DEVELOPMENT OF A NEW ATD THORAX

Richard J. L ' Abbe , James A . Newman and Andre M . St-Lauren t Biokinetics and Associates Limited

Ottawa , Canada

David A . Dainty Department of Kinanthropology

University of Ottawa Ottawa , Canada

Kevin Smyth and Anthony Bosik Davis Engineering Limited

Ottawa , Canada

A new p r o totype ATD thorax h a s been developed to be compa tible w i th the G . M . H y b r i d I I I te s t dum m y . T h i s new ehe s t provides a b e t te r opportuni ty to i n­corporate certain characteristics of live human beings when subj ected to upper torso b e l t load i ng. This paper describes the deflection response character­istics of the new surrogate at subinjurious and inj urious impact leve ls. These results are compared to the responses obtained for other ATD ' s .

INTRODUCTION

This paper is divided into three sections. The first deals with the continua­tion of the research program f i r s t reported by the authors i n 1 9 8 2 ( 1 ) . The second section describes the mechanical design of a new thorax structure. The des i gn of the new tho rax i s based partly on h u m a n volunteer r e s p o n s e to be l t loading ( 1 ) and partly on cadaver response to blunt sternal loading ( 2 - 5 ) . The third section describes the results of a s led test program designed to quantify the response of the new thorax and to s tudy the overa l l ATD kinematic response in a documented inj urious loading environment ( 6 , 7 ) .

THORACIC IMPACT RESPONSE TO STRIP LOADING

The testing described i n this section i s a continu a tion of the tes t program i n i t i ated i n 1 9 8 1 ( 1 ) . The original te s t apparatus w a s developed to a s s i s t investigators in mapping thoracic deflections under static point loading, and static and �uasi static strip loading (driver confi�uration). These tests were conducted with the subjects lying in a supine position, with a fully supported thoracic spine.

During the s e cond phase o f this prog r a m , a d e ta i le d a n a l y s i s o f thora c i c de­f lections was performed only along the path of the belt, namely the right 7th r i b , lower and upper s te rnum and c lavi c le locations. I t was a s s u m e d that d e f lec ti ons in other regions of the thorax were of s e c ondary i mportance i n t e r m s o f overa l l body r e sponse. The surrogates te s te d were: The Part 5 7 2 , Hybrid I I I and M IRA ( OPAT ) ATD ' s , and one human volunte e r . The human s ubj e c t was chosen f r o m the pool o f voluntee r s u s e d i n the 1 9 8 2 s tudy. During the current phase, he was re-tested for the tensed state.

Surrogate Response to Belt Loading

Deflection vs time traces were taken for three locations along the path of the belt. Belt force vs time was also recorded. Upon detailed examination of the test results, the human volunteer's response to loading was found to have poor repeatabili ty. l t became apparent that the degree of muscular "tensing" from one te s t to the next could n o t be contro l le d to the degree o r i g i n a l ly anti­c ip a ted by the inve s tigator s . I n terpretation of s u c h data s hould thus be libera l .

Response to strip loading was also examined on the M IRA, Hybrid I I ( Part 5 7 2 ) and Hybrid I I I d u m m i e s . F i g u r e s 1 through 6 i l lus trate f o r c e /d e f le c ti o n responses for a 1 08 Joule impact, yielding a n average peak belt load o f 3 . 2 kN (see Reference 1 for measurement techni�ue) . Each surrogate was then re-tested without its standard soft tissue cover in an attempt to quantify the net effect of the soft tissue cover on the overall deflection response of the thorax.

The Hybrid I I e h e s t exhibi ted the low e s t a m p l i tude d e f l e c t ion for a l l three locations , i n s o m e c a s e s as much a s 50% lower than the human voluntee r . The Hybrid III ehest response in the upper sternal region was quite simi lar to the

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numan vo1untee r. The Hyb r i d I I I appe a red too s t i f f i n the right 7 th r i b and lower sternum locations. The MIRA gave a more human-like response in the lower rib area than both the Hybrid II and Hybrid I I I , however, it appeared too stiff in the sternal area.

The use of s o f t tissue cover has an e f f e c t on both the b e l t path, and on the structure 's response to loading. In the lower rib, and upper sternum location, the Hybrid I I I and MIRA responses were markedly inf luenced by the soft tissue. In the lower sternum region, the soft tissue cover appears to play a prominent role in the Hybrid II response, increasing its externally measured deflection by 20%. The externally measured ehest deflections are generally higher wi th soft tissue cover, although this is not always the rule. The MIRA exhibits the opposite result in the upper sternum location.

