1、_ 6$(7HFKQLFDO6WDQGDUGV%RDUG5XOHVSURYLGHWKDW7KLVUHSRUWLVSXEOLVKHGE6$(WRDGYDQFHWKHVWDWHRIWHFKQLFDODQGHQJLneering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising tKHUHIURPLVWKHVROHUHVSRQVLEL
2、OLWRIWKHXVHU SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2012 SAE International All rights reserved. No part of this publication may be reproduced, stor
3、ed in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside USA) Fax: 724-776-0790
4、Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J2860_201209 SURFACE VEHICLE RECOMMENDED PRACTICE J2860 SEP2012 Issued 2012-09 Superseding EA-26 OCT2003 Users Manu
5、al for the Hybrid III Large Male Test Dummy RATIONALE This Surface Vehicle Report describes the assembly/disassembly and certification procedures for the Hybrid III Large Male Test Dummy. Storage and handling, measurement procedures for external dimensions, clothing specifications and part numbers a
6、re additions to this Surface Vehicle Report. TABLE OF CONTENTS 1. SCOPE 8 2. REFERENCES 8 2.1 Applicable Documents 8 2.2 Related Publications 8 3. ASSEMBLY/DISASSEMBLY . 9 3.1 Head/Neck 9 3.2 Upper Torso 16 3.3 Lower Torso 28 3.4 Legs . 33 3.5 Arms 38 4. CERTIFICATION TEST PROCEDURES 40 4.1 Head Dro
7、p Test . 40 4.2 Neck Tests 42 4.3 Thorax Impact Test . 47 4.4 Knee Impact Test 50 4.5 Knee Slider Test 52 5. INSPECTION PROCEDURES AND TESTS . 55 5.1 Chest Depth Measurements . 55 5.2 External Measurements 55 5.3 External Dimensions . 58 5.4 Mass Measurements . 58 5.5 Torso Flexion Test 59 5.6 Foot
8、Test . 62 5.7 Ankle Motion Test . 64 6. NOTES 68 6.1 Marginal Indicia . 68 APPENDIX A ACCELEROMETER HANDLING GUIDELINES . 69 APPENDIX B GUIDELINES FOR REPAIRING FLESH 71 SAE J2860 Issued SEP2012 Page 2 of 74 APPENDIX C JOINT ADJUSTMENT PROCEDURES 72 APPENDIX D AXIAL INTEGRITY OF THE NECK . 73 APPEND
9、IX E BOLT TORQUE VALUES . 74 FIGURE 1 ACCELEROMETER LOCATIONS 7 FIGURE 2 HEAD, EXPLODED VIEW 9 FIGURE 3 NECK ADJUSTMENT SHCS AND WASHER 10 FIGURE 4 UPPER NECK BRACKET AND BIB 10 FIGURE 5 SKULL CAP . 11 FIGURE 6 NECK TRANSDUCER 11 FIGURE 7 NECK COMPRESSION TOOL . 11 FIGURE 8 NECK REMOVAL 12 FIGURE 9
10、NODDING JOINT 12 FIGURE 10 NODDING BLOCK ORIENTATION 13 FIGURE 11 NECK TRANSDUCER REMOVAL 13 FIGURE 12 NECK, EXPLODED VIEW 15 FIGURE 13 NODDING JOINT BRACKET REMOVAL . 16 FIGURE 14 CLAVICLE LINK, EXPLODED VIEW 17 FIGURE 15 CLAVICLE AND SHOULDER YOKE, EXPLODED VIEW 18 FIGURE 16 CLAVICLE LINK 19 FIGUR
11、E 17 ARM REMOVAL 19 FIGURE 18 CLAVICLE LINK BOLT 20 FIGURE 19 BUMPER STOP 20 FIGURE 20 SHOULDER YOKE ROTATION STOP . 21 FIGURE 21 UPPER ARM STOP 21 FIGURE 22 CLAVICLE SHSS 21 FIGURE 23 URETHANE SPRING STOP . 22 FIGURE 24 CLAVICLE SPACERS . 22 FIGURE 25 CLAVICLE LOCK NUT 23 FIGURE 26 FRONT RIB STIFFE
12、NER 24 FIGURE 27 CHEST CAVITY, STERNUM SLIDER 24 FIGURE 28 STERNUM SLIDER AND BIB . 24 FIGURE 29 RIB AND RIB STIFFENER REMOVAL . 25 FIGURE 30 RIB AND DAMPING MATERIAL . 25 FIGURE 31 THORACIC SPINE ASSEMBLY, EXPLODED 26 FIGURE 32 THORACIC SPINE REMOVAL . 27 FIGURE 33 CHEST POTENTIOMETER 27 FIGURE 34
13、LOWER TORSO, EXPLODED VIEW . 29 FIGURE 35 LEG REMOVAL . 29 FIGURE 36 LOWER TORSO ASSEMBLY (ABDOMEN NOT SHOWN) . 30 FIGURE 37 ABDOMEN 31 FIGURE 38 FEMUR REMOVAL . 31 FIGURE 39 FEMUR ASSEMBLY . 32 FIGURE 40 ASIS LOAD CELL REMOVAL . 32 FIGURE 41 UPPER LEG, EXPLODED VIEW 33 FIGURE 42 BALL SLIDER ASSEMBL
