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Full text of "NHTSA NCAP: Volkswagen 1979 VW Rabbit 2-Door Hatchback"

U I 



y/yy^ 



REPORT NO, 6525 -V-4 



NEW CAR ASSESSMENT AND STANDARDS 
ENFORCEMENT INDICANT TESTING 
FMVSS NQS. 212, 219 AND 301^75 



Volkswagen 
1979 VW Rabbit 2-Door Hatchback 
NHTSA 3Q8-T4-44Q 

CALSPAN CORPORATION 
ADVANCED TECHNOLOGY CENTER 
P, 0, BOX 400 
BUFFALO, NEN YORK 14225 




July 9, 1979 



Prepared For 
th S, DEPARTMENT OF TRANSPORTATION 
NAT TONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION 
Enforcement 
Office of Vehicle Safety Compliance 
2100 Second Street, S, VL , Transport Building 
Washington, D. C, 2059O 



This Final Test Report was prepared for the LL S. Department 
of Transportation, National Highway Traffic Safety Administration, 
under contract number D0T-HS-8-0I938. This document is dissemin- 
ated under the sponsorship of the U + S, Department of Transportation 
in the interest of information exchange. The United States 
Government assumes no liability for its contents or use thereof. 



FINAL REPORT ACCEPTED BY: 



Contract Technical Manager 



Date of Report Acceptance 



ii 6S2S-V-4 



CORPORATION * Q *°* *« *lj**jjO ww>o« \+ns *iiii*o*it r?T*i*ji :«6 



TECHNICAL REPORT STANDARD TjTlt PAGE 



1, HflpQrt No 



2, Ooirth-nmtftT AcftUion No. 



3 Bccip'oni v CjTtiog No. 



4. TlH# iftd SubTitU 

NEW CAR ASSESSMENT AND STANDARDS ENFORCEMENT 
INDICANT TESTING - FMVSS KOS, 212, 219 AND 501-75 



4. f**0Ort 041* 

Jul/ 9, 1979 



6. Performing OrgtnJttiiQn CQ0e 

92325 



?. Autnorii Walter E, Levan, Test Engineer 

Donald A, AUanello, Hd p Experimental Operations 
Barbara J* Kelleher, Staff Associate 



8 Pcrl^'Tiing Or^tmraiiO" R*pOf( No 

6525-V-4 



Calspan Advanced Technology Center 

P, + Box 400 

Buffalo, New York 14225 



10 Y*Ofl< UfUT fiJO 



1 I. COflUICt Of Gftnt No. 

DOT-HS-S-0193S 



13 Type ol RopOT iftd P**i&d Co»ft*frd 



13 Soonupmg Agincy ^ito end Ad*™ 

LL S* Department of Transportation 

National Highway Traffic Safety Administration 

Office of Vehicle Safety Compliance 

71 Qfl <^rrtnd ^fr^r. £tf. ttashiogton, D f C T 20SSQ 



14. Sponsoring A^iky CoO* 

NAD^30 



15 Sut>0tmtnT4/y 

Reviewed: 

Approved: 






Project Manager 

Head, Transportation Research Department 



16 AOttr*ct 



Lai span Advance~d _ Technoiogy L enter 



Rear impact test of a 1979 VW Rabbit 2-door Hatchback* was performed at Calspan 
Corporation, Advanced Technology Center, Transportation Research Department 
facility for the New Car Assessment and Standards Enforcement Indicant Testing 
for FMVSS 212, 219 and 301-75 - Fuel System Integrity for the Office of Vehicle 
Safety Compliance, the Office of Automotive Ratings and for Research and 
Development , 

The impact speed was 35. OS roph< 

Driver and passenger passed FMVSS 208 injury criteria for head, chest and femurs 

The rear-end crush was 21.35", 

Compartment intrusion was IS, 3 1h . 



17 Krv W<ytfi 



1fl r Socunry Omit, lo* Thli ftpcn* 

Unclassified 



20 Sretincv Omi 

Unclassified 



IS DrtinbuhOT Sr*T4*nfnt 

Copies of this report are available from 

Technical Reference Division 
National Highway Traffic Safety Admin. 
Room 5108, Nassif Building 
-400 7th Street, SW. Washington, D + C. 20S90- 



0*^*1 



Form DOT F 1700,7 c»«e> 



iii 



6525-V-4 



TABLE OF CONTENTS 

Page No 

Section L Purpose and Test Procedure 1-1 

Section 2 Summary of Test Number 4 2-1 

Appendix A Photographs A-l 

Appendix B Vehicle and Dummy Response Data B- 1 

Appendix C Dummy Certification Test C-l 



iv 6525-V-4 



CORPORATION PO aow *°° ■ l*' 1 *^ w*yo« ujji telei^ons fr^mr-fwc 



C*U* CALVIN / IWvH 7«MJ -**Or Ltffej ft*J?0 



LIST OF FIGURES (continued) 



Figure No. Page No 



APPENDIX C 



C-l LUMBAR SPINE TEST APPARATUS C- 15 

C-2 ABDOMEN PRCSS TEST APPARATUS C- 1 3 

C-3 HEAD DROP TEST APPARATUS C-l 3 

C-4 KNEE IMPACT TEST APPARATUS C- 14 

C-S THORAX IMPACT TEST APPARATUS C-U 

C-6 NECK IMPACT TEST APPARATUS C-14 

C-7 PART S72 TEST DUMMY - FROtTT AST) SIDE VIEW C-15 

C-S ELECTRONIC TEST EQUIPMENT C-16 



Caflspan 



vi fc>S25-V-J 



AN ^ftfv^-4 OO^fcVt 1 ! 






