.
Federal, U. (1992). US Federal Regulation Part 572 Anthropomorphic Test dummies,

subpart E 50th percentile Male, issued August 1, 1973; Consolidated as CFR
49 dated October 1, 1991; Ammended by Vol. 56. No 220 November 14, 1991
and Vol. 57. No 199 October 14, 1992
.
Humanetics. (2017a). User Manual Flex PLI. 133-9900 User Manual Flex PLI GTR
Rev J. Retrieved from Humanetics Inovative Solutions Inc.
Humanetics. (2016). User Manual Q3 Advanced 3 year old child Rev G.
Humanetics. (2017b). User Manual Harmonized ES-2. E2-9900-H Rev H. Retrieved

from Humanetics Inovative Solutions Inc.
J Bovenkerk, O. Z. (2009). Evaluation of the extended scope for FlexPLI obtained by

adding an upper body mass. APROSYS (D3.3.3H) AP-SP33-026R.
APROSYS.
NCAP, E. (2016). EURO NCAP. Retrieved from EURO NCAP Pedestrian testing
protocol: https://cdn.euroncap.com/media/25840/euro-ncap-pedestrian-
testing-protocol-v83-december-2016.pdf
UNECE. (2015). IG onUN-R UNECE. Flex PLI GTR User Manual. GTR-9-9-07-
Rev3e. Retrieved from wiki.unece: https://wiki.unece.org/display/trans/GTR9-
2+9th+session
UNECE. (22 January 2015). United Nations Economic Commision for Europe. 2015.
Agreement Concerning the Adoption of Uniform Technical Prescriptions for
wheeled Vehicles, Equipment and Parts which can be fitted and/or be Used on
Wheelde Vehicles and the Conditions for Reciprical Recognition of Approvals
Granted on the Basis of these Prescriptions (Revision 2, including the
amendments which were entered into force on 16 October 1995) Addendum
126: Regulation No. 127 01 series of amendments to the Regulation – Date of
entry into force: 22 January 2015. Uniform provisions concerning the approval
of motor vehicles with regard to there pedestrian safety performance.
Wisch M, Lerner M, Vukovic E, Hynd D, Fiorentino A, Fornells A (2009). Injury

Patterns of Older Car Occupants, Older Pedestrians or Cyclists in Road Traffic
Crashes with Passenger Cars in Europe – Results fromSENIORS. IRCOBI
Conference 2017. Proceedings IRC-17-17.
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APPENDICES
Appendix 1
Femur and tibia quasi static certification results
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Appendix 2
Knee quasi static certification results
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Appendix 3
Pendulum dynamic certification results
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Appendix 4
Inverse dynamic certification results
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Appendix 5
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ACKNOWLEDGMENTS
This project has received funding from the European Union's

Horizon 2020 research and innovation programme under grant
agreement No 636136.
DISCLAIMER
This publication has been produced by the SENIORS project, which is funded under the
Horizon 2020 Programme of the European Commission. The present document is a draft
and has not been approved. The content of this report does not reflect the official opinion of
the European Union. Responsibility for the information and views expressed therein lies
entirely with the authors.
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SAFETY ENHANCED INNOVATIONS FOR OLDER ROAD USERS

Deliverable No. D3.3

Burleigh, Mark Humanetics

Written by Lemmen, Paul Humanetics

Zander, Oliver BASt

Checked by Fornells, Alba IDIADA 17/10/2017

Hynd, David TRL 17/10/2017

Approved by Wisch, Marcus BASt 30/10/2017

Issue date 30/10/2017

The elderly as occupant is being addressed by a new Elderly Overweight Dummy

Contributions of the partners:

This Deliverable report D3.3 consists of two parts:

Deliverable No. D3.3a

The dummy will be baseline certified before testing.

Contributions of the partners:

IDIADA/BASt Report review

Executive summary ...................................................................................................................... 2

CAR OCCUPANT PEDESTRIAN/CYCLIST

Safety of older road users

Figure 1 Flowchart of the SENIORS project

1.2 BACKGROUND TO THIS DELIVERABLE

1.3 OBJECTIVE OF THIS DELIVERABLE

Figure 2 Head Drop Test setup WorldSID-5F

2.4 UPPER THORAX

Figure 3 Dummy Position for Upper Thorax Certification Test

Figure 4 Upper Thorax Pendulum Impact Points

o Carefully reinstall the dummy suit zipping up at the rear

Figure 5 Expected Upper Thorax Force deflection Response

2.5 LOWER THORAX QUALIFICATION

o Instrumentation to measure impact velocity

Figure 7 Expected Force / Deflection Liver Side

Figure 8 Expected Force / Deflection Spleen Side

2.6 ABDOMEN QUALIFICATION

Figure 9 Abdomen Qualification Set-up

Figure 10 Rectangular Impactor Face used in Lower Abdomen Test

Figure 11 Elderly Dummy Abdomen Qualification Test Setup

o Instrumentation to measure impact force (accelerometer on impact or load cell /

Pre Test Procedure

Figure 12 Lower Abdomen Probe Alignment Definition

Figure 13 Lower Abdomen Typical Test Result

2.7 LUMBAR SPINE

2.8 KNEE CERTIFICATION

2.9 FOOT CERTIFICATION

3.1 HEAD AND NECK ASSEMBLY

3.2 SHOULDER ASSEMBLY

Table 1: Shoulder Assembly Parts List

16 2 9000121 ¼-20 X ½ LG SHCS

Figure 14 Shoulder Assembly Exploded View

3.3 THORAX ASSEMBLY

Table 2: Thorax Assembly Parts List

23 1 164-3053-05 RIB No 5 FLESH RIGHT

Figure 15 Thorax Assembly Exploded View

Figure 16 Pictures of Thorax Assembly

UPPER TORSO ASSEMBLY SUPPLEMENT

3.4 ABDOMEN, LUMBAR SPINE AND PELVIS ASSEMBLY

Table 3: Pelvis Assembly Parts List

Figure 17 Pelvis Assembly Exploded View

Figure 17 Assembled Pelvis without Abdomen

3.5 LUMBAR SPINE ASSEMBLY

Table 4: Lumbar Spine Assembly

Figure 18 Lumbar Spine Assembly