MODIFIED CHF.ST DESIGN

Upon detailed examination of the Hybrid I I I ehest responses to be l t loading, it was determined that an improvement could be made in the responses of the lower rib and clavicle regions. It was further determined that the anthropometric measurements were not 50th percentile ( 1 ) in terms of ehest depth, ehest length and ehest breadth. The thoracic assembly had also demonstrated to be sensitive to temperature ( 8 ) . H e n c e , a new e h e s t s tr u c ture was developed to more accurately simulate a 50th percentile human male.

Structural Design

Ove r a l l thor a c i c s tr u c ture measure m e n t s were based on anthrop o m e t r i c data obtained from a s a m p l e o f 5 0 th percen t i le m a le subj e c ts ( 1 ) . The " Mod i f i e d Hybrid III" (or Hybrid IIIE) ehest has redesigned rib elements to improve both overall anthropometry and thoracic response to strip loading.

This new design is composed of ten rib elements which are hinged at the spine and constrained at the front by a spli t s ternum which resembles an i nverted "Y" ( Figure 7 ) . Two telescopic clavicles were also integrated into the structure. These are ball j ointed at the outer extremities of the shoulder assemblies and on the top of the s ternum a s s e mbly. S o f t t i s s ue cove r i n g was not used s i n ce Typical polymer foam materials serve largely to make contemporary dummies lock m ore r e a l i s t i c . The p r e s e n t d e s i g n e ndeavou r s to provide s u i ta b l e f orce deformation characteristics without the use of such external coverings.

Inside the thoracic cavi ty, two adj ustable linear decelerators were added to �rovide investigators with the option of controlling ehest damping character­i s t ics. Both dashpots are b i l a t e r a l l y suppor ted by the spine box and are linked to the mid-sternal region by means of a bell-crank lever arm mechanism.

FIGURE 7 : MODIFIED THORAX CONSTRUCTION

Determination of Mechanical Characteristics using Finite Element Modelling

The STARDYNE f i n i te e le m e n t mode l l i n g program was used to deter m i ne the properties of the ehest. The ehest structure was s i mulated using a 1 5 2 node, 1 4 7 beam data set. Ten ribs were mode l l ed. They were hi nged at the s p i ne which was assumed to be restricted from motion. In addition, the top rib was

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restricted trom lateral movement tnereby simulating the presence o f clavicles.

The f i r s t des ign phase i n volved dete r m i n i n g the required s ternum and r i b prope rties. The model w a s used to dete r m ine the s i z e o f the r i b e le m e nts i n order to achieve correct sti ffness under applied static loads at various sites. Member stresses were restricted to allowable levels under a 7.5 cm deflection at each rib. The thickness of certain ribs had to be doubled in order to meet th i s cri terion.

In the second d e s i g n phas e , the dyna m i c re sponse of the s tructure to low and h i g h speed b lunt s te r n a l i m pacts , as s p e c i f i ed by the Hyb r i d I I I ehe s t calibration procedure s , was determined.

The two l i near variable hydraul i c dashpots were then inc orporated i n to the model and their performance characteristics were determined.

The DYNRE1 option o f the STARDYNE program was then u t i l i z e d to model two dyna m i c e ve n t s : 4 . 2 7 m / s and 6.67 m / s b lunt sternal i mpacts w i th a 2 3 . 3 6 kg impactor. The force/time functions measured during previous calibration tests on a Hybrid I I I ehest were used as input load approximations. Force/deflection corr idors ( 3 ) f o r the high and low speed events were used as target curves. The dyna m i c re sponse w a s then adj u s ted by varying the theo r e t i c a l damper re s i s tance to f a l l w i th i n the d e s i red response corridors. To val idate the response, the differential equations of motion of an approximate system were so lved .

Validation of Structure

The new thoracic structure was evaluated for def lection response to sub-injur­i ous s t r i p loadi n g u s i n g the tes t m e thod previous ly d e s c r i bed ( 1 ) . No s o f t tissue cover was employed. The rib s tructure was first tested w i th dash.Pots a d j u s ted to produce no damping. The response i n the lower r i b and c l a v i c l e r e g i on s were d e m o n s tra ted to be a marked i mprove m en t over the H y b r i d I I I a s shown i n Figure 8.

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( 1982) S T A T E

Upon completion of a preliminary evaluation program designed to determine the effect of damping on ehest response, a specific dashpot setting was chosen for high speed i m pa c t i mpacts. The thorax was then subj ected to the s tandard Hybrid III ehest certi fication procedure. Since the structure was not covered w i th a s o f t t i s s ue eo ve r i n g , the force/ t i m e response of the ches t e xh i b i ted some degree of high frequency noise during the high speed impact.