Figure No, 


1 


2 


I 


a 


5 


APPENDIX A 



LIST OF FIGURES 

Page No 

PRE-TEST AND POST-TEST MEASUREMENT POINTS 2-6 

OCCUPANT CLEARANCE DIMENSIONS 2-3 

CAMERA POSITION FOR REAR IMPACT 2-9 

VEHICLE ACCELEROMETEP LOCATIONS 2-11 

POST- IMPACT DATA - STDS, 219 & 301 2-14 



1A PRE-VIEW FULL PROMT, SIDE, REAR AND THREE- A-2 
QUARTER 

2A POST-VIEW FRONT, SIDE, REAR AND THREE-QUARTER A- 3 

3A PRE- AND POST-TEST DRIVER AND PASSENGER ^-* 
POSITION 

4A PRE- AND POST-TEST VIEW OF REAR UNDERBODY A-S 

5^ PRE- AND POST-TEST VIEW OF FRONT UNDERBODY A- 5 

6A FUEL/VAPOR LINES AND FILLER PIPE A-6 

7A PRE-TEST VIEW OF FILL LINE, TANK AND FUEL PUMP A-7 

SA POST-VIEW OF FILL TUBE COLLAPSE AND BREAK A-7 
ALLOWING FUEL LEAKAGE 

9A PEN INDICATING BREAK IN FILLER TUBE A-3 

IDA POST -TEST VIEW OF ROOF COLLAPSE A-8 

11A VIEW OF MOVING BARRIER A-3 

12A VELOCITY TRAP COUNTER DISPLAY A-3 



652S-V-U 



CORPORATION f»o»x*w i*j"*lu **•■* tc^k **a-Jj f(k(ewO*t in&^a* ?mo 



IN iHvi^ COW#A^l¥ 



LIST OF TABLES 



Table No. 



1 CRASH TEST SENARY 

2 VEHICLE TEST WEIGHTS AS TESTED 

3 DUMMY INJURY CRITERU VALUES 

4 VEHICLE MEASUREMENTS 

3 HIGH SPEED CAMERA INFORMATION 

6 SUMMARY Of TEST CONDITIONS 




vii 6S25-V-4 



C+tH* CM. SPAN / Tr»l Y oe T'q.vj.iiij; T*4»p 9 I ■ J 7^ 



r 



— p« 



SECTION 1 
PURPOSE AND TEST PROCEDURE 



PURPOSE- The purpose of this test was to obtain structural and occupant 

performance information for a 1979 vw Rabbit 2-door Hatchback 

for the Offices of Research and Development and Automotive 
Ratings of the NKTSA. This test is part of the New Car Assessment 
Program BOA, Task 2, sponsored by the National Highway Traffic 
Safety Administration (NKTSA) under Contract DOT-HS-3-01938. 

TEST PROCEDURE: The Calspan Corporation, Advanced Technology Center, 

Transportation Research Department Test Procedure for the 
New Car Assessment Crash Tests submitted to p and approved 
by, the Contract Technical Manager (CTM) contains the specific 
procedures used to perform this test. 

With the exception of a higher test speed, this procedure is 
not in conflict with any portion of FMVSS Procedures issued 
by the Office of Standard Enforcement and the amendments in 
effect as noted by the applicable contract. 



1,1 6S25-V-4 



CORPORATION »o eo* *w *u***lo **w o**f umi teli^x?** Ll*i&3?-TW> 



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SECTION 2 
SUMMARY OF TEST NUMBER 4 



A 1979 Volkswagen 2-door Hatchback was impacted from the rear by a 
barrier moving at a velocity of 35, OS mph. The maximum rear end crush measurement 
was 21.4 inches and vehicle intrusion was 13 + 3 inches. Pre- and post-test 
photographs of the vehicle can be found in Appendix A. 

The driver and right front passenger positions were occupied by 50th 
percentile Part S?2 anthropometric test devices {ATO). Both of these occupant* 
were restrained with the VW production 2-point passive torso belts. These ATDs 
were instrumented with femur load cells and triaxidl accelerometers in the head 
and chest regions. Injury criteria data were recorded and are summarised in 
T.ihle 3. All measured data from both the occupants and the vehicle are 
presented in Appendix B. 

The ATDs were certified prior to this crash test and all pertinent 
certification and instrumentation data can be found in Appendix C, 

Post-impact observations are discussed briefly in General Comments. 



2-1 6S2S-V-4 




TEST NO. 308-T4-440 
DATE: 



7/9/79 



Table 1 



CRASH TEST SUMMARY 



PROJECT: NEW CAR ASSESSMENT PROGRAM 



TIME 



1458 



TEMP 



86°F 



VEHICLE 

TEST WEIGHT (lbs) 

IMPACT ANGLE (deg)* 



VW Rabbit 2 -Door Hatchback 
2470 



180 



IMPACT VELOCITY (mph)** 35,05 
MAX. CRUSH (in) 21.55 

MAX. INTRUSION (in) 18.3 



DUMMIES 

TYPE 

LOCATION 
RESTRAINT 



Hybrid II Part 572 
LFCn, RF(2) 
Passive Belt Syste m 



NUMBER OF DATA CHANNELS _J8 

NUMBER OF HIGH SPEED CAMERAS 5 + Real Time 

*With respect to tow track Center] ine 
**Speed trap measurement (+ .05% accuracy) 



2-2 



6525-V-4 



GENEEUL COMMENTS 



Rear-end damage to the Volkswagen Hatchback is displayed in the 
post -test photos found in Appendix A< Both rear side windows and the rear window 
shattered on impact. There was extensive vehicle daraage, including a buckled 
roof and intruding B-pillais. Both rear tires deflated. 

