1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2009 SAE International All rights reserved. No part of this publication ma
3、y be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA)
4、Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSURFACEVEHICLEINFORMATIONREPORTJ2856 SEP2009 Issued 2009-09Superseding EA-23 APR2005 Users Manual for the 50thPercentile Male Hybrid III Dummy RATIONALEThe 1986 version of Engineering Aid 23 focused on differences betw
5、een the Hybrid III and its predecessor, the Hybrid II dummy.The 1998 revision of EA-23 removed the differences between the Hybrid II and Hybrid III, as most users had experience in using the Hybrid III. Instead of presenting two variations on the calibration procedures that were included in the 1986
6、 version, only the currently accepted practice is listed. It included modifications which are based on many years experience with the Hybrid III, and addresses changes incorporated into the dummy. The most significant differences result from some changes in the Hybrid III dummy. One change now calls
7、 for using feet with a 45 degree range of motion rather than 30 degrees; the feet also have a prescribed force-deflection characteristic. The other major change is a redesigned upper femur, which makes the hip joint range of motion more symmetric and biofidelic, and also prevents metal-to-metal cont
8、act between the hip bone and the femur. These part changes require additional procedures to ensure the proper range of motion at the hip joint. SAE J2856 replaced EA-23 in 2009. In addition to the format change and the correction of typographical errors, the following corrections were made to this I
9、nformation Report: References to SAE J211 were changed to SAE J211-1 throughout the report Section 2 REFERENCES was added Section 3.1 corrected the reference to the drawing package from “the updated 1997 engineering drawing package” in EA-23 to “the engineering drawing package dated August 30, 1998”
10、 Section 3.1 corrected the reference to the drawing package from “The latest drawing package for the Hybrid III dummy was issued in 1997” in EA-23 to “The latest drawing package for the Hybrid III dummy was issued in 1998” Section 3.2 added title “HYBRID III 50thPERCENTILE MALE DUMMY INSTRUMENTATION
11、” to Table 1 Section 3.7 corrected inconsistency in terminology from “chest jacket” in EA-23 to “chest flesh” Section 3.7 Figure 12 was replaced to more clearly show the correct orientation of the nodding blocks Section 3.9 changed the disassembly instructions for the sternum from “Detach the bib as
12、sembly after loosening the set screw (Figure 27) on the chest displacement slider arm at the displacement pot” to “Detach the bib assembly. Do not loosen the set screw (Figure 27) because this will invalidate the chest pot calibration of SAE Recommended Practice J2517.”Section 3.13 corrected the ins
13、pection of buttock compression from “apply a 335 N (75 lbf) force to the bottom of the pelvis, parallel to the ground” to “apply a 334 N (75 lbf) force to the bottom of the pelvis, perpendicular to the ground” SAE J2856 Issued SEP2009 Page 2 of 74Section 3.16 changed the assembly instructions for th
14、e pin that holds the optional displacement potentiometer displacement rod to the slider from “tightened reasonably” to “tight”Section 3.17 corrected an error in lumbar cable torque from “1.2 to 1.4 Nm” in EA-23 to “1.1 to 1.4 Nm”Section 3.17 corrected inconsistency in terminology from “chest jacket”
15、 in EA-23 to “chest flesh” Section 3.18 added title “CENTERS OF GRAVITY” to Table 2 Section 3.18 revised headers of Table 2 consistent with SAE format guidelines Section 3.18 corrected Center of Gravity Location for the foot in Table 2 from “2.30” inches along the X-axis in EA-23 to “2.20” inches. T
16、he metric dimension was correct Section 3.18 corrected Center of Gravity Location for the foot in Table 2 from “-52.7” mm and “-2.20” inches along the Z-axis in EA-23 to “-53.3” mm and “-2.10” inches Section 4.1 (A) corrected inconsistency in terminology from “chest skin” in EA-23 to “chest flesh” S
17、ection 4.1 (C) changed from “Torque the two spine cables to 1.1 Nm (10 inlbf)” in EA-23 to “Torque the two lumbar cables to 1.1 to 1.4 Nm (10 to 12 inlbf)” to be consistent with Section 3.17 Section 4.1 (L) corrected inconsistency in terminology from “chest skin” in EA-23 to “chest flesh” Section 4.