Deflection response in the low speed test was "within" specifications. However, the high speed i mpact d e f lection response w a s 3 0 % below s pe c i f i cati on. The

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ehe s t foree responses were a l s o 2 5 and 3 3 % low for the low and h i gh veloeity impaets respeetively. One should note that ehest forees are measured at 1 9 m s from time o f probe eontaet on the ehest strueture. This method o f evaluation may not be tota l l y approp r i a t e , s i n e e the response i s i n f a e t e o mparab le to some of the eadavers upon whieh the Hybrid I I I speeifieations are based.

SLED TEST PROGRAM

In 1 9 8 2 , Ka l l i e r i s e t a l ( 6 ) repor ted on a s e r i e s of s led te s t s , u s i n g a pulse similar to the pulse from a Volvo P- 1 40 i mpaeting a fixed barrier at 5 0 km/h, i n a n a ttempt to l i nk eadaver and aeeident da ta. In 1 9 8 3 , S a u l ( 7 ) expanded upon the work by obtai n i n g r e s ponse e o mp a r i sons for the P a r t 5 7 2 , Hybrid I I I and APR dum mies i n the same three point belt restraint syste m environment. In an a t te m p t to ve r i fy the r e sponse o f the new mod i f ied Hybrid I I I and M I RA d u m m i e s , the s a m e te s t proeedures as e m ployed by S a u l were adopted in this program.

Experimental Results

The average peak aeeeleration of the half sine pulse in the present test series was 3.1 % higher than in Saul's test pro9ram and the delta v was 9% lower. The res traint s y s te m data i s s u m m ar i z e d i n Table 1 , and the ATD ins trumentation measure m e n ts are s u m m a r i z ed i n Table 2. Observations a r e s u m m arized a s follows:

The mean values of peak shoulder belt load for the Hybrid IIIE dummy are higher than either the Part 572 or M IRA. The Part 572 in the eurrent test program produeed head aeeelerations 53.4% lower than those reeorded in Saul's test series. In this test series, the Hybrid IIIE peak resultant head aceeleration was approxi m a t e l y 1 9 g ' s higher than the Part 5 7 2. The Hybrid I I I E head a e e e le r a tion w a s comparable to S a u l ' s r e s u l ts for Part 5 7 2 and APR dummies. The peak r e s u l tant ehe s t a e e e l e r a t i o n for the Part 5 7 2 in the eurrent series is s i milar to that obtained i n Saul's program ( 38.7 g's vs 38.0). The Hybrid IIIE ehest aeceleration was only 2.3 g's higher than the window containing results of the APR, Hybrid II and Hybrid I I I in Saul ' s program. Peak thoraeie deflee tions for Hybrid IIIE are 9% lower than for the Hybrid I I I as measured in Saul's program. The Part 572 is much stiffer with 1 .05 i n. d e f l e c tion. This measured d e f l e c tion is subs tantia l l y h i gher than results obtained by S a u l ( 1 . 0 5 i n. v s 0 . 2 8 i n. ) . The d e f l e c t i o n / t i m e h i s to r i e s f o r both t h e Part 5 7 2 a n d the Hybrid I I I E e xhibi t s u b s tanti a l differences i n terms o f event duration. The def lection event duration was 1 5 0 ms for the Hyb r i d I I I E , as opposed to 1 0 0 ms f o r the Part 5 7 2 . The shape of the curve re sponse w a s a ls o m a rked l y d i f fe r e n t as s e e n i n Figure 9 .

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Peak r e s u l tant pelvic acce lerations a r e w i th i n the w i ndow of values obtained in Saul ' s program. Though two clavicle failures were recorded on the initial tests using the Hybrid I I IE, all measurements were within a eoefficient of variation of 4 . 9% .

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TABLE 1 : RESTRAINT SYSTEM MEASUREMENTS

TEST SERIES TEST # PEAK SIOJI.DER PEAK I.AP co-MENT BELT LOAD BELT LOAD

N (lb) N (lb) 001B)!>,RD

Part 572 455 7940 ( 1 785) 6730 ( 1 513) N::> clothi.ßJ 459 7575 ( 1 703) 7042 ( 1 583) -4 Iap Eelt soore 460 8171 ( 1 837) 6695 ( 1 505) +4 I.ap Eelt Score

Part 572 t-ean 761 1 ( 1 7 1 1 ) 6734 ( 1 514) Fran Reference 7 (Saul) Stil. Dev. 1 73 (39.0) 1 25 (28.0)

