Foreword...viii Introduction...ix 1 Scope ...1 2 Normative references ...1 3 Definitions ...2 4 Mechanical requirements for the motorcyclist anthropometric impact dummy...2 4.1 Basis dum
Basis dummy
The basis dummy shall be the Hybrid III 50th percentile male dummy 1) The dummy shall be equipped with:
⎯ the head/neck assembly which is compatible with the six axis upper neck load cell which is specified in 4.4.1.2 of ISO 13232-4 2) ;
The basis dummy specified components shall be modified or replaced as described below
1) Basis dummy as specified in 49 CFR Part 572, subpart E, or equivalent.
The ISO Central Secretariat and the Secretariat of ISO/TC 22/SC 22 maintain a list of example products that meet specific requirements, primarily for the convenience of ISO 13232 users This list does not constitute an endorsement by ISO of these products, and alternative products may be used provided they demonstrate equivalent results.
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Motorcyclist dummy head and head skins
The head skin components include the two basic Hybrid III head skins and two extensions designed for helmet compatibility, with their geometries shown in Figure A.1 The original Hybrid III head skin is labeled as 1, the rear skull cap as 2, while the jaw and nape extensions, labeled as 3 and 4 respectively, enhance helmet compatibility The mass of the jaw extension should be 0.27 kg ± 0.05 kg, and the nape extension 0.15 kg ± 0.05 kg Head-neck skin modifications attached to the Hybrid III head must be secured with suitable adhesives, such as cyanoacrylate, which must provide a bond that fails at the parent material under tensile loading before the bond itself.
The complete assembly, including the head, head skins, head skin extensions, head accelerometer mount, head accelerometers and cables, as well as the neck load cell and cables, has a total mass of 5.35 kg ± 0.1 kg Ensuring precise weight specifications is essential for optimal performance and safety in head and neck load testing applications This detailed assembly weight information is crucial for maintaining consistency and accuracy in biomechanical research and testing setups.
Motorcyclist dummy neck components
The complete assembly of the neck, nodding blocks, head attachment pin, bib simulator, and the upper half of the serrated lower neck mount shall have a mass of 1,55 kg ± 0,1 kg
The neck shroud must conform to the specifications outlined in Figure A.2 2) The upper half of the zipper should be securely attached to the jaw skin extension using a suitable adhesive This adhesive must demonstrate the ability to create a bond that fails prior to the parent materials under tensile stress, ensuring reliable attachment For example, “Loctite® 401” cyanoacrylate is recognized as an appropriate adhesive that meets these requirements.
For proper motorcycle crash testing, the lower neck mount should be set at a 5.25-degree extension position, suitable for most dummy rider configurations In cases involving extreme dummy postures, the Hybrid III lower neck mount can be modified as demonstrated in Figure A.3 to enhance head position adjustability, ensuring accurate simulation of diverse rider impacts.
The standard Hybrid III neck and its interfaces with the head and upper torso assembly shall be replaced by the neck shown in Figure A.4 2)
NOTE The neck shown in Figure A.4 is designed specifically for use in motorcycle crash testing Use and limitation information is contained in B.2.5
The standard Hybrid III nodding blocks shall be replaced with the pair of nodding blocks shown in Figure A.4 2)
4.3.5 Neck initial conformity of production
To certify a new neck and nodding block design that meets the material specifications or manufacturing processes outlined in Figure A.4, one neck must undergo dynamic testing following the procedures specified in section 6.8 The test results should demonstrate that the neck responses fall within the defined corridors detailed in section 6.8 and illustrated in Figures 1 through 7, ensuring compliance with quality and safety standards.
4.3.6 Neck subsequent conformity of production
Once a production design, material specification, or manufacturing process has been certified under section 4.3.5, all subsequent neck and nodding block assemblies must undergo testing according to procedures in section 6.9 This ensures that each manufactured assembly consistently meets the specified characteristics outlined in Table 1, maintaining quality and compliance with ISO standards.
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Motorcyclist dummy upper torso components
For testing purposes, either a standard Hybrid III thoracic spine or a compatible replacement thoracic spine shall be used If a replacement spine is employed, it must be compatible with the internal data acquisition system specified in ISO 13232-4 When integrated with the data acquisition system, the replacement thoracic spine shall ensure accurate data collection and reliable test results, adhering to ISO standards for compatibility and performance.