The 30th percentile occupants complied with all FMVSS-208 injury 
criteria values . 

A, brief surantary of post -impact observations: 

• Front bucket seats failed at impact. 

• Hatchback window and both rear side windows shattered, 

• Both rear tires deflated. 

• Right front door opened, driver side door could not 
be opened, 



2-3 6S2S-V-4 



mm 



J 



r 



Table 2 
VEHICLE TEST WEIGHTS AS TESTED 



Left Front 770 lbs Left Rear 460 lbs 

Right Front 790 lbs Right Rear 450 lbs 

Total Front 1560 lbs Total Rear 910 lbs 



Total Weight = 1560 lbs + 910 lbs = 2470 lbs 
Wheel Base =94.5 inches 



r ff - 910 lbs x 94.5 inches ,, „, . , 
g F.W. " 2470 lbs = 34 * 81 lnches 



CALCULATION FOR TEST WEIGHT 

RCLW = Rated Cargo and Luggage Weight 
UDW = Unloaded Delivered Weight (1890 lbs) 
VCW = Vehicle Capacity Weight (862 lbs) 
DSC = Designated Seating Capacity (4) 

RCLW = VCW - 150 (DSC) 

RCLW = 862 - 150(4) = 262 lbs 

TEST WEIGHT = UDW + RCLW + No, of DUMMIES X 164 lbs 
TEST WEIGHT = 1890 lbs + 262 lbs + 2 (164 lbs) 
TEST WEIGHT = 2480 lbs 



2-4 6525-V-4 



Table 3 
DUMMY INJURY CRITERIA VALUES 







MAXIMUM ACCELERATION V*G"\ * 






HEAD 


CHEST 




PELVIS 




X 


Y 


2 


R 


X 


Y 


Z 


ft 


X 


Y 


2 


R 


DUMMY U) 


29 


3 


14 


3Q 


13.5 


3 


12. S 


17 










DUMMY (2) 


33 


3 


18 


36 


14 


1.6 


12 


17 










DUMMY (3) 






1 




















DUMMY {4} 





























MAXIMUM FORCE FEMUR LOAD (LBS) 


R10MT FEMUR 


LEFT FEMUR 


DUMMY {11 


116 


170 


DUMMY (2) 


170 


228 


DUMMY 131 






DUMMY (41 









MAXIMUM FORCE SEAT BELTS LOADS (LBSI 




SHOULOER STRAP 
UPPER BELT LOAD 


LAP STRAP ' 
RIGHT BELT LOAD 


LAP STRAP 

LEFT BELT LOAO 


DUMMY HI 


40 






OUMMY 121 


sn 






DUMMY OJ 








DUMMY 141 











■ ! 

MEAD INJURY CRITERIA* * 


SEVERITY INDEX 


HIC 


1, LSEO 


i 7 ISEQ 


AVE ACC (flJ 
l t TO \ 2 


HEAD 


CHEST 


OUMMY til 


lid S 


Jlfi40 


una 


?? J 


1R7.4 




DUMMY [?1 


102,8 


.0711 


,1476 


17.8 


U0.9 




DUMMY 13) 














DUMMY {4) 















* DEFINED AS EXCEEDING 0002 SEC. DURATION 
**AS DEFINED IN FMVSS NO 206 






2-5 



6S2S-V-J 



FIGURE 1 
PRE- TEST AND POST- TEST MEASUREMENT POINTS 



REAR DATUM REFERENCE 



Length of 
Engine Block 



To Edge of Door 
Even number for 
right side and 
odd number for 
left side 




To Trailing Edge 
Behind Door 
(Right/Left Side) 

To Leading Edge 
in Front of Door 
(Right/Left Side) 



X17 

To l A' Pest 



X16__ 
To Strg. Column 



2-6 



_ REAR DATUM REFERENCE 
To Bottom of AT CENTER 0F R£AR 

,n. l 0% ,} * , BUMPER 

(Right/Left side) 

To Firewall (Right/Left Side) 

6525-V-4 



.X 



- 








*T" 








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2-7 



6S2S-V-4 



HH 



iH 



pMiHV 



pWMM 



DRIVER 



PASS 



m . 


19,5 19,5 


HW 


25.0 


24.75 


CD 


23.5 


25,25 


cs 


16.0 


N/A 


KDL 


3,25 


3.12 


CDR 


3.50 


3.25 




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6.5 


7.75 


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8.75 


9,0 


AC 


"4.0. 


4.25 


HD 


6.5 


6.5 




FIGURE 2 



OCCUPANT CLEARANCE DIMENSIONS 



2-8 



6525-V-4 



§ 
I 



FIGURE 3 
CAMERA POSITIONS FOR REAR IMPACTS 



Note: Camera information shovn on Table 5 



Camera 4 




Real Time 
Camera 6 



Test vehicle position 
for rear impact 



Camera 2 



Camera 3 



Camera 



V 



F3993 lbs 



Moving Barrier 
(+0, -10 lbs) 



^ftonorail J 
Tow Cable 



^ 



"Level" 
Tow Road 



TOP VIEW 



2-9 



6S25-V-J 



«^H 




TABLE 5 
HIGH SPEED CAMERA INFORMATION 

308, T4, 440 
REAR 1979 VW RABBIT 



CAMERA NO. 