MIRA 456 7330 ( 1 648) 5507 ( 1 238) N::> clothing used 457 7691 ( 1 729) 6356 ( 1429) Clothing used 458 7900 ( 1 796) 6276 ( 1 41 1 ) Clothing used

Mean 7669 ( 1 724) 6045 ( 1 359) Stil Dev. 330 (74. 1 ) 469 ( 1 05.4) All tests Mean 7842 ( 1 763) 6316 ( 1 420) '.leSts using clothing Stil Dev. 211 (47.4) 57 ( 12. 7) on A'ID

Hybrid IIIE 461 8527 ( 1917) 7744 ( 1741 ) I.eft Clavicle Brcke (at shoulder) 462 8309 (1868) 7855 ( 1 766) Ri.ght Clavicle Brcke (at sOOulder) 463 8358 ( 1 879) 8016 ( 1 802)

Mean 8398 ( 1 888) 7893 ( 1 770) Stil Dev. 143 ( 25.8) 1 37 ( 30.7)

Hybrid III Mean 8100 ( 1 841 ) 8095 ( 1820) Fran reference 7 (Saul) Stil Dev. 307 ( 69) 320 (72)

TABLE 2: ATD INSTRUMENTATION MEASUREMENTS

TEST SERIES TES'T # PEAK UPPER SPINE PE71.K OIEST PE71.K RESULT RESULTANI' PEAK RE3ULT DEFLECI'ICN PELVIC NX:'N HEAD NX:'N <lIEST Nr.'N an (in) (g ' s )

(g's) (g's)

PARI' 572 455 42.1 39.9 2.64 ( 1 .04) 55.1 459 38.7 38.7 2.57 ( 1 .01 ) 54.0 460 31 . 1 37.5 2.77 ( 1 .09) 58.6

Part 572 t-ean 57.2 38.0 o. 71 ( 0.28) 54.7 ( Saul) Stil Dev. 4.95 1 . 2 0.8 (0.03) 9.8

MIRA 456 NA 52.6 NA NA 457 54.3 NA NA 458 47.8 NA NA

Mean NA 51.6 NA NA Stil Dev. 3.4

Hybrid IIIE 461 58.5 46.4 3.81 ( 1 .5) 54.7 462 56.8 42.2 3.56 ( 1 .4) 53.8 463 53.1 43.6 3.56 ( 1 .4) 56.8

Mean 56.1 44.1 3.63 ( 1 .43) 55.1 Stil Dev. 2.8 2.1 0. 1 5 (O.CX'i) 1 .5

Hybrid III t-ean 74.5 40.0 3.99 ( 1 .6) 57.6 (Saul) Stil. Dev. 0.18 0.4 0.05 (0.02) 1 .9

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Overall the ATD thoracic responses were quite similar. As pointed out by Saul ( 7 ) , these response s i m i l a r i t i e s o c c u r d e s p i t e v e r y d i f f e r e n t d u m m y cons truc tions. Pho tographie a n a l y s i s i n the current study revealed that the thoracic spines underwent a displacement of approximately 30 cm. Since ehest compression accounts for only 8- 1 3% of the ATD excursion. This supports Saul's conc lusion that the r e s t r a i n t s y s t e m is a p r i m a r y f a c tor i n c o n tro l l i n g the dummy response.

Comparison to Previous Work

Avai lable data f r o m Ka l l i e r i s ( 6 ) and Saul ( 7 ) , are i n c luded i n Table 3 . The f i ndings of the current s tudy for the Part 5 7 2 a r e in c lose agre e m e n t w i th Ka l l i e r i s ' r e s u l ts i n t e r m s o f head and thorax d i s p lacements , and lap b e l t loads. The Part 5 7 2 resultant thorax acce leration variance was only 4.4% among a ll three investigators.

TABLE 3 : ATD DATA COMPARISON TO KALLIERIS AND SAUL RESULTS

HF.AD 'lH:RAX WlKlARD 'lllRAX SIOJI.DER A'ID � DISPUCEMENI' DISPLACEMENI' UIP BELT RESULTANI' BELT WAD

an (in) an (in) N (lb) g's N (lb) arliver Kallieris 56 (22) 41 ( 16) 5293 ( 1 1 90) 41 N/A Part 572 Kallieris 48 ( 1 9) 25 ( 1 0) 691 7 ( 1 555) 37 N/A Part 572 Saul 58 (23) 43 ( 1 7) 6734 ( 1 514) 38 761 1 ( 1 71 1 ) Hybrid III Saul 59.7 ( 23.5) 40.4 ( 1 5.9) 8095 ( 1 820) 40 8189 ( 1 841 ) Part 572 present 49 ( 1 9.3) 23.4 (9.2) 6824 ( 1534) 38. 7 7896 ( 1 775) MIRA present 52.6 (20.7) 22.9 (9) 6045 ( 1 359) 51 .6 7842 ( 1 763) Hybrid IIIE present 52.8 (8.2) 20.8 (8.2) 7873 ( 1 770) 44. 1 8398 ( 1 888.)