⎯ maintain the same interface geometry and overall height as the standard Hybrid III spine box, including the shoulder, rib, lower neck mount, and lumbar spine attachment points;
⎯ not interfere with the motion of the shoulders;
⎯ provide at least 75 mm of sternum deflection in the sagittal plane, measured perpendicularly, relative to the front surface of the spine box;
⎯ not exceed 125 mm in lateral width;
⎯ result in the same upper torso mass and centre of gravity as specified for a standard Hybrid III upper torso except that the centre of gravity tolerance shall be ± 30 mm
Proper installation of the chest skin on the upper torso is essential for accurate measurements The back of the chest skin can be modified with four holes to expose the two upper and two lower rib attachment screws This modification allows for precise measurement of the upper torso angle using a torso inclinometer, such as the device illustrated in ISO 13232-6, Figure C.1.
Motorcyclist dummy lower torso components
When fully assembled, the lower torso assembly shall result in the same lower torso mass as specified for the standard Hybrid III lower torso 3)
For compatibility with both six-axis and three-axis lumbar load cells, use the straight lumbar spine and cable with FTSS part numbers 1260004 and 1260005 The lower lumbar spine transducer mount and ballast block should be replaced with the parts illustrated in Figure A.5 for six-axis load cells and Figure A.6 for three-axis load cells, ensuring proper fit and accurate measurement.
3) Refer to General Motors Hybrid III drawing numbers 78051-70 and 78051-338 in 49 CFR Part 572.
Parts 1260004 and 1260005 are products supplied by First Technology Safety Systems in Plymouth, Michigan, USA This information is provided for user convenience regarding ISO 13232 compliance and does not constitute an endorsement by ISO Alternative products may be used if they can demonstrate equivalent performance © ISO 2005 – All rights reserved.
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The 5 abdomen reaction plate, shown in Figure A.7 Revision 1 for the six-axis load cell or in Figure A.8 for the three-axis load cell, must be securely mounted to the lower lumbar spine transducer mount and ballast block Proper installation ensures accurate load measurement and optimal system performance.
When assembling the pelvis and ballast block, if hard contact interference prevents the proper positioning of the parts either part may be trimmed as required to facilitate the assembly
When using the dummy without either of the permissible lumbar load cells described in 4.4.1.4 of ISO 13232-4, the load cell shall be replaced with a lumbar load cell simulator 2)
The basis Hybrid III abdominal insert shall be replaced with a frangible solid abdominal insert, as shown in Figure A.9 The replacement insert shall have a mass of 53 g ± 3 g
When tested according to the method described in 6.7, the specified values of force shall be as given in Table 2 2)
Table 2 — Specified values for certification of replacement abdominal insert
The internal data acquisition system may be contained within a sit/stand pelvis which has been suitably modified to accommodate it 2) Whether modified or not, the sit/stand pelvis shall:
⎯ maintain the same interface geometry and external dimensions as the standard Hybrid III sit/stand pelvis;
⎯ not interfere with the motion of the legs.
Arms and modified elbow bushing
The Delrin elbow bushing, Hybrid III part number 78051-199 5) , shall be modified with scribe marks, as shown in Figure A.10
The masses of the upper and lower arms shall be as specified for a standard Hybrid III.
Motorcyclist dummy hands
The basis Hybrid III hands shall be replaced with the Itoh-Seiki Co part number 065-322048 6)
Motorcyclist dummy upper leg components
The mass of the upper leg assembly shall be 4,89 kg ± 0,2 kg
5) Refer to General Motors Hybrid III drawing number 78051-199 in 49 CFR Part 572.
Part number 065-322048 is supplied by Itoh-Seiki Co., Tokyo, Japan, for users of ISO 13232 This information is provided solely for convenience and does not constitute an endorsement by ISO of the product Alternative products may be used if they demonstrate equivalent performance and results.
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Table 3 — Specified values for certification of frangible femur components
Static deflection Dynamic peak strength Static strength
When using the dummy without the permitted femur load cells outlined in section 4.4.1.5 of ISO 13232-4, the load cell must be replaced with an upper femur load cell simulator, as illustrated in Figure A.13.
Motorcyclist dummy frangible knee assembly
The frangible knee assembly and the interface with the knee clevis assembly shall be as shown in Figure A.14 The knee assembly shall have a mass of 1,00 kg ± 0,05 kg
When conducting static tests following the methods outlined in section 6.6, the rotational angles corresponding to the specified moments must align with the values provided in Table 4 Additionally, the rotational angles and moments that demonstrate peak strength at shear pin failure are detailed in Table 4.2 These parameters are essential for assessing the structural performance and ensuring compliance with safety standards.