18、2 (A) corrected inconsistency in terminology in Table 4 from “Upper Torso Assembly with Torso Jacket” in EA-23 to “Upper Torso Assembly with Chest Flesh” Section 4.2 (A) corrected description of Lower Torso Assembly in Table 4 from “(includes femurs and their lower lumbar adapting plate)” in EA-23 t
19、o “(includes femurs and lower lumbar adapting plate)” Section 4.2 (A) corrected mass of Upper Arm Assembly, Left and Upper Arm Assembly, Right in Table 4 from “4.4 0.1” lb and “2.00 0.05“ kg in EA-23 to “4.4 0.2” lb and “”2.00 0.09” kg in SAE J2856 Section 4.2 (A) corrected terminology in Table 4 fr
20、om “Total Dummy Weight” in EA-23 to “Total Dummy Mass” Section 4.3 (E) 1 changed torque specification for skull cap screws from “18 Nm (160 inlbf)” to “18 Nm minimum (160 inlbf minimum)” Section 4.3 (E) 2 changed environment temperature for head drop test from “18.9 to 25.6 C (66 to 78 F)” to “20.6
21、to 22.2 C (69 to 72 F)” Section 4.4 (E) 3 added title “PENDULUM IMPULSE FOR THE NECK FLEXION TEST” to Table 5 Section 4.4 (F) 3 added title “PENDULUM IMPULSE FOR THE NECK EXTENSION TEST” to Table 6 Section 4.5 (A) corrected inconsistency in terminology from “vest and panty” in EA-23 to “shirt and pa
22、nts” Section 4.5 (B) updated the test probe description to include “the mass of rigid attachments and the lower 1/3 of the suspension cable mass” Section 4.5 (C) changed the filter channel class for the thorax impact test from “Filter all data channels using Channel Class 180 phaseless filters” in E
23、A-23 to “Filter pendulum force using a Channel Class 180 phaseless filter and chest deflection using a Channel Class 600 phaseless filter” for consistency with SAE J211-1 Section 4.5 (D) 1 corrected inconsistency in terminology from “chest skin” in EA-23 to “chest flesh” SAE J2856 Issued SEP2009 Pag
24、e 3 of 74Section 4.5 (D) 1 changed from “Torque the spine cables to 1.2 to 1.4 Nm (10 to 12 inlbf)” in EA-23 to “Torque the two lumbar cables to 1.1 to 1.4 Nm (10 to 12 inlbf)” to be consistent with Section 3.17 Section 4.5 (D) 6 corrected inconsistency in terminology from “chest skin” in EA-23 to “
25、chest flesh” in two places Section 4.5 (D) 7 corrected inconsistency in terminology from “chest skin” in EA-23 to “chest flesh” in three places Section 4.5 (D) 11 corrected inconsistency in terminology from “chest skin” in EA-23 to “chest flesh” Section 4.5 (E) 3 added “as shown in Figure 72.” Inser
26、ted a new figure and the figure title “FIGURE 72 HYSTERESIS REGIONS.” Indexed the figure numbers of Figures 72 through 78 from EA-23 Section 4.6 (B) updated the test probe description to include “the mass of rigid attachments and the lower 1/3 of the suspension cable mass” Section 4.6 (D) 2 changed
27、environment temperature for knee impact test from “between 18.9 to 25.6 C (66 to 78 F)” to “of 20.6 to 22.2 C (69 to 72 F)” Section 4.6 (D) 3 changed “Torque the load cell simulator bolts to 40.7 Nm (30 ftlbf)” to “Torque the mounting bolts to 40.7 Nm minimum (30 ftlbf minimum)” Section 4.7 (B) corr
28、ected and tightened the specification on the knee slider test probe mass from “12.0 kg 0.14 kg (26.5 lb 0.3 lb)” to “12.00 kg 0.02 kg (26.46 lb 0.04 lb)” Section 4.7 (B) updated the probe description to include “the mass of rigid attachments and the lower 1/3 of the suspension cable mass” Section 4.
