1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2011 SAE International All rights reserved. No part of this publication m
3、ay be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA)
4、 Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/J2857_201103SURFACEVEHICLEINFORMATIONREPORTJ2857 MAR2011 Issued 2011-03 Superseding EA-31 NOV2006
5、Hybrid III 3-Year Old Child Dummy Users Manual RATIONALE J2857 replaced EA-31 in 2011. In addition to the format change and the correction of typographical and grammatical errors, the following corrections were made to this Information Report: “Calibration Tests“ was changed to “Certification Tests“
6、 throughout the report. References to SAE J211 were changed to J211-1 throughout the report Section 1 SCOPE - added Section 2 REFERENCES - corrected spelling from “Qwings“ to “Owings“ Section 2 REFERENCES corrected spelling from “Reynold” to “Reynolds.” Section 2 REFERENCES added “SAE J211-1 Instrum
7、entation for Impact Test Part 1 Electronic Instrumentation.” Section 2 REFERENCES added “SAE J2517 Hybrid III Family Chest Potentiometer Calibration.” Section 3 definitions of certification test and inspection test were consolidated from various sections of EA-31 to Section 3 of J2857 Section 3.3.1
8、- deleted drawing references and changed the description of the shirt and pants from “Childrens XS (size 4-5) thermal knit, waffle weave, 50%/50% polyester and cotton underwear or equivalent. The shirt and pant should weigh no more than 0.18 kg (0.4 lb) total together. (Note: pants must end above th
9、e knee)“ in EA-31 to “Childrens XS (size 4-5) cotton-polyester based, tight-fitting shirt with long sleeves and ankle-length pants. The neckline must be small enough to prevent contact between the shoulder belt and the dummys flesh. The shirt and pant should weigh no more than 0.25 kg (0.55 lb).“ to
10、 harmonize with NHTSA specifications. Other SAE Documents moved to REFERENCES Section 4 updated address for Reprographic Technologies Section 5 added paragraph to refer to Table 1. Added “TABLE 1 TORQUE SPECIFICATIONS” to the first table in the section. Indexed all other table numbers accordingly. S
11、AE J2857 Issued MAR2011 Page 2 of 83Section 7.1 changed section header from “Disassembly/Reassembly and Inspection” in EA-31 to “Complete Assembly” in J2857 Section 7.1.1 corrected length of shoulder dampers from “19.5 mm (3/4 inch)” in EA-31 to “19.1 mm (3/4 inch)” in J2857 Section 7.1.2 changed jo
12、int setting from “1-2 g” in EA-31 to “1 g” for consistency with procedures in Appendix C. Added sentence “Refer to Appendix C Joint Adjustment Procedures” Section 7.2 changed section header from “Head/Neck” in EA-31 to “Head” to more accurately represent the contents of the section Section 7.2.1 and
13、 7.2.2 moved note, “Make sure that there is a good tight fit between the head skin and the skull when reassembled. (Refer to Appendix B Guidelines for Flesh Repair)” from 7.2.1 Head Disassembly to 7.2.2 Head to Upper Neck Reassembly Section 7.2.2 changed section header from “Head to Upper Neck Reass
14、embly” to “Head Reassembly” to more accurately represent the contents of the section Sections 7.2.2 changed “headskin” to “head skin” for consistency with parts list Section 7.3.2 changed “upper load cell” and “lower load cell” to “upper neck load cell” and “lower neck load cell” for consistency wit