14、Y, EXPLODED VIEW . 34 FIGURE 43 LOWER LEG, EXPLODED VIEW . 35 FIGURE 44 ANKLE ASSEMBLY, EXPLODED VIEW 36 FIGURE 45 FEET AND ATTACHMENT BOLT 37 FIGURE 46 ARM ASSEMBLY, EXPLODED VIEW 39 FIGURE 47 HEAD DROP TEST SET-UP SPECIFICATIONS . 41 FIGURE 48 NECK PENDULUM SPECIFICATIONS 45 FIGURE 49 NECK EXTENSI
15、ON TEST SET-UP SPECIFICATIONS . 46 FIGURE 50 NECK FLEXION TEST SET-UP SPECIFICATIONS 46 FIGURE 51 THORAX IMPACT TEST SET-UP SPECIFICATIONS . 49 FIGURE 52 HYSTERESIS DEFINITION 50 FIGURE 53 KNEE IMPACT TEST SET-UP SPECIFICATIONS 52 FIGURE 54 KNEE SLIDER TEST SET-UP SPECIFICATION . 54 FIGURE 55 CHEST
16、DEPTH MEASUREMENT TOOL . 55 FIGURE 56 EXTERNAL DIMENSION MEASUREMENT . 57 SAE J2860 Issued SEP2012 Page 3 of 74 FIGURE 57 TORSO FLEXION TEST SETUP 61 FIGURE 58 TORSO FLEXION PULL BRACKET SPECIFICATIONS 62 FIGURE 59 COMPRESSION TEST SETUP 63 FIGURE 60 FOOT TEST SPECIFICATIONS . 64 FIGURE 61 LEG REFER
17、ENCE PLANES . 66 FIGURE 62 ANKLE/FOOT REFERENCE PLANES . 67 TABLE 1 INSTRUMENTATION 6 TABLE 2 HEAD, EXPLODED VIEW PART LIST . 9 TABLE 3 NECK EXPLODED VIEW PART LIST 14 TABLE 4 CLAVICLE LINK EXPLODED VIEW PARTS LIST . 17 TABLE 5 CLAVICLE AND SHOULDER YOKE EXPLODED VIEW PART LIST 18 TABLE 6 SPINE BOX
18、EXPLODED PART LIST . 26 TABLE 7 LOWER TORSO EXPLODED PART LIST . 28 TABLE 8 UPPER LEG EXPLODED VIEW PART LIST . 33 TABLE 9 BALL SLIDER ASSEMBLY, EXPLODED VIEW PART LIST 34 TABLE 10 LOWER LEG, EXPLODED VIEW PART LIST . 35 TABLE 11 ANKLE ASSEMBLY, EXPLODED VIEW PART LIST . 36 TABLE 12 FOOT ASSEMBLY, E
19、XPLODED VIEW PART LIST . 37 TABLE 13 ARM ASSEMBLY, EXPLODED VIEW PART LIST . 38 TABLE 14 HEAD DROP TEST SPECIFICATIONS 41 TABLE 15 NECK FLEXION TEST SPECIFICATIONS. 43 TABLE 16 NECK EXTENSION TEST SPECIFICATIONS . 44 TABLE 17 THORAX IMPACT TEST SPECIFICATIONS . 48 TABLE 18 KNEE IMPACT TEST SPECIFICA
20、TIONS . 51 TABLE 19 KNEE SLIDER TEST SPECIFICATIONS . 53 TABLE 20 EXTERNAL MEASUREMENTS 58 TABLE 21 SEGMENT MASS . 59 TABLE 22 FOOT TEST SPECIFICATIONS . 64 TABLE 23 ANKLE MOTION SPECIFICATIONS 68 TABLE E1 TORQUE SPECIFICATIONS 74 INTRODUCTION FOREWORD The Hybrid III Large Male dummy was developed u
21、nder a grant awarded by the Center for Disease Control (CDC) to the Ohio State University in 1997. A task force of experts from the SAE International Mechanical Human Simulation Subcommittee of the Human Biomechanics and Simulation Standards Committee supported the development activity. The design i
22、ncorporated the same level of biofidelity and measurement capacity as the Hybrid III mid-size adult male. Therefore, the certification procedures are based on the test procedures that were developed for the Hybrid III mid-size adult male dummy. The basic test fixtures are the same. The Hybrid III La
23、rge Male Dummy is based on the characteristic size and weight measurements taken from anthropometry studies of the large adult male. Its impact response requirements for the head, neck, chest, hip, knee and ankle were scaled from the biofidelity requirements of the Hybrid III mid-size male dummy. (S
24、ee Mertz, H. J., Irwin, A. L., Melvin, J. :6WDOQDNHU5/%HHEH066LH:HLJKWDQG%LRPHFKDQLFDO,PSDFW5HVSRQVH5HTXLUHPHQWVIRU$GXOW6LH6PDOO)HPDOHDQG/DUJH0DOHXPPLHV6$(63-782, 1989.) The Hybrid III Large Male dummy is designed to represent the upper extreme of the United States adult population. Much of the anth
