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Activity ReportTask Force regarding Review and Update Certification Corridor
(TF-RUCC) under the IG GTR9-PH2
6th Sep. 2012TF-RUCC
GTR9-4-07
2
Contents
1. Background2. Meetings3. Historical Review
3.1. Component Level Certification Corridor3.2. Assembly Level Certification Corridor
4. Update Activity4.1. Component Level Certification Corridor4.2. Assembly Level Certification Corridor
5. Discussion6. Conclusion7. Working Documents
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1. Background
• Flex-TEG had made three component level certification corridors for Thigh, Knee and Leg Quasi-static certification tests as well as two dynamic assembly level certification corridors for Pendulum type and Inverse type for Flex-PLI.
• However, Humanetics had some difficultly producing a production Flex-PLI that could completely meet the inverse level certification corridors. This was assumed to be due to differences between the prototypes and production type.
• IG GTR9-PH2 had discussed and decided to settle a Task Force regarding Review and Update Certification Corridor (TF-RUCC) under IG GTR9-PH2 at the kick-off meeting of IG GTR9-PH2 in November 2011 to solve the above situation.
• Japan had an assignment to take a chair of the TF-RUCC, then Humanetics had an assignment to be a secretariat of the TF-RUCC.
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2. Meetings
• TF-RUCC had a kick off meeting in November 2011, then TF-RUCC had 1st to 5th TF-RUCC meeting by July 2012.
• TF-RUCC conducted historical review of certification corridors, then made update proposal for component level as well as assembly level certification corridors.
Date Nos. Main Topic
28th Nov. 2011 Kick-off •Make Terms of Reference
•Historical Review
27th Jan. 2012 1st •Historical Review
•Overall Working Schedule to Update Certification Corridor
23rd Mar. 2012 2nd •JARI test results (Component Level)
•Update Proposal for Component Level Certification Corridor
25th May 2012 3rd •JARI and BASt Test Results (Assembly Level)
•Agreement on the Update Proposal for Component Level Certification Corridor
18th Jun. 2012 4th •BASt and Bertrandt Test Results (Assembly Level)
•Update Proposal for Assembly Level Certification Corridor
30th Jul. 2012 5th •Humanetics and Ford Test Results (Assembly Level)
•Agreement on the Update Proposal for Assembly Level Certification Corridor
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3. Historical Review
• TF-RUCC conducted historical review of certification corridors for component level as well as assembly level certification corridors.
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3. Historical Review3.1. Bone core production corridor
• At the first, bone core production corridor, which is only used by Flex-PLI production maker to keep bone core quality, was evaluated.
• The bone core production corridor was made by JARI from Flex-PLI type GT level, and it works well at JARI test lab with JARI test rig.
• However, Humanetics (Japan and US) test results with Humanetics (Japan and US) test rig shows slight differences compared to JARI one.
• The difference came from the difference of the test rig and maybe from the difference of test lab (sensors, settings, etc.).
• Flex-GTR bone core characteristic shall be investigated/certified by JARI because JARI is the master test lab that developed the corridors using the master test rig.
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Humentics (HU) JPN Test Rig
JARI Test Rig
JARI Test Rig
HU-JPN Lab.
HU-JPN Test Rig
Corridor:GT Corridor:GT Corridor:GTCorridor:GT
JARI Test Rig
JARI Lab. HU-US Lab.
HU-US Test Rig
Humanetics (HU) JPN Test Rig
ram ram
Humanetics (HU) US Test Rig
ram
JARI Test Rig
ram
JARI Test Rig
mid in corridor mid-high in corridor high in corridormid in corridor
3.1. Bone core production corridor (Femur bone core)
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3.1. Bone core production corridor (Tibia bone core)
JARI Test Rig HU-JPN Test Rig
Corridor:GT Corridor:GT Corridor:GT Corridor:GT
JARI Test Rig HU-US Test Rig
mid in corridor mid-high in corridor high in corridor
Humanetics (HU) JPN Test Rig
ram
Humanetics (HU) US Test Rig
ramram
JARI Test Rig
ram
JARI Test Rig
mid in corridor
HU-JPN Test Lab.JARI Test Lab. HU-US Test Lab.