LOCATION 


TYPE 


LENS {mm) 


SPEED (fps) 


1 
2 
3 
4 
5 
6 


SOUTH WIDE 
SOUTHEAST DUMMY 
SOUTH DUMMY 
NORTH DUMMY 
TOWER 

NORTH WIDE 


FASTEX 
FASTEX 
FASTEX 
FOSTEX 
PHOTOSONIC 

REAL TIME 


50 mm 
50 mm 
50 mm 
50 mm 
13 mm 


1200 
1400 
1500 
1000 
1050 
24 



NOTE: CAMERAS ARE NUMBERED ACCORDING TO SPLICING SEQUENCE OF FILM. 

(24 fps) REALTIME MOVIE FILM COVERAGE OF PRECRASH, POST-CRASH 
AND CRASH EVENT SPLICED AT START AND END OF F! LM. 



L 



2-10 



6525-V-4 




L.±s 

—34.81— -T 



® 



DRIVERS SIDE 




ACCELOCMETIK 



Frost £*»t ''CrcflscfW 



near S»a- ■C-ragbcag' 

ICG 



DiHcrrca 



? 2 



x I x | 



The accelerometar pack number can oe correlated --ith tte vehicle response date 
traces found in Appendix B, 



Figure 4 VEHICLE ACCELERATES LOCATIONS 



2-11 



6S23-V-4 



i^^m 



j 



Table 6 
STOMAS* OF TEST CONDITIONS 



TEST VEHICLE ICTO?-MATIOH ; 

Vehicle Manufacturer:, Volkswagen 



Hake/Model:. VW Rabbit 

Body Style : 

YIN: 1793858496 



2 Dr. Hatch Back 



79 



NHTSA No 



308-T4-440 



Model Tear: 
Build Date: 6-79 
Color: Lt. Blue 



Engine Data: _ _ 
Transmission Data 



cylinders; 89 cu.in 



displaceaient 



4 speed (X ) Manual/ ( ) Automatic 

Date Vehicle Received by Laboratory 6/25/79 

Dealer's Name & Address : Jim Kelly's, 5325 Genesee St., Buffalo, N.Y. 
1 DATA FROM CERTIFICATION LABEL OH LEFT DOOR REAR FACE OR 'B' POST:] 

Vehicle Manufactured 3y: VW of America 

Date of Manufacture: ' 6-79 - VTN : 1795858496 

GWffi; 2822 lbs.; GAWR: Front = 1609 lbs.; Rear = 1278 i bg 
JPAIA FROM ''asCCKMSKDSD TIRE PRESSURE" LABEL ON 3CCR, PCS?, GLOVE 3CX t ETC.: 

Vehicle Load: 



Up to Capacity 



FRONT REAR 
nsi 



Vehicle Capacity: ^ mt ^ 



1561 



RSCCMMINIID T^Z Sir 
1555R13 



LOAD RAJi'GE 
(f? C D 



Type of Seats *] j Bench 
Bucket 
Split Bench 
2|lbs. 



CASGO LOAD = ^2 

TOTAL =fO|S_j6 



TtLbs. 



Number of Occupants = 
(Designated Seating 
Capacity) 

Rim 4 1/2 J 



Front 
Rear 

Total 



Wj^GKT OF TEST VEHICLE AS RECEIVED FROM ^ZALZR (with Ea*. fluidsT] 



Right Front = 
Left Front = 

TOTAL FRONT WEIGHT = 
TOTAL REA£ WEIGHT = 
TOTAL DELV. WEIGHT = 



lbs. 
lbs. 



Right Rear g ' \l 
Left Rear = 







lbs. 
jllbs. 



6 5 



OJlbs. ( 65.6 % of Total Vehicle Weight} 
Ojlbs. ( 54.4 % of Total Vehicle Weight) 
lbs. ; 



tw^GHT OF TEST VZ5ICIS 'WITH -QUIRED DUMMIES AND -^£— lbs. CARGO: 



9 



Right Front = 

Left Front = 

TOTAL FRONT WEIGHT = IT 
TOTAL REAS WEIGHT = 



lbs 



TRIlbs. 



Right Rear =] 4 
Left Rear = 



416 



lbs. 
lbs. 



9 1 



TOTAL TEST WEIGHT = H 



7 



Weight of ballast secured in vehicle trunk area = 
TEST CONDITIONS : 

Date of Test: . V^/79 . nae of ^^ 



lbs. ( 63.2 % of Total Vehicle Weight) 
lbs. ( 56 ' 8 % of Total Vehicle Weight) 
lbs. 

lbs. 













1458 



am/Sin 



Ambient Tenner ature: 



85 



5 F at impact area. 



Tear;, In Occ . Corrrnart 



79 



_°F.; V/Shld. Kldg. Temp 



96 



2-12 



6525-V-4 



Table 6 - continued 

YEEZCZZ ATTITUDE: (all difflroaiana La inchea) 

Delivered Attitude: R T2S a" ; L T 25 4 n ; 5 5 25 J r ' ; L3 25 J M 

Teat Attitude: 2 F23 ^ - 17 23 ^ ; E5 23 jj" ; L323 *>■ 

^^^^^^^ ^^^^^^^ ^^^^^^^ ■ i^**i<M 

VE5ICL5 TTSS DATA : ..^ ... . 