25、ropometry and design is a scaled version of the Hybrid III midsize adult male dummy. SAE J2860 Issued SEP2012 Page 4 of 74 MANUAL OVERVIEW Appendices Several guidelines and procedures apply to various parts throughout the dummy and are included in the appendices for easier reference. x When handling
26、 an instrumented dummy, improper techniques can damage instrumentation, particularly accelerometers. Appendix A contains guidelines for safe handling of instrumented dummies. x The vinyl flesh of dummies can be damaged, but is often repairable. Appendix B contains instructions for repairing dummy fl
27、esh. x Procedures for adjusting the joints throughout the dummy are included in Appendix C. x The axial integrity of the neck is listed in Appendix D. x A bolt torque value chart is Appendix E. SAE Documents In addition to the attached appendices, other SAE publications are particularly useful when
28、working with the Hybrid III dummy. SAE J211-1 provides the most recent guidelines and procedures for dummy instrumentation and filtering. SAE Information Report J1733 illustrates the instrumentation available for the Hybrid III dummy family, along with descriptions of how to apply the positive right
29、-hand rule sign convention. SAE Test Definitions Certification Test Certification tests are specified for dummy responses which could affect dummy measurements that are used by government and safety engineers to assess occupant injury potential. Certification tests are performed by the dummy manufac
30、turer to assure that a new component or assembly meets the SAE specified response requirements. The crash dummy user will periodically perform the certification tests to assure the dummy is maintained at the SAE specified performance levels. Inspection Test Inspection tests are supplemental to the c
31、ertification tests to insure that a component meets its design intent. They are performed by the dummy manufacturer on new parts. The dummy user may conduct inspection tests when a part is damaged or replaced. Abbreviations ASIS Anterior Superior Iliac Spine LCR Load Cell Replacement SAE J2860 Issue
32、d SEP2012 Page 5 of 74 The following threaded fastener abbreviations are used in this manual. SHCS Socket Head Cap Screw FHCS Flat Head Cap Screw BHCS Button Head Cap Screw SHSS Socket Head Shoulder Screw SSCP Socket Screw, Cup Point RHMS Round Head Machine Screw CONSTRUCTION x The skull and skull c
33、ap are both one-piece cast aluminum, with a removable one-piece vinyl head and skull cap skin. The skull cap is removable for access to the head instrumentation. The vinyl skin is tuned to give a human-like response to forehead impacts. x 7KHQHFNKDVDELRILGHOLFDQJOHYHUVXVPRPHQWUHVSRQVHLQERWKGQDPLFIOH
34、LRQ IRUZDUGEHQGLQJ DQGHWHQVLRQ(rearward bending) articulations. x A neck cable controls stretching responses, and LQFUHDVHVWKHQHFNVGXUDELOLWWRKLJKDLDOWHQVLRQIRUFHV x The two-piece aluminum clavicle and clavicle-link assembly have cast integral scapulae (with a lip along the superior-medial edge) to
35、prevent the neck from interfacing with shoulder belts. x Six spring steel ribs with polymer-based damping material approximate the human chest force-deflection response characteristics. The sternum assembly connects to the front of the ribs and incorporates a slider for a chest deflection transducer