Humentics (HU) JPN Test Rig
JARI Test Rig
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3. Historical Review3.2. Component level certification corridor
• At the second, component level certification corridor, which is used by Flex-PLI user to investigate component level Flex-PLI quality, was evaluated. Findings are described as follows:
• The roller support system, which is used for the certification test, causes high variations in the test results.
• The plastic plate support system, used for Flex-GT, provides stable test results.
• Recommend to use the plastic plate support system for Flex-GTR certification tests.
• Need to update the Flex-GTR component corridors.• Draft proposal shall be developed by mid March 2012 using JARI test
data.
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3.2. Component level certification corridor (Femur)
Plastic PlateRoller System
No gap
0
50
100
150
200
250
300
350
400
450
500
0 5 10 15 20 25
Deflection: Dc (mm)
Mom
ent:
Mc
(Nm
)
0
50
100
150
200
250
300
350
400
450
500
0 5 10 15 20 25
Deflection: Dc (mm)
Mom
ent:
Mc
(Nm
)
0
50
100
150
200
250
300
350
400
450
500
0 5 10 15 20 25
Deflection: Dc (mm)
Mom
ent:
Mc
(Nm
)
0
50
100
150
200
250
300
350
400
450
500
0 5 10 15 20 25
Deflection: Dc (mm)
Mom
ent:
Mc
(Nm
)
GapPlastic Plate
No NeopreneWith Neoprene
Corridor:GT Corridor:GTR Corridor:GTR Corridor:GTR
•easy setting•good repeatability
•easy setting•good repeatability
•difficult setting•difficult to control which data can be obtained
ram
plastic plate plastic plate
neopreneramram
roller system
ram
roller system
Free movement Contact to housing
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3.2. Component level certification corridor (Tibia)
0
50
100
150
200
250
300
350
400
450
500
0 10 20 30 40
Deflection: Dc (mm)
Mom
ent:
Mc
(Nm
)
0
50
100
150
200
250
300
350
400
450
500
0 10 20 30 40
Deflection: Dc (mm)
Mom
ent:
Mc
(Nm
)
0
50
100
150
200
250
300
350
400
450
500
0 10 20 30 40
Deflection: Dc (mm)
Mom
ent:
Mc
(Nm
)
0
50
100
150
200
250
300
350
400
450
500
0 10 20 30 40
Deflection: Dc (mm)
Mom
ent:
Mc
(Nm
)
Plastic PlateRoller System
No GapGapPlastic Plate
No NeopreneWith Neoprene
Corridor:GT Corridor:GTR Corridor:GTR Corridor:GTR
•easy setting•good repeatability
•easy setting•good repeatability
•difficult setting•difficult to control which data can be obtained
plastic plate
neopreneram ram
roller system
ram
plastic plate
ram
roller system
Free movement Contact to housing
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3.2. Component level certification corridor (Knee)
Plastic PlateRoller System
No GapGapPlastic Plate
With Neoprene
0
50
100
150
200
250
300
350
400
450
500
-2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
MCL elongation [mm]
Kn
ee
be
nd
ing
mo
me
nt
[Nm
]
GTR Lower corridor MCL
GTR Upper corridor MCL
MCL (mm)
-2
0
2
4
6
8
10
12
14
0 1000 2000 3000 4000 5000 6000
Force [N]
AC
L a
nd
PC
L e
lon
ga
tio
n [
mm
]
GTR Lower
corridor ACL
GTR Upper
corridor ACL
GTR Lower
corridor PCL
GTR Upper
corridor PCL
ACL (mm)
PCL (mm)
0
50
100
150
200
250
300
350
400
450
500
-2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
MCL elongation [mm]
Kn
ee
be
nd
ing
mo
me
nt
[Nm
]
GTR Lower corridor MCL
GTR Upper corridor MCL
MCL (mm)
-2
0
2
4
6
8
10
12
14
0 1000 2000 3000 4000 5000 6000
Force [N]
AC
L a
nd
PC
L e
lon
ga
tio
n [
mm
]
GTR Lower
corridor ACL
GTR Upper
corridor ACL
GTR Lower
corridor PCL
GTR Upper
corridor PCL
ACL (mm)
PCL (mm)
0
50
100
150
200
250
300
350
400
450
500