Secoaaendtd Cold Tire Preaaure: Front * ^ 7 ^si 



Bear »■ 31 psi 



2e«aMnded Tire Size; 1SSSRI3 



Load Range: 



Tireo on Vehicle: 15 5SR13 



la Spar* Tire a TI SpACt Saver": No (yee/ao) 

la Spar* Tire standard equipment; y^ (yea/no) 

*SST FLUID DAJA: _.__ L 

Teat Fluid Type: 2ed Stoddard Solvent *5 i Spec. Grav«: Q«76^ 
Xineoatic Ylacoaitr: .96 Centistokes 

Spill Point Volnse*: 9 - 44 Gallons (s?V) 

!Mt Volume: s » ss Gallons (90 to 91* of SFT)- 

?Ml Syatea Caoacity (data fr^m Cvner's Manual): 10 + 5 ral* 

Detail* of fuel grates: Fuel Filler Cap is on Right Rear Side of Car 



Electric ThBl Fusp: JC_ T«; So; Tuel -n^ect^o;;: _X_ 7*3 : :ro 

Deee electric fuel punp operate with imitlon switch "on" and 
the engirt not operatise* Tea; * tfa 

YZ5ZCLZ HZ5QOTD AND C5U5H : 

Overall Length of Test Vehicle; Pre-Teat = 2i53 + 5 /L 153.4 inches 



CTU5H= 3 21.3 /L 2 1 . 4 



?oat-reet= HH2. 2 /L M2.0 inches 



?0R F20NTAL IMPACTS, distance froa front of test 7*j-cle to 
the barrier after impact = - inches 

•With entire fuel system filled froa fuel ta^k through cariureto: 
bowl* 



2-13 6S25-V-4 



■ 



A 



FIGURE 5 
FCST IMPACT PATA - 3TTS. 2^9 & *01 



DATA SHEET 

® TYPE 05 TEST: □ Frontal (90°) Impact 

□ Oblique ( °) Impact on □ left (Driver's) Side 

□ Sight Side 

□ Lateral or Side Impact on □ Left (Driver's) Side _H 

□ Hight Side 
l Xj Rear Impact 

# DATS OF TEST: 7/9/79 j TIME: 1458 . ; T^p >: 85 ?. 

• VEH, }IHTSA NO,: 308-T4-440 ; VT2T; 1793858496, 

$ REQUIRED VEH. VELOCITY RANGE: 34.5 to 55,5 ^ h 

$ IMPACT VELOCITY : (traps within 5 feet of impact event) 

Trap #1 = 35.03 mph; Trap #2 = 35.07 mvh 

Distance from the vehicle's front bumper to the barrier face 
entering the vehicle velocity measurement device = 58 



exiting the vehicle velocity measurement device = 18 

^ ■ — — ^^ — __ ___ ____ 

VEE. STATIC CRUSH : (for Frontal and Rear Impacts Only) 

Driver's Side = 21.3 in- . p assenger - £ Side = 21.4 

Average s 21.35 inches 
Crush Details: 



VEH. STATIC CRUSH : (for Side Impacts Only) 

Amount of Crvsh - inches on 

Crush Details: 



side 



$ 'ZEE, REBCUTO : (from rigid carrier cnly) 

Driver's Side = " inches; Pass. Side = 



.rcr.es 



Average = inches 



REMARKS : 



FIGURE 5 



2-14 6525-V-4 



APPENDIX A 
STILL PHOTOGRAPHS 



A _l 6S2S-V-4 










H> ,'.* f 



— .aawT 




FIGURE U PRE- VIEW FULL FRONT, SHJE, REAR AND THREE-QUARTER 

K _ 2 6525-V-4 








FIGURE 2A POST-VTEN FRONT, SIDE, REAR AND THREE-QUARTER 

A ~ 3 6525-V-4 







FIGURE 3A PRE- AND POST-TEST DRIVER AND PASSENGER POSITION 



A-4 



652S-V-4 




r ••-.■: ".'." •* ■ •"""• t 




FIGURE 4A PRE- AND POST-TEST VIEW OF REAR UNDERBODY 





FIGURE SA PRE- AND P05T-TEST VIEW OF PRONT UNDERBODY 



A-5 



652S-V-4 







FIGURE 6A FUEL/VAPOR LINES AND FILLER PIPE 



A-6 



6525-V-4 





FIGURE 7 A PRE -TEST VIEW OF FILL LINE, TANK AND FUEL PUMP 





FIGURE 8A POST- VIEW OF FILL TUBE COLLAPSE AND BREAK ALLOWING FUEL LEAKAGE 



A-7 



6S25-V-4 



■.' 








FIGURE 9A ?m INDICATING BREAK IN 
FILLER TUBE 



FIGURE 10A POST-TEST VIEW OF ROOF 
COLLAPSE 





FIGURE 1IA VIEW OF MOVING BARRIER 



FIGURE 12A VELOCITY TRAP COUNTER 
DISPLAY 



A-S 



6525-V-4 






APPENDIX B 
VEHICLE ANO DUMMY RESPONSE DATA 



E-l 



652S-V^4 



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«« 



APPENDIX C 
DUMMY CERTIFICATION TEST 



C-l 



6S25-V-4 



This test report contains results from certification tests per- 
formed on Alderson Research Laboratories Model ATD 30034, 50th percentile 
anthropomorphic test dummies, Serial Nos. 319, 320, which were completed on 
June 29 and July 2, 1979, respectively. The results indicate that the dummies 
meet all of the performance requirements of the six standard tests as specified 
in 49 CFR Part 572, Federal Register, Vol. 42, No. 25, dated February 7, 1977. 