15、h Table 2 Section 7.3.2 deleted “If you are not doing any more work on upper/lower torso then reassemble these, being careful not to damage the chest deflection arm when you reconnect it” because it does not pertain the reassembly of the neck Section 7.3.2 changed “the Y Snyder et al., 1977; Reynold
16、s et al., 1976; Irwin and Mertz, 1997). TABLE OF CONTENTS 1. SCOPE 72. REFERENCES 72.1 Applicable Publications . 72.1.1 SAE Publications . 72.1.2 Other Publications . 73. DEFINITIONS AND ABBREVIATIONS . 73.1 BHCS 73.2 Certification Tests . 73.3 Clothing Specifications 83.3.1 Shirt and Pants 83.3.2 S
17、hoes 83.4 FHCS. 83.5 Inspection Tests 83.6 Midsagittal Plane . 83.7 SHCS 83.8 SHSS. 83.9 SSCP. 83.10 1 g Joint Setting 84. PART NUMBERS 85. CONSTRUCTION & CONFIGURATION 96. INSTRUMENTATION 106.1 Head 106.2 Neck 106.3 Shoulders 106.4 Thorax . 106.5 Pelvis . 107. DISASSEMBLY AND REASSEMBLY PROCEDURES
18、127.1 Complete Assembly 127.1.1 Arms, Legs, and Flesh Removal . 137.1.2 Arms, Legs, and Flesh Reassembly . 13SAE J2857 Issued MAR2011 Page 5 of 837.2 Head 137.2.1 Head Disassembly 147.2.2 Head Reassembly . 157.3 Neck 157.3.1 Neck Disassembly . 167.3.2 Neck Reassembly . 177.4 Upper Torso 187.4.1 Uppe
19、r Torso Disassembly . 217.4.2 Upper Torso Reassembly . 217.5 Complete Shoulder . 217.5.1 Complete Shoulder Disassembly 227.5.2 Complete Shoulder Reassembly 227.6 Lower Torso 237.6.1 Lower Torso Disassembly . 267.6.2 Lower Torso Reassembly . 277.7 Chest Deflection Assembly . 277.7.1 Chest Deflection
20、Transducer Disassembly . 287.7.2 Chest Deflection Transducer Reassembly 287.8 Arms 297.8.1 Arm Disassembly 307.8.2 Arm Reassembly . 307.9 Legs . 307.9.1 Leg Disassembly . 317.9.2 Leg Reassembly . 328. CARE AND MAINTENANCE 328.1 General Inspection 328.1.1 Head 328.1.2 Neck 328.1.3 Upper/Lower Torso .
21、 328.1.4 Shoulder 338.1.5 Hip . 338.1.6 Limbs (all) 338.2 Storage of Rubber Parts . 339. CERTIFICATION PROCEDURES FOR THE HYBRID III 3-YEAR OLD 349.1 Head Drop Test . 349.2 Neck Tests 369.3 Thorax Impact Test . 419.4 Chest Depth Measurement Procedure . 4410. INSPECTION TEST PROCEDURES . 4610.1 Exter
22、nal Measurements 4610.2 Mass Measurements . 5010.3 Head Center of Gravity Location . 5010.4 Torso Flexion Test Procedure . 5011. NOTES 5211.1 Marginal Indicia . 52APPENDIX A ACCELEROMETER HANDLING GUIDELINES . 53APPENDIX B GUIDELINES FOR REPAIRING FLESH 55APPENDIX C JOINT ADJUSTMENT PROCEDURES 57APP
23、ENDIX D DRAWINGS 58FIGURE 1 INSTRUMENTATION LOCATIONS 11FIGURE 2 SIDE VIEW H3-3YO ASSEMBLY . 12FIGURE 3 HEAD AND NECK ASSEMBLY 14FIGURE 4 HEAD ASSEMBLY 15SAE J2857 Issued MAR2011 Page 6 of 83FIGURE 5 NECK ASSEMBLY 16FIGURE 6 SIDE VIEW OF TORSO ASSEMBLY . 19FIGURE 7 FRONT VIEW OF TORSO ASSEMBLY . 20F
24、IGURE 8 COMPLETE SHOULDER ASSEMBLY . 22FIGURE 9 SIDE VIEW LOWER TORSO ASSEMBLY . 24FIGURE 10 FRONT VIEW OF LOWER TORSO ASSEMBLY . 25FIGURE 11 SPINE ASSEMBLY . 26FIGURE 12 CHEST DEFLECTION ASSEMBLY 28FIGURE 13 COMPLETE ARM ASSEMBLY . 29FIGURE 14 COMPLETE LEG ASSEMBLY 31FIGURE 15 HEAD DROP SETUP 35FIG
25、URE 16 PART 572 NECK PENDULUM . 38FIGURE 17 NECK EXTENSION TEST ASSEMBLY 39FIGURE 18 NECK FLEXION TEST ASSEMBLY . 39FIGURE 19 NECK EXTENSION WITH ZERO BRACKET INSTALLED 40FIGURE 20 NECK FLEXION WITH ZERO BRACKET INSTALLED 40FIGURE 21 THORAX IMPACT SETUP 43FIGURE 22 HYSTERESIS REGIONS 44FIGURE 23 CHE
26、ST DEPTH CHECKING PROCEDURE. 45FIGURE 24 EXTERNAL DIMENSIONS . 48FIGURE 25 TORSO FLEXION TEST . 52TABLE 1 TORQUE SPECIFICATIONS 10TABLE 2 AVAILABLE INSTRUMENTATION . 10TABLE 3 EXTERNAL DIMENSIONS . 49TABLE 4 ASSEMBLY MASSES . 50SAE J2857 Issued MAR2011 Page 7 of 831. SCOPE This users manual covers t