-2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
MCL elongation [mm]
Kn
ee
be
nd
ing
mo
me
nt
[Nm
]
GTR Lower corridor MCL
GTR Upper corridor MCL
MCL (mm)
-2
0
2
4
6
8
10
12
14
0 1000 2000 3000 4000 5000 6000
Force [N]
AC
L a
nd
PC
L e
lon
ga
tio
n [
mm
]
GTR Lower
corridor ACL
GTR Upper
corridor ACL
GTR Lower
corridor PCL
GTR Upper
corridor PCL
ACL (mm)
PCL (mm)
MCL
ACL, PCL
Contact to housingFree movement
Corridor:GT
Corridor:GTR Corridor:GTR Corridor:GTR
Corridor:GT
Corridor:GTR Corridor:GTR Corridor:GTR
•easy setting•good repeatability
•easy setting•good repeatability
•difficult setting•difficult to control which data can be obtained
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3. Historical Review3.3. Assembly level certification corridor
• At the third, assembly level certification corridor, which is used by Flex-PLIuser to investigate assembly level Flex-PLI quality, was evaluated. Findings are described as follows:
• Pendulum type impact test• Not brand-knew knees were used to develop the current pendulum test
certification corridors.• Bone core bending characteristics were unclear.• Need to update the current pendulum test certification corridors using
brand-knew/overhauled impactors.• Draft proposal shall be developed by using JARI (master test lab for
pendulum) and BASt and Bertrandt (comparable with master test lab) data.
• Inverse type impact test• Short flesh rubber as well as not brand-new bone cores were used to
develop the current inverse test certification corridors. • Need to update the current inverse test certification corridors using
brand-knew/overhauled impactors.• Draft proposal shall be developed using BASt (master test lab for
inverse) JARI and Bertrandt (comparable with master test lab) data.
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3.3. Assembly level certification corridor (Inverse)
Flex-GT Flex-GTR-prototype Flex-GTR-production
Test Method
-
- Flesh - •With •same as left
- Honeycomb - •With •same as left
- Outer rubber - •Short •Long
Corridor- same as left
- Developed by - •BASt • same as left
- Base data - •Flex-GTR-prototype with Short outer rubber*
• same as left
- Test lab - •BASt (3 impactors) and JARI (1 impactor), n= 31 in total
• same as left
- Impactor conditions - •Tibia: Used • same as left
- •Femur: Used • same as left
- •Knee: Used • same as left
Upper Lower Upper Lower(Nm) (Nm) (mm) (mm)
Tibia-1 277 237 ACL 11 9
Tibia-2 269 223 PCL 6 5
Tibia-3 204 176 MCL 23 18
Tibia-4 120 98
* Short outer rubber was used for initial version of Flex-GTR-prototype
Honeycomb
Moving ram
Hanging system
Short outer rubber
Moving ram
Hanging system
Honeycomb
Long outer rubber
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15
3.3. Assembly level certification corridor (Pendulum)Flex-GT Flex-GTR-prototype Flex-GTR-production
Test Method
same as left
- Flesh •Without •With •same as left
- Attachment position •Top of femur •Bottom of tibia •same as left
- Additional mass •Without •With •same as left
- Outer rubber length - •Long •same as left
Corridorsame as left
- Developed by •JARI •same as left • same as left
- Base data •Flex-GT •Flex-GTR-prototype with Long outer rubber*
• same as left
- Test lab •JARI •JARI (2 impactors), n=12 in total
• same as left
- Impactor conditions •Tibia: Brand-New •same as left • same as left
•Femur: Brand-New •same as left • same as left
•Knee: Brand-New •Knee: Used • same as left
Pin joint FemurKnee
Released(Free fall around the pin joint)
Tibia
Suspension angle15 deg.