l t i s interesting to note that the MIRA and Hybrid I I I E d u m m i e s , exhi b i te d h i g h e r h e a d displacements than t h e Part 5 7 2 , b u t exhibi ted substan t i a l ly d i f f e r e n t lap b e l t load s , and peak thoracic r e s u l t a n t acce lerations. A l s o , based on the findings i n this study, the effect o f clothing on ATD kinematics are negligible in terms of head excursion, but accounts for approximately a 1 0% decrease in thorax displacement. The lap belt load is also approximately 1 5% higher and the shoulder belt load is approximately 7% higher.

The Part 5 7 2 and Hybr id I I I E responses are qui te s i m i lar to the r e s u l t s obtained by Saul's ( 7 ) ATD samples, exce�t for the pelvic responses. The peak pelvic a c c e l e r ations were typ i c a l ly higher i n the p r e s e n t s tudy. The MIRA sternal responses were different from the other ATD's, though no explanation i s proposed. The MIRA upper spine response though repeatable, was not as smooth as the Part 5 7 2 and Hybrid I I I E.

Comparison of Overall Responses of Hybrid IIIE to Hybrid III

Data obtained in this program for the Hybrid I I I E was compared to the responses of the GM Hybrid I I I as measured by Saul ( 7 ) . Mean shoulder belt and lap be lt responses varied by a maximum 2.4% from the Hybrid III to the Hybrid I I I E the latter having the higher values. Mean peak resultant head acceleration was 25% higher ( 74.5 g's) on the Hybrid I I I , but peak resultant ehest acceleration was 1 0 % lower ( 4 0 g ' s ) , in comparison to the mod i f i ed Hybrid I I I. Peak m i d ­sternal deflection was 9 % lower for the Hybrid I I I E. Mean peak resultant pelvic acceleration were 4% higher for the Hybrid I I I dummy. Maximum head displace­m e n t w a s 1 2 % higher for the Hybrid I I I compared to the Hybrid I I I E. Che s t displacement was 50% lower for the Hybrid I I I E. l t i s interesting to note that Saul's thoracic displacement for the Part 572 was also approximately 50% higher than for the Part 5 7 2 d u m m y tes ted in the p r e s e n t program. The reasons f o r these latter differences are not apparent a t the time o f writing.

Comparison to Cadaver Data

A detai led comparison was m ad e w i th a data base u s i n g 1 3 cadaver te s t s a s chosen b y Saul ( 7 ) based on the Heidelberg cadaver data described b y Kallieris ( 6 ) . From the s e te s t s , ATD comparisons were made for belt load s , s te r n a l ( upper and lowe r ) , spinal ( upper and lower) and pelvic accelerations. Typica l comparisons appear in Figures 1 0 to 1 3.

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SUMMARY AND CONCLUSIONS

Fini te element modelling has proven to be a very useful tool in the qesign of the new ATD thorax.

The ne w l y des i gned ATD thorax compri s e s ten r i b e le m e n t s , each of which are pivoted at the spine box j unction. Internally, adj ustable linear decelerators provide the necessary viscous properties.

Statically and quas istatically, the design has been shown to faithfully emulate the re laxed human thorax s tructure response to strip loading. Dynamically, the r e s ponse can be m ade more or l e s s human-like by adj u s tm e n t o f the vis cous elements .

In a realistic 3-point belt system impact environment, the restraint system i s the primary factor in controlling the dummy response.

ACKNOWLEDGEMEN'l'S

The authors w i s h to thank M r . Roger Saul o f VRTC, o f Colombu s , Ohio, for h i s assistance and guidance i n the preparation o f the s led test program. W e would also like to thank Dr. Tim Bowden and Mr. Don Day at the HyGe Sled Facility at DCIEM, in Toronto, Canada, for thei r constant support and suggestions. We wish to acknow ledge the Road S a f e t y and Motor Veh i c l e Re g ulation D i r e c torate, of Transport Canada, for supporting this program. Fina l ly, the authors wish to thank Helen O ' Hara and Margo W i l l i a m s for the i r patience i n preparing this manuscript.

REFERENCES

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