27、he Hybrid III 3-year old child test dummy. The manual is intended for use by technicians who work with this test device. It covers the construction and clothing, assembly and disassembly, available instrumentation, external dimensions and segment masses, as well as certification and inspection test
28、procedures. It includes guidelines for handling accelerometers, guidelines for flesh repair, and joint adjustment procedures. Finally, it includes drawings for some of the test equipment that is unique to this dummy. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of th
29、is specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Snyder, R.G., Schneider, L.W., Owings, C.L., Reynolds, H.M., Golumb, D.H., and Schork, M.A., “Anthropometry of Infants, Children and Youths to Age 18
30、for Product Safety Design”, SP-450, SAE International, Warrendale, PA, 1977. Irwin, A.L. and Mertz, H.J., (1997) “Biomechanical Bases for the CRABI and Hybrid III Child Dummies”, SAE 973317, 41st Stapp Car Crash Conference. SAE J211-1 Instrumentation for Impact Test Part 1 Electronic Instrumentation
31、 SAE J1733 Sign Convention for Vehicle Crash Testing SAE J2517 Hybrid III Family Chest Potentiometer Calibration Procedure 2.1.2 Other Publications Schneider, L.W., Lehman, R.J., Pflug, M.A., and Owings, C.L., “Size and Shape of the Head and Neck from Birth to Four Years”, UMTRI-86-2, Ann Arbor, MI
32、1986. Reynolds, H.M., Young, J.W., McConville, J.T., and Snyder, R.G., “Development and Evaluation of Masterbody Forms for Three-Year Old and Six-Year Old Child Dummies”, DOT HS-801 811, University of Michigan, Ann Arbor, MI, 1976. 3. DEFINITIONS AND ABBREVIATIONS 3.1 BHCS Button Head Cap Screw 3.2
33、Certification Tests Tests conducted to assure that the dummy is manufactured and maintained at the SAE specified performance levels for responses which could affect dummy measurements that are used by government and safety engineers to assess occupant injury potential. Certification tests are perfor
34、med by the dummy manufacturer to assure the performance of new components or assemblies. Certification tests are performed periodically by dummy users to assure that the dummy is properly maintained. SAE J2857 Issued MAR2011 Page 8 of 833.3 Clothing Specifications 3.3.1 Shirt and Pants Childrens XS
35、(size 4-5) cotton-polyester based, tight-fitting shirt with long sleeves and ankle-length pants. The neckline must be small enough to prevent contact between the shoulder belt and the dummys flesh. The shirt and pant should weigh no more than 0.25 kg (0.55 lb). 3.3.2 Shoes Drawing: 210-5920, Childre
36、ns size 8, canvas oxford style sneakers. Each shoe weighs 0.21 kg 0.05 kg (0.47 lb 0.10 lb). 3.4 FHCS Flat Head Cap Screw 3.5 Inspection Tests Inspection tests are supplemental to the certification tests to insure that a component meets its design intent. Inspection tests are performed by the dummy
37、manufacturer on new parts. Inspection tests may be performed by dummy users when a part is damaged or replaced. 3.6 Midsagittal Plane The plane that divides the body into left and right halves. 3.7 SHCS Socket Head Cap Screw 3.8 SHSS Socket Head Shoulder Screw 3.9 SSCP Set Screw, Cup Point 3.10 1 g
38、Joint Setting The torque setting of a joint that supports the weight of its distal limb that will move when a minimal external force is applied (see APPENDIX C JOINT ADJUSTMENT PROCEDURES). 4. PART NUMBERS All part numbers in this manual refer to the drawing package in the docket of the National Hig