Upper Lower Upper Lower(Nm) (Nm) (mm) (mm)
Tibia-1 163 133 ACL 5.0 2.6
Tibia-2 122 92 PCL 4.1 1.7
Tibia-3 86 56 MCL 14 12
Tibia-4 52 22
Upper Lower Upper Lower(Nm) (Nm) (mm) (mm)
Tibia-1 272 235 ACL 11 9.0
Tibia-2 211 185 PCL 5.4 4.0
Tibia-3 160 135 MCL 26 23
Tibia-4 108 94
* Long outer rubber has been officially accepted from Flex-GTR-production type.
Suspension angle
15 deg.
Femur
Additional
Mass
5kg
Knee
Tibia
Released(Free fall around the pin joint)
Long outer rubber
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16
4. Update Activity
• TF-RUCC made update proposal for component level as well as assembly level certification corridors.
• Component level certification corridor• Update proposal regarding component level certification corridor
was made based on JARI (master test lab for component level certification test) test results using master legs (SN01, SN03, E-leg).
• Detailed procedures ware described in "TF-RUCC-3-03 Japan-Progress-Report 120508, Page 1 to Page 39".
• Assembly level certification corridor• Update proposal regarding assembly level certification corridor was
made based on JARI, BASt and Bertrandt (master test lab and test labs comparable with master test lab for assembly level certification test) test results using master legs (SN01, SN03, E-leg).
• Detailed making procedures were described in "TF-RUCC-4-04_BASt-Refinement of Dynamic Assembly Certification Corridors_FINAL_2012.06.18.".
• Above update proposals were accepted by TF-RUCC members in the 5th
TF-RUCC meeting in July 2012.
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17
4. Update Activity- Component Level Certification Corridor -
0
50
100
150
200
250
300
350
400
0 5 10 15 20 25 30 35
Deflection (mm)
Mom
ent (
Nm
)
0
50
100
150
200
250
300
350
400
0 5 10 15 20 25
Deflection (mm)
Mom
ent (
Nm
)
ram
plastic plate
ram
plastic plate
Thigh Leg
0
50
100
150
200
250
300
350
400
450
-2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
MCL elongation [mm]
Kne
e be
ndin
g m
omen
t [N
m]
-2
0
2
4
6
8
10
12
14
0 500 1000 1500 2000 2500 3000 3500 4000 4500Force [N]
AC
L an
d P
CL
elon
gatio
n [m
m]
Knee-MCL Knee-ACL, PCLACL
PCL
MCL
MCL
PCL
ACL
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18
4. Update Activity- Assembly Level Certification Corridor: Pendulum -
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
Tibia A1 Tibia A2 Tibia A3 Tibia A4
Bending m
om
ent (N
m)
SN01@JARI, 120328-01
SN01@JARI, 120328-02
SN01@JARI, 120328-03
SN03@JARI, 120327-01
SN03@JARI, 120327-02
SN03@JARI, 120327-03
E-leg@JARI, 120423-01
E-leg@JARI, 120423-02
E-leg@JARI, 120423-03
SN01@BASt, 120605-01
SN01@BASt, 120605-02
SN01@BASt, 120605-03
SN03@BASt, 120523-01
SN03@BASt, 120523-02
SN03@BASt, 120523-03
E-leg@BASt, 120523-01
E-leg@BASt, 120523-02
E-leg@BASt, 120523-03
SN01@Bertrandt, 120612-01
SN01@Bertrandt, 120612-02
SN01@Bertrandt, 120612-03