Table 4 — Specified values for certification of frangible knee assembly components
Degree of Freedom Condition Specified value
Rotation at maximum torque 40,0° © ISO 2005 – All rights reserved
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Leg retaining cables
Each frangible leg bone must be installed with leg retaining cables to prevent the loss of parts during fracture, ensuring safer testing procedures The total mass of these cables should not exceed 200 grams per frangible bone to maintain proper functionality Additionally, cables should be installed with at least 5 mm of slack to accommodate bone movement and prevent undue stress or damage.
Motorcyclist dummy lower leg components
The mass of the lower leg and foot assembly shall be 5,29 kg ± 0,2 kg
4.11.1 Frangible tibia bone and mounting hardware
The frangible tibia bone must be securely mounted to the ankle joint using the specified adaptor shown in Figure A.15 It should meet the interface and size specifications outlined in Figure A.16 and have a mass of 120 g ± 10 g Additionally, the materials and design of the frangible bone must remain consistent in the axial direction along the minimum frangible length, as depicted in Figure A.16.
Statically tested bones must meet the specified static deflection values outlined in Table 5, following the methods described in sections 6.1 and 6.2 For dynamic fracture tests, the peak strength of the bone should align with the values specified in Table 5.2, according to the testing procedures detailed in sections 6.3 and 6.4.
Table 5 — Specified values for certification of frangible tibia components
Static deflection Dynamic peak strength
The basis Hybrid III lower leg skins shall be modified according to Figure A.17, to:
⎯ include a vertically aligned rear surface zipper to permit installation and removal of the skin from the leg;
⎯ conform to the frangible knee structure
The mass shall be 1,05 kg ± 0,10 kg.
Complete motorcyclist dummy
When fully assembled the complete motorcyclist dummy shall have a mass of 75,84 kg ± 1,64 kg.
Certification documentation
Manufacturers of dummies and dummy components compliant with ISO 13232 must provide certification confirming their products meet the specified requirements This certification ensures that all supplied dummies or dummy components adhere to the relevant safety and performance standards outlined in ISO 13232 (© ISO 2005 – All rights reserved)
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The standard deviation must be less than 7% of the sample mean for all strength tests and abdominal insert static forces, ensuring measurement consistency Additionally, the sample standard deviation should not exceed 10% of the mean value for all static deflections, supporting the reliability of the test results These criteria help maintain precise and accurate assessments across different test parameters.
Once a design, material specification, and manufacturing process are certified, three components from each identically manufactured lot must be tested to verify compliance with the specified characteristics outlined in Table 6, ensuring product quality and consistency.
Table 6 — Frangible component subsequent conformity of production characteristics
Frangible abdominal insert Frangible leg bone
Knee shear pin Knee compliance element
Forces at 40 mm deflection Dynamic bending strength Failure moments given in Table 4 Pre-failure rotations given in Table 4
According to ISO 13232-6, a lot is considered acceptable for full-scale impact testing if none of the components deviate by more than two standard deviations from the established mean value for the specified characteristic If one or more components deviate by more than two standard deviations, a new sample of three components from the same lot must be tested The lot is rejected if more than two of the six tested components deviate beyond this threshold.
5.3 Condition of sampled frangible components
For the testing specified in 5.1 and 5.2, such sampling shall be performed using new, unused frangible components
6.1 Frangible bone static bending deflection test
Attach rigid extensions of equal length to each end of the frangible bone using pins, ensuring the combined length meets the specifications in Table 7 Support the specimen radially at both ends according to the distances outlined in Table 7 Position a 25 mm diameter solid rigid cylindrical bar at the mid-span, perpendicular to the bone’s axis, with their curved surfaces in contact Apply the radial load as specified in Table 7 to accurately assess the specimen’s response under testing conditions.
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Table 7 — Frangible bone static bending deflection test specifications
Measure the perpendicular linear deflection at the mid-span location of the specimen relative to the supported ends
6.2 Frangible bone static torsional deflection test
Apply a torsional load of 69 N ⋅ m to the femur and 48 N ⋅ m to the tibia Measure the torsional deflection of one end of the bone relative to the other end
6.3 Frangible bone dynamic bending fracture test
Attach the rigid extensions and support the specimen using pins as outlined in section 6.1, with the bone extensions demonstrated in Figure A.18 and the specimen supports shown in Figure A.19 Ensure the specimen is precisely aligned perpendicular to both the cylindrical bar and the impactor head's movement direction, as depicted in Figure A.20 Secure the impactor head to the impactor device, illustrated in Figures A.21 through A.24 Conduct the impact test by striking the specimen at a velocity of 7.5 m/s ± 0.2 m/s at mid-span, using the impacting mass shown in Figure A.21.
