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Evaluation of BioRID II Dummies in Ford Safety Lab Tests: Insights and Recommendations

This report presents an evaluation of BioRID II dummies, SN45 and SN70, subjected to Ford Safety Lab sled tests. The findings indicate that both dummies are certifiably passing current standards pre- and post-test. Key evaluations assess repeatability across various test scenarios. While new tests show promise in distinguishing between dummies and jackets, gaps in lower spine assessments signal areas for improvement. Recommendations include enhancing the test matrix, better characterizing the lower spine dynamically, and standardizing chest stops to prevent dummy damage.

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Evaluation of BioRID II Dummies in Ford Safety Lab Tests: Insights and Recommendations

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  1. TEGID-07 BioRIDII New Sled Evaluation Data Observations from Ford Safety Lab Tests

  2. Test Matrix • 2 BioRIDII-G dummies tested – SN45, 70 • Both passing current cert pre- and post-test • Evaluation 1: Are the tests repeatable? • Evaluation 2: Are the new tests with and without Head Restraint able to discriminate between…? • Dummy 45 vs. 70 • New vs. Old vs. Repaired Jackets • New vs. Old Teflon Pad • Bolts @ base plate loose vs. tight (common mistake) • With vs. Without Chest Stop

  3. Repeatability • Mass only tests show good repeatability (link) • Foam impactor repeats after many runs • Strange sled accel on a few of tests, unknown cause, but likely due to settling at initial setup • 6+ tests with each dummy appear to have good repeatability (plots in shown in eval 2) • Peaks and data traces for dummy responses • Peaks and data traces for pots/sled data • However, Pot D had 2 issues • Data loss due do damaged wire • Data variability due to pot rod contacting shoulder (also Pot C) • Improved mounting is recommended

  4. Tests With Head Restraint • SN 70 (red) vs. SN 45 (blues) • Curve differences seen in Head Az, Upper Neck LC, T1 LC/Accel, Lumbar LC/Accel, Head Cap LC (link) • New (blue/turq) vs. Old style jacket (red/drk turq) • Curve differences seen in Head Az, Upper Neck LC, T1 LC/Accel, Lumbar LC/Accel • Some curve shapes distinguish a difference between dummies, some distinguish the jacket type • Differences are often revealed during rebound

  5. Tests Without Head Restraint • SN 70 (reds) vs. SN 45 (other) • Curve differences seen in Head Az, Upper Neck Fx, Fz, My, Mz, T1 Fx, Fz, My, Lumbar Fx, Fz, Mz, Pots A, B, C (link) • Jacket: New (blue) vs Old (pink/turq) vs Repaired (drk turq) • Upper Neck Fx, My, Mz, T1 Fx, Fz, My, Lumbar Mz, Pot A, B, C

  6. Tests Without Head Restraint • Teflon Pad: New (turq) vs Old (pink) • No significant curve differences • Loose bolts @ base plate (drk blue vs yellow) • Only Lumbar shows differences • Indicates that issues in the lower spine are not evaluated in this certification test • Chest Stop (blue vs drk blue) • Lumbar MY shows large differences as the sled stops • Recommend addition of chest stop as standard to prevent damage to the dummy vertebrae

  7. Observations • Foam impactor reusability seems very good – pulse overlays well after many runs • Repeatability for a single dummy is better than previous cert test • 2 New tests show promise in distinguishing differences between dummies and jackets • New test does not reveal issues in lower spine • Additional channels should be included in the certification to distinguish issues • Upper Neck LC, T1 LC, Lumbar LC • Chest Stop should be added to all tests • Alignment of the rod between Pots C and D can be difficult

  8. Next Step Recommendations • Investigate the causes of dummy to dummy differences and how they can be fixed • Create test corridors with additional promising channels • Investigate how to characterize the lower spine dynamically • Characterize the jacket for better manufacturing repeatability

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