29、7 (B) corrected an error in the diameter of the impacting face of the knee slider test probe from “75 mm 0.2 mm” in EA-23 to “76.2 mm 0.3 mm” Section 4.7 (C) replaced Figure 74 with corrected probe mass and hole diameters. The figure was Figure 73 in EA-23. Section 4.7 (D) 2 changed environment temp
30、erature for knee slider test from “between 18.9 to 25.6 C (66 to 78 F)” to “of 20.6 to 22.2 C (69 to 72 F)” Section 4.7 (D) 4 changed the torque specification for the femur load cell mounting bolts from “40.7 Nm (30 ftlbf)” to “40.7 Nm minimum (30 ftlbf minimum)” Section 4.7 (E) 1 added title “FORCE
31、 VERSUS DISPLACEMENT FOR THE KNEE SLIDER TEST” to Table 7 Section 4.7 (E) 1 corrected errors in Table 7, by changing knee slider displacements from “10.0 mm” and “18.0 mm” to “10.2 mm” and “17.8 mm” respectively Section 4.8 (C) replaced Figure 75 to remove incorrect loading rate from EA-23. The figu
32、re was Figure 74 in EA-23 Section 4.8 deleted the reference “NOTE: For details of the procedure development, reference the Final Report of the SAE Hip Calibration Task Group (August 1995).” Section 4.9 corrected source information for EC Directive 96/79/EC Section 5.1 Inserted new section “Low-speed
33、 Thorax Impact Test,” referring to SAE Recommended Practice J2779 as an additional inspection test. Contents of EA-23 Section 5.1 were moved to Section 5.3 in SAE J2856 Section 5.2 Inserted new section “Low-speed Knee Slider Test,” referring to SAE Recommended Practice J2876 as an additional inspect
34、ion test. Contents of EA-23 Section 5.2 were moved to Section 5.4 in SAE J2856 SAE J2856 Issued SEP2009 Page 4 of 74Section 5.3 (D) 1 Was section 5.1 (D) 1 in EA-23. Changed environment temperature for foot test from “between 18.9 to 25.6 C (66 to 78 F)” to “of 20.6 to 22.2 C (69 to 72 F)” Section 5
35、.4 (E) 2 Was section 5.2 (E) 2 in EA-23. The notation on the angle referenced in the bottom of Figure 79 was corrected from “50 REF” to “90 REF.” The figure was Figure 78 in EA-23 Section 5.4 (E) 4 Was section 5.2 (E) 4 in EA-23. Changed environment temperature for ankle motion test from “between 18
36、.9 to 25.6 C (66 to 78 F)” to “of 20.6 to 22.2 C (69 to 72 F)” FOREWORDA group of Hybrid III users met at an SAE workshop held in June, 1984 to learn more about the design and use of the Hybrid III 50thpercentile male dummy. They noted that a users manual would be helpful. In response, the SAE Dummy
37、 Testing Equipment Subcommittee of the Human Biomechanics and Simulation Standards Committee prepared a Users Manual which became SAE Engineering Aid 23, published in June 1986. It has since become the basis for manuals on the entire Hybrid III family of dummies. TABLE OF CONTENTS 1. SCOPE 72. REFER
38、ENCES 72.1 Applicable Publications . 72.1.1 SAE Publications . 72.2 Related Publications . 72.2.1 SAE Publications . 73. ASSEMBLY AND DISASSEMBLY PROCEDURES FOR THE HYBRID III 50THPERCENTILEMALE DUMMY 73.1 Introduction . 73.2 Special Tools . 93.3 Disassembly and Inspection . 113.4 Whole Dummy . 113.