36、 to measure rib cage deflection relative to the thoracic spine. x A curved lumbar spine gives a sitting posture to simulate a person of larger stature in the driving position. x The pelvis has a human shape and comes equipped with load cell replacements that can be replaced by transducers that indic
37、ate submarining of the pelvis. x A knee slider mechanism is used that consists of steel ball sliders with energy absorbing molded rubber mounted on aluminum knees. This allows for displacement of the tibia relative to the femur, simulating ligament response. x The leg assemblies are steel structures
38、 covered with vinyl. The legs are interchangeable with instrumented versions. x Constant friction movable joints are used that need few adjustments and provide consistent articulations. x The staQGDUGPRGHOKDVDVHDWHGSHOYLVFRQVWUXFWLRQ$VLWVWDQGSHOYLVYHUVLRQLVRSWLRQDODVDUHDQHFNFRYHULQJfor airbag testin
39、g, a deformable face for steering wheel rim testing, and a deformable abdomen for lap belt submarining and steering wheel rim evaluations. SAE J2860 Issued SEP2012 Page 6 of 74 CLOTHING When used in testing, the dummy should wear snug-fitting cotton knit T-shirt and pants. The neckline should be sma
40、ll HQRXJKWRSUHYHQWFRQWDFWEHWZHHQDVKRXOGHUEHOWDQGWKHGXPPVVNLQ7KHSDQWVVKRXOGHQGDERYHWKHGXPPVknee. The T-shirt and pants should each weigh no more than 0.27 kg (0.6 lb). Garments similar to thermal underwear (trimmed to be short-sleeved and above the knee) usually meet these requirements. To improve th
41、e quality of high-speed films taken of the dummy during testing (by avoiding excessive glare), the garments are usually dyed to a light pink. A size large shirt (L) and double extra large pants (XXL) are suggested sizes for proper fit and weight. The shoes used with the large male dummy are size 11X
42、W shoe which meets the configuration size, sole, and heel thickness specifications of MIL-S-FKDQJH3DQGZKRVHZHLJKWLV 0.2 pounds. INSTRUMENTATION When ordering a new dummy, inform the dummy manufacturer of the type and model of accelerometer you intend to use. This will ensure that you obtain the corr
43、ect accelerometer mounts for the head, chest and pelvis. The following is an instrumentation list currently available for the Hybrid III Large Male dummy. TABLE 1 - INSTRUMENTATION HYBRID III LARGE MALE DUMMY INSTRUMENTATON Location Measurement Number of Channels Head C.G. Acceleration 3 Head Angula
44、r Acceleration 9 or 12 Head Angul Rate 3 Head-Neck Interface Forces the clavicle, clavicle link and shoulder yoke, which bolt to each other and then to the thoracic spine. These three sections permit arm rotation, up-down motion at the shoulder, forward-rear excursion (hunching), and up-down motion
45、of the entire shoulder-clavicle unit. See Figure 16 for the assembled view of the shoulder clavicle link. SAE J2860 Issued SEP2012 Page 19 of 74 FIGURE 16 - CLAVICLE LINK To begin disassembling the clavicles, it is optional to first remove each arm at the shoulder yoke by unscrewing the SHSS (Figure
46、 17). If necessary, clean the clavicle bushing and washers with isopropyl alcohol. Never lubricate any of the plastic bushings. FIGURE 17 - ARM REMOVAL Detach the shoulder-clavicle unit from the thoracic spine assembly by reaching through a hole in the plastic chest “bib“ and removing the SHSS at the extreme top of the thoracic spine (Figure 18). Pull