39、hway Traffic Safety Administration, or to drawings attached to this manual in Appendix D. Copies of the drawing package for this dummy can be obtained from Reprographic Technologies: 2000 L Street N.W., Washington, D.C. 20036, Voice (202) 331-0576, Fax (202) 331-0985. Shop hours: Monday Friday, 8:00
40、 AM to 10:00 PM http:/www.repro- SAE J2857 Issued MAR2011 Page 9 of 835. CONSTRUCTION & CONFIGURATION The skull and head back are manufactured from fiberglass and the head back (skull cap) has an aluminum structural insert for support. Both the head skin and cap skin are molded vinyl. The head assem
41、bly allows for the installation of a triaxial configuration of uniaxial accelerometers at the center of gravity (CG). A separate accelerometer can be installed in the rear of the head to measure angular acceleration in the sagittal plane. A flexible, molded neck is used to give the head-neck assembl
42、y human-like flexion and extension characteristics. A six-axis load cell can be mounted at the upper and lower ends of the neck assembly. Three damped, spring steel ribs make up the chest section and allow for measurement of chest compression through the use of a rotary potentiometer mounted in the
43、thorax. The sternum provides positions for mounting two uniaxial accelerometers. The shoulders are made of flexible rubber joints to provide the correct biofidelic range of motion. They also have the capability of mounting a two-axes load cell in each shoulder to measure “X” and “Z” axis loading. Th
44、e thoracic spine is a welded steel structure that provides mounting locations for three sets of triaxially configured accelerometers at the “T1”,“T4”, and “T12” vertebrae and a single uniaxial x-axis accelerometer that aligns with the third rib opposite the lower sternal accelerometer. Biomechanical
45、 response targets are specified for forehead and sternal impacts, and for fore and aft neck bending. These targets were obtained by scaling of the corresponding requirements of the Hybrid III 50th percentile ATD, taking into account the effects of differences in size, geometry, mass, and tissue prop
46、erties between children and adults (Irwin and Mertz, 1997). The welded steel pelvis/lumbar structure includes a flexible molded rubber spine that provides the mounting configuration for a six-axis load cell between the base of the lumbar spine and the top of the pelvis. There is also a two-axes load
47、 cell on each iliac wing to measure upper and lower loading in the “X” axis along with a triaxially configured accelerometer at the rear of the pelvis structure. Table 1 gives the torque specifications for fasteners used in the dummy. The torque values specified apply to clean and dry parts. They sh
48、ould be used, unless specified otherwise. Note that a lubricated screw requires less torque (15% to 25% less) to attain the same clamping force as a non-lubricated screw. TABLE 1 TORQUE SPECIFICATIONS Thread Size Torque (in-lb) Torque (N-m) 0-80 2-56 4-40 6-32 8-32 10-24 10-32 1/4-20 1/4-28 5/16-17
49、5/16-24 3/8-16 3/8-24 1.00 2.50 12.0 23.0 41.0 60.0 68.0 144 168 300 300 540 600 0.113 0.283 1.36 2.60 4.63 6.78 7.68 16.3 19.0 33.9 33.9 61.0 67.8 NOTE:1. The references for these specifications are Smith Fastener Company, Brake Products Inc., and C & J Fastener Inc. SAE J2857 Issued MAR2011 Page 10 of 836. INSTRUMENTATION Refer to Table 2 and Figure 1. 6.1 Head
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