39、5 Clothing . 113.6 Arms 113.7 Head and Neck . 123.8 Shoulder-Clavicles 183.9 Ribs and Sternum . 213.10 Thoracic Spine 253.11 Lumbar Spine 273.12 Abdomen . 283.13 Pelvis and Upper Femurs . 283.14 Upper Legs and Knees . 313.15 Lower Legs and Feet 313.16 Non-Instrumented and Optional Force-Indicating L
40、ower Legs . 323.17 Assembly . 363.18 General Comments . 384. CALIBRATION PROCEDURES FOR THE HYBRID III 50THPERCENTILE MALE DUMMY 404.1 External Measurements 404.2 Mass Measurements . 444.3 Head Drop Test . 444.4 Neck Tests 474.5 Thorax Impact Test . 534.6 Knee Impact Test 574.7 Knee Slider Test 59SA
41、E J2856 Issued SEP2009 Page 5 of 744.8 Hip Joint Range of Motion Test . 624.9 European Calibration Tests 645. INSPECTION PROCEDURES FOR THE HYBRID III 50THPERCENTILE MALE DUMMY 645.1 Low-Speed Thorax Impact Test 645.2 Low-Speed Knee Slider Test 645.3 Foot Test . 645.4 Ankle Motion Test . 666. NOTES
42、696.1 Marginal Indicia . 69APPENDIX A ACCELEROMETER HANDLING GUIDELINES . 70APPENDIX B GUIDELINES FOR REPAIRING FLESH 72APPENDIX C JOINT ADJUSTMENT PROCEDURES 73FIGURE 1 ASSEMBLED HYBRID III DUMMY . 8FIGURE 2 SHOULDER YOKE ASSEMBLY . 11FIGURE 3 EXPLODED VIEW OF THE SHOULDER YOKE ASSEMBLY . 12FIGURE
43、4 SHOULDER YOKE PIVOT NUT . 12FIGURE 5 NECK ANGLE ADJUSTMENT SCREW AND CURVED WASHER . 13FIGURE 6 NECK-TO-UPPER-NECK BRACKET ATTACHMENT HARDWARE . 13FIGURE 7 NECK COMPRESSION TOOL . 14FIGURE 8 NECK COMPRESSION TOOL ASSEMBLED TO THE HEAD AND NECK . 14FIGURE 9 THREE-CHANNEL NECK LOAD CELL OPTIONAL COM
44、PRESSION TOOL . 14FIGURE 10 NECK PIVOT PIN SET SCREWS 15FIGURE 11 NECK PIVOT PIN INSTALLED . 15FIGURE 12 NECK RUBBER NODDING BLOCKS ON NODDING JOINT 15FIGURE 13 DRAWING OF NODDING BLOCK ORIENTATION . 16FIGURE 14 NECK BRACKET ANGLE MEASUREMENT 16FIGURE 15 NECK LOAD CELL PIVOT JOINT (SLOT) AND ATTACHI
45、NG CAP SCREWS . 17FIGURE 16 SPECIAL WASHERS FOR THE SIX-CHANNEL NECK TRANSDUCER 17FIGURE 17 BALL HEX WRENCHES . 17FIGURE 18 SKIN THICKNESS MEASURING TOOL 18FIGURE 19 CLAVICLE LINK-TO-SPINE ATTACHMENT SHOULDER SCREWS . 18FIGURE 20 THORACIC BUMP STOP . 19FIGURE 21 CLAVICLE-TO-CLAVICLE LINK SHOULDER SC
46、REW . 19FIGURE 22 CLAVICLE SPACER . 19FIGURE 23 URETHANE SPRING “STOP“ 20FIGURE 24 SHOULDER ROTATION BUMP STOP 20FIGURE 25 SHOULDER YOKE-TO-CLAVICLE NUT 21FIGURE 26 EXPLODED VIEW OF THE CLAVICLE AND SHOULDER YOKE . 21FIGURE 27 DISPLACEMENT TRANSDUCER AND SET SCREW . 21FIGURE 28 SLIDER ASSEMBLY ATTAC
47、HED TO BIB . 22FIGURE 29 STERNUM INSTALLED ON DUMMY 22FIGURE 30 STERNUM ASSEMBLY WITH RUBBER STERNUM STOPS . 23FIGURE 31 STERNUM STOPS MOUNTED TO THE SPINE (SPINE BOX HIGHLIGHTED WHITE) 23FIGURE 32 RIB ASSEMBLY 24FIGURE 33 REAR RIB SUPPORTS 24FIGURE 34 STEEL RIB AND BONDED DAMPING MATERIAL 24FIGURE
48、35 CHEST DEPTH GAUGE . 25FIGURE 36 THORACIC INSTRUMENTATION ADAPTOR . 25FIGURE 37 SPINE ASSEMBLY HOLES - MODIFIED FOR EASY REMOVAL OF ACCELEROMETERS . 26FIGURE 38 CHEST DEFLECTION TRANSDUCER ASSEMBLY . 26FIGURE 39 UPPER LEG ACCESS HOLE TO FEMUR . 27FIGURE 40 LUMBAR SPINE ASSEMBLY . 27FIGURE 41 REMOVAL PROCEDURE FOR REAR SCREWS HOLDING LUMBAR ADAPTOR . 28FIGURE 42 LUMBAR SPINE ADAPTOR . 28SAE J2856 Issued SEP2009 Page 6 of 74 FIGURE 43 MEASURING LUMBAR SPINE INCLUDED ANGLE 29 FIGURE 44 FEMUR BALL AND FLANGE ASSEMBLY . 29 FIGURE 45 REMOVAL OF UPPER FEMUR BUMPERS FOR INS
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