To assess the impactor's linear acceleration, measure data from just before bone contact to immediately after bone fracture using an Endevco model 2262A-1000 accelerometer mounted rigidly at the specified location The collected data should be filtered with an analog filter designed to attenuate signals by at least 40 dB at frequencies of 7.21 Hz and above, ensuring accurate analysis of the acceleration during impact.
To ensure accurate data processing, sample the data at 10 kHz and filter the digital signals to match the ISO 6487, CFC 600 frequency response standards This process allows for precise determination of the peak linear acceleration related to bone impact events Additionally, calculate the maximum bending moment based on the provided example to assess mechanical stress during impact These steps are essential for reliable biomechanical analysis and adherence to industry safety protocols.
The maximum bending moment (Mx,max), measured in Newton-metres, is a critical factor in structural analysis It depends on the distance between supports (d_s), expressed in metres, and the mass of the impactor (m), given in kilograms Additionally, the maximum linear acceleration of the impactor (a_m,max), measured in g units, influences the magnitude of the bending moment Understanding these variables is essential for assessing structural integrity under impact loads.
9,807 is a conversion factor from g units to newtons
6.4 Frangible bone dynamic torsional fracture test
Attach a rigid extension to each end of the frangible bone and secure one end of the specimen using a Denton load cell, model B-2193 Then, connect a rigid moment arm to one of the extensions to facilitate precise load application This setup ensures accurate measurement of mechanical properties, crucial for biomechanical testing and research. -**Sponsor**Struggling to rewrite your article for better SEO and coherence? I understand the challenge! With [Article Generation](https://pollinations.ai/redirect-nexad/JUzPae70), you can instantly create 2,000-word, SEO-optimized articles, saving you time and money Imagine transforming complex content into engaging, reader-friendly paragraphs effortlessly Stop struggling and start generating high-quality content today – it's like having your own content team!
The Model 2262A-1000 is a product supplied by Endevco Corp., based in San Juan Capistrano, California, USA This information is provided to assist users of ISO 13232 but does not imply an endorsement of the product by ISO Alternative products may be utilized if they can demonstrate equivalent performance and results.
The load cell model B-2193, supplied by Robert A Denton, Inc of Rochester Hills, Michigan, USA, is referenced for users of ISO 13232; however, this mention does not imply ISO endorsement Users may opt for alternative products if they demonstrably achieve equivalent results, ensuring flexibility and compliance with the standard © ISO 2005 – All rights reserved.
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Align the centerline of the specimen with the hydraulic plunger's centerline and position the lower end fixture on a Denton load cell, model B-2193 Apply a steadily increasing load at a rate of approximately 6,500 N/sec, allowing for a variation of ±2,000 N/sec, until failure occurs Continuously record the applied load electronically until the specimen fails to capture accurate failure data for analysis. -**Sponsor**Need help polishing your article and making it SEO-friendly? [editorr](https://pollinations.ai/redirect-nexad/lm594LSb) can assist! We specialize in rewriting content, ensuring each paragraph is coherent and impactful, like focusing on the key steps of your hydraulic plunger test: aligning the center lines, applying a consistent load increase until failure, and recording the load electronically Let us refine your writing to meet the highest standards Try Editorr today and transform your text into a compelling narrative.
6.6 Frangible knee static strength and deflection test
Use either the apparatus shown in Figure A.26, or the equivalent, including a
⎯ lever arm with minimum length of 0,5 m;
⎯ load cell located at the load application point;
Apply a continually increasing moment to the frangible knee valgus or torsional axis, at a rate of 30 N ⋅ m/s ±
5 N ⋅ m/s Record the rotational angle and applied moment until shear pin failure occurs
Use the apparatus depicted in Figure A.27 or an equivalent device to perform the test Apply a steadily increasing load at a rate of 450 N/s ± 150 N/s to the center of an unused frangible abdominal insert Record both the crush deflection and the applied load continuously until the load exceeds 3,300 N.
6.8 Motorcyclist neck dynamic test for initial conformity of production
To conduct the test, assemble a Hybrid III lower neck mount set at 5.25 degrees extension, ensuring the motorcyclist neck is properly positioned without the shroud and with nodding blocks Equip the setup with a Denton upper neck load cell (model 1716-9) and a standard Hybrid III head Adjust the mid-neck angle to the full forward (flexion) position to ensure accurate and consistent testing conditions.