The tests were conducted at the Dummy Certification Test Facility 
of Calspan Corporation, Advanced Technology Center. A summary of the test 
results is presented in the following tables, Table 1C through 8C along with 
the Part 572 requirements. 



C-2 6525-V-4 



P.572 DUMMY CALIBRATION TEST 0A7A 



J- 


-L- 


-2- 



WTSA DUMMY I.D. NO. 

LABORATORY "rwwrcUN: FRED JUllAKO 

APPROVED BY: /fi V^ A~*jdrj 



Pre-Test 
Cal ibration 



Post-Test 



Date of Dunvny Calibration ----- 

Calibration Sequential Number for Dunrny - - - 

Temperature In Lab. (Spec, 3 66 to 78*F) 

Relative Humidity In Lab. (Spec. = 10 to 70S) 



29 Jine 1979 



t:st PARAMETER 



1 . HEAD DROP. TEST ; 

a. Peak Resultant Accel . 

b. Peak Lateral Accel. - 

c. Time above 10CG - - - 



a. Pendulum Speed 

b. Pendulum Avg, DeceU 
{over t3 - tj 

c. Peak Resultant Head 
Acceleration - - 



d + Pendulum DeceK ( t 2" t l ^ 

e. Pendulum Decel ♦ (tj^l 

f . Pendulum Oecel « ( c^-*^ ) 

g« Pendulum Direction 
Reversal Time - - - - 



Max. Head Rotation 
Chordal Displacement 
Head Rotation Angle 



30' 



60 ( 



Maximum 
( °) 




Continued 



C-3 



6S25-V-4 



r 



P. 572 DUMMY CALIBRATION TEST OATA ..., Continued 



Dummy I.D. No 




TEST PARAMETER 



SPECIFICATION 



Pre-Test 
Calibration 



Post-Test: 
Calibration 



2. NECK 3ENDING TEST .... 
Continued 

i. Chorda! Displacement: 

Head Rotation Angle - 

W 



30 



Time 



Displ 



Time 
Disnl . 



67.0 to 83.0 ms 



4.3 to 5.3 in. 



85.4 to 104.5 ms 



2.1 to 3.1 in 



Time 



101.0 to 123.0 ms 



Displ. 



.5 to 0.5 in. 



3. ABDOMINAL COMPRESSION 
TEST : 

(Preload = 10 pounds) 

a. Force 9 ^ n 

b. Force (? 1.3" 



50 to 53 lbs 



73 to 88 lbs 



4, LUMBAR FLEXION TEST 

a. Force 9 20° - - 

b. Force 9 30° 

c. Force 40° - - 

d. Return Anale 



CHEST IMPACT TESTS: 
a- High Speed 

(1 ) Probe Speed - • 

(2) Peak Delfection 

(3) Peak Resistive 
Force - - - - - 

(4} Internal - - - 
Hysteresis 



22 to 34 lbs 



34 to 46 lbs. 



46 to 58 lbs 



12° maximum 



b. Low Speed 

(1 ) Probe Speed - - - 

(2) Peak Deflection - 

(3) Peak Resistive 
Force - — - - - 

(4) Internal 
Hysteresis* - - - 



21.78-22.22 fos 



1 .7" maximum 



2250 lbs. maximum 



50 to 70% 



13.86-14.14 fos 



1 .1" maximum 



1450 lbs. maximum 



50 to 70% 



88 



4.9 



92 



2.35 



1QQ 



^ 



5£l 



M 



M 



31 



50 



21.81 



1.45 



1916 



51% 



13.88 



1.0 



1201 



C-4 



6525-V-4 



P.S72 DUMMY CALIBRATION TEST DATA Continued: 



TEST PARAMETER 



6. &NEE IMPACT TESTS ; 

a. Right Side ~ 

(1) Probe Speed - - < 

(2) Maximum Force - - 
(31 Time Above 1000* 

b. Left Side — 
{]} Probe Speed - - 

(2) Maximum Force - 

(3) Time Above 1000* 



specificat:on 



5,76 to 7,0* fps 



Ou croy LP. No, : 
Pretest 
Cal i oration 



Calibration 



6.94 



1850 to 2£OQ lbs 
1 .7 ms minimum 



ossa 



? ] 



6,76 to 7,04 fos 



7,03 



1850 to 2500 lbs 



?5QQ 



1 J ms .in ni mum 



C-5 



A525-V-J 



INSTRUMENT CALIBRATION INFORMATION 



DUMMY I.O. NO.: 



3 


1 


9 



CALIB. SEQ. NOS. FOR DUMMY: 



DUMMY INSTRUMENTS: 

1. Head Accel erometers 



a, Triaxial unit 

b. Uniaxial units 



(1) Longitudinal (A x ) 

(2) Lateral (A ) - - 

(3) Vertical (A,) - - 



2. Chest Accel erometers— 
(Vehicle Crash Test Usage) 



a. Triaxial unit • 

b. Uniaxial units 



(1) Longitudinal (A x ) 

(2) Lateral (A y ) 

(3) Vertical (A,) - - 



3. Chest Potentiometer 

4. Femur Load Cells— 

a. Right Side - - ■ 

b. Left Side 



MANUFACTURER 



SERIAL 
NUMBER 



1 DATE OF 
DATE LAST' I NEXT 
CALIBRATED [CALIBRATION 



B. CALIB . LAB . INSTRUMENTS : 

1. Pendulum Accel erometer - - 

2. Test Probe Accel erometer - 

3. Lumbar Flexion Test Push 
Force Gauge ------- 

4. Abdominal Compression Test 
Force Gauge - - - - — - 

5. Abdominal Compression Test 
Displacement Gauge - 



ENDEVCO 



ENnrvcn 



ENDEVCO 



CEC 



ENDEVCO 



CEC 



KUMANOID 
SPECIAL 



J&L 



GSE 



B&H 



B&H 



m. 



BLH 



CIC 



C-6 



CKRd 



1ES2. 



CE76 



17938 



CG05 



21480 



306 



310 



17547 



16928 



73141 



72952 



567-11 



1=12. 



^23. 



4-79 



1-79 



1-79 



1-79 



1-79 



1-79 



2-79 



1-79 



6525-V-4 

J L 



1-80 



1-80 



1-80 



1-80 



1-80 



1-80 



1-80 



1-80 



1-80 
1-80 



P. 572 DUMMY CALIBRATION TEST CA7A 



3 


2 


; 



HHTSA QUWV 1.3. NO.: 

LABORATORY TECHNICIAN: FRED JULIANQ 

APPROVED 8Y; &~7^ tfU+idL*. _ 



Pre-Te$t 
Ca 1 ibration 



Dite of Dummy Calibration ---------- 

Calibration Sequential Number for Duuwy - - - 
Temperature in Lab, {Spec. » 66 to 78 q F)- - - 
Relative Humidity in Lab, (Spec. * 10 to 705] 



TEST PARAMETER 



SPECIFICATION 



1 # HEAD DROP TEST ; 

a. Peak Resultant Acce 
b + Peak Lateral Accel . 
C. Time above 100G - - 



210 to 260G 



<)0G 



0,9 to 1 .5 ms 



fr. MEdK flgN&iHfl TEST; 



a. Pendulum Speed - - - - 

b« Pendulum Avg. Oecel . 
(over t3 - tg) - - * ■ 

c- Peak Resultant Head 
Acceleration - - - - 

d. Pendulum Oecel ♦ (tj-tj) 
e + Pendulum Oecel. (t-j-t^) 

f. Pendulum Oecel . U^-t^) 

g. Pendulum Direction 
Reversal Time - - - - 

h. Nax, Kead Rotation - - 
* + Chordal Diiplace^ent: 
Kead Rotation Angle - - 



21.5 to 25,5 fps 



20 to 24G 



26G maximum 
< 3 ms 



25 to JO ms 

<1Q :ns 



>123 m$ 



53 to 73' 



Time 



2 to 2 ms 



Ofsol- 



5 to .5 in 



30 



60 



Time 



25,6 to 2&A ms 



01soK I 



2,1 to 3.1 in 



fme 



10,3 to 51 ,7 ms i 



OiSOl 



i . 3 to 5.3 i>. 



Maximum 



T iTne 



53.2 to 65.3 *s 



Displ. 



5.0 to 6.0 in. 



Continued 



C-7 



Post-Test 



2 Ju'y 1979 



72 
72 



212 



12 



JU2 



23.68 



24 



II 



1.5 



26 



.7 



117 



70 



30 



2.95 



Al 



U& 



M 



il 



6S25-V-J 



r 



P_j72 GUMMY CALIBRATION TEST DATA . -.< Continued ; 




Dummy LD. No. : 



TEST PARAMETER 



SPECIFICATION 



2. NECK BENDING TEST 



Continued 

i. Chorda! Displacement: 
Head Rotation Angle - 



Pre-Test 
Calibration 



3 ? 2 ? 

Post-Test 
Calibration 



W 



I Time 



Displ 



30' 



0° 



Time 



Disol 



67.0 to 83.0 ms 



4.3 to 5.3 in 



85,4 to 104.6 ms 

2.1 to 3.1 in. 



i ime 



101 .0 to 123.0 ms 



Displ 



5 to 0.5 in 



83 



AJL 



Ifll 



Z^i 



04£ 



r 

3. ABDOMINAL COMPRESSION 
TEST: 

(Preload = 10 pounds) 

a. Force @ T 

b. Force @ 1.3" 


50 to 63 lbs. 




54 


73 to 88 lbs. 




76 


4. LUMBAR FLEXION TEST: 

a. Force 20° 

b. Force § 30° 

c. Forca @ 40° 

! d. Return Anqle - - - 


22 to 34 lbs. 




26 


. 34 to 46 lbs. 




37 I 


46 to 58 lbs. 




52.5 | 


12° maximum 


6° 1 


5. CHEST IMPACT TESTS: 

a. High Speed 
| (I) Probe Speed - - 


21.78-22.22 fos 




22.03 


(2) Peak Delfection - 


1 .7" maximum 




1.54 


! (3) Peak Resistive 
I Force ------ 


2250 lbs. maximum 




2124 i 


(4) Internal - - - - 
Hysteresis 


50 to 70S 




64% | 


b. Low Speed 

(1 ) Probe Speed - - - 

(2) Peak Deflection - 

(3) Peak Resistive 

| Force ------ 


13-86-14.14 fos 




14.12 


1.1" maximum 




1.07 i 


1450 lbs. maximum 




1227.6 


I (4) Internal 

1 Hysteresis- - - - 


50 to "70% 




50% ! 



C-8 



6525-V-4 



P + 572 OUWY CALlSaATIQN TEST DATA Continued 



TEST PARAMETER 



6, KWEE IMPACT TESTS; 
a, Right Side — 

(1) Probe Speed - - 

(2) Maximum Force - 
{2) Time Above 1000* 



b. LeTt Side « 

(1 ) Probe Spesd - - 

(2) Maximum Force - 
(3} Time Above 1QC0* 



SPECIFICATION 



D ummy LP, .No. 
Pre-Test 



Calibration I 



6.76 to 7.04 fps 



1850 to 2S0O lbs 



1 . 7 ms minimum 



6.76 to 7.04 fos 



1850 to 2500 lbs. 
1 4 7 ms minimum 



u 



Post-Test 
Calibration 



6-98 



Z2fltt 



!£ 



6,5^ 



2375 



C-9 



6S25-V-4 



INSTRUMENT CALIBRATION INFORMATION 



DUMMY I.O. MO.: 



3 1 2 ! 



CALIB. SEQ. NOS. FOR DUMMY: 



A. DUMMY INSTRUMENTS 



1. Head Accel erometers-- 



a. Tri axial unit - - - - - 

b. Uniaxial units 

(1) Longitudinal (A x ) - 

(2) Lateral (A ) - - - 

(3) Vertical (A ) - - • 

Chest Accel erometers— 
(Vehicle Crash Test Usage 

a. Triaxial unit - - - - ■ 

b. Uniaxial units 

(1) Longitudinal (A x ) 

(2) Lateral (A ) - - 

(3) Vertical (A ) - - 



3. Chest Potentiometer 

a. Femur Load Calls— 

a. Right Side - - 

b. Left Side 



3. CALIS. LAB. INSTRUMENTS 

1 
2 



MANUFACTURER 



SERIAL 
NUMBER 



OATE LAST" 
CALIBRATED 



DATE OF 

NEXT 

CALIBRATION 



ENDEVCO 



ENDEVCO 



ENDEVCO 



Pendulum Accel arometar - - 
Test Probe Accel erometer - 



Lumbar Flexion Test Push 
Force Gauge ------ 



4. 



Abdominal Compression Test 
Force Gauae ------- 



5. Abdominal Compression Test 
Displacement Gauge - - - - 



CEC 



ENDEVCO 



CEC 



HUMANOID 
SPECIAL 



GSE 



GSE 



mi. 



B&H 



BLH 



BLK 



CIC 



C-10 



CL60 



CG34 



CK11 



18118 



1-79 



1-79 



1-79 



4-79 



AA07 



22292 



4-79 



4-79 



311 



312 



17n47 



16928 



73141 



1-79 



1-79 



2=21 



1-79 



72952 



567-11 



6525-V-4 



1-80 



1-80 



1-80 



1-80 



1-80 



1-80 : 



1-80 



1-80 



1-80 



1-80 



Electronic Test Equipment 

The complement Of signal conditioning recording and display equipment 
used in conjunction with durrcny certification tasting is shown in Figure 3- 

t Data Acquisition - Sangamo Mod 3500 14 channel 
FM Tape Transport (recording Speed: 60 in/sec). 

• Data Reduction - Brush Mark 260 6-channel recorder 
or Pace X-Y plotter. 

• Signal Conditioning - Calspan designed and fabricated 
bridge amplifiers providing gain, balance, and shunt 
calibration of all sensor inputs, 

• Computational Equipment - Calspan designed and 
fabricated analog computer consisting of operational 
amplifiers in circuit configurations providing con- 
tinuous computation of acceleration vector magnitude 
and Severity Index relationships. 

• Signal Filtering - Calspan designed and fabricated 
second order active filters (6 channels) with 
selectable frequency responses consistent with SA£ 
J21 lb Class 60, 180, 600, and 1000 requirements. 
Filters are compensated for 32:1 real time expan- 
sion resulting from data recording at 60 in/sec and 
playback at 1-7/8 in/sec, 

• Real Time Reference - Tektronix Time Mark Generator; 
1 and 10 millisecond is synchronously recorded with 
all certification data and reproduced at playback on 
all strip chart records. 



Ml 



The data acquisition, reproduction, and time reference ' 
equipment is maintained by Cal span's Equipment and 
Standards Laboratory (ESL), which is an NBS traceable 
calibration facility. Other special purpose equipment 
is maintained by qualified test facility personnel using 
support equipment maintained and standardized by all ESL 



C-12 




FIGURE C-l 
LUMBAR SPINE FLEXION TEST APPARATUS 




FIGURE C-2 
ABDOMEN PRESS TEST APPARATUS 




FIGURE C-3 
HEAD DROP TEST APPARATUS 



C-13 




I 

I 




FIGURE C-4 

knee impact test apparatus 



FIGURE OS 

THORAX IMPACT TEST APPARATUS 




Figure C-6 
NECK IMPACT TEST APPARATUS 



C-U 




FIGURE C-7 




FIGURE C-7 
PART 572 TEST DUMMY 
FRONT & SIDE VIEW 



C-15 




Figure C-8- l ELECTRONIC TEST EQUIPMENT 



I 



C-16 



I