SN03@Bertrandt, 120606-01
SN03@Bertrandt, 120606-02
SN03@Bertrandt, 120606-03
E-leg@Bertrandt, 120606-01
E-leg@Bertrandt, 120606-02
E-leg@Bertrandt, 120606-03
BASt Updated Corridor - Upper
BASt Updated Corridor - Lower
Tibia
272-235 Nm (range 37 Nm)
219-187 Nm (range 32 Nm)
166-139 Nm (range 27 Nm)
111-90 Nm (range 21 Nm)
JARI BASt Bartrandt
JARI BASt Bartrandt
JARI BASt Bartrandt
JARI BASt Bartrandt
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19
4. Update Activity- Assembly Level Certification Corridor: Pendulum -
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
ACL PCL MCL
Elongation (m
m)
SN01@JARI, 120328-01
SN01@JARI, 120328-02
SN01@JARI, 120328-03
SN03@JARI, 120327-01
SN03@JARI, 120327-02
SN03@JARI, 120327-03
E-leg@JARI, 120423-01
E-leg@JARI, 120423-02
E-leg@JARI, 120423-03
SN01@BASt, 120605-01
SN01@BASt, 120605-02
SN01@BASt, 120605-03
SN03@BASt, 120523-01
SN03@BASt, 120523-02
SN03@BASt, 120523-03
E-leg@BASt, 120523-01
E-leg@BASt, 120523-02
E-leg@BASt, 120523-03
SN01@Bertrandt, 120612-01
SN01@Bertrandt, 120612-02
SN01@Bertrandt, 120612-03
SN03@Bertrandt, 120606-01
SN03@Bertrandt, 120606-02
SN03@Bertrandt, 120606-03
E-leg@Bertrandt, 120606-01
E-leg@Bertrandt, 120606-02
E-leg@Bertrandt, 120606-03
BASt Updated Corridor - Upper
BASt Updated Corridor - Lower
Knee
10.5-8.0 mm (range 2.5 mm)
5.0-3.5 mm (range 1.5 mm)
24.0-20.5 mm (range 3.5 mm)
JARI BASt Bartrandt
JARI BASt Bartrandt
JARI BASt Bartrandt
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4. Update Activity- Assembly Level Certification Corridor: Inverse -
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
Tibia A1 Tibia A2 Tibia A3 Tibia A4
Bending m
om
ent (N
m)
SN01@JARI, 120425-01
SN01@JARI, 120425-02
SN01@JARI, 120425-03
SN03@JARI, 120425-01
SN03@JARI, 120425-02
SN03@JARI, 120425-03
E-leg@JARI, 120424-01
E-leg@JARI, 120424-02
E-leg@JARI, 120424-03
SN01@BASt, 120605-01
SN01@BASt, 120605-02
SN01@BASt, 120605-03
SN03@BASt, 120516-01
SN03@BASt, 120516-02
SN03@BASt, 120516-03
E-leg@BASt, 120516-01
E-leg@BASt, 120516-02
E-leg@BASt, 120516-03
SN01@Bertrandt, 120612-01
SN01@Bertrandt, 120612-02
SN01@Bertrandt, 120612-03
SN03@Bertrandt, 120606-01
SN03@Bertrandt, 120606-02
SN03@Bertrandt, 120606-03
E-leg@Bertrandt, 120606-01
E-leg@Bertrandt, 120611-02
E-leg@Bertrandt, 120611-03
BASt Updated Corridor - Upper
BASt Updated Corridor - Lower
272-230 Nm (range 42 Nm)
252-210 Nm (range 42 Nm)
192-166 Nm (range 26 Nm)
108-93 Nm (range 15 Nm)
JARI BASt Bartrandt
JARI BASt Bartrandt
JARI BASt Bartrandt
JARI BASt Bartrandt
Tibia
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21
4. Update Activity- Assembly Level Certification Corridor: Inverse Knee -
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
ACL PCL MCL
Elongation (m
m)
SN01@JARI, 120425-01
SN01@JARI, 120425-02
SN01@JARI, 120425-03
SN03@JARI, 120425-01
SN03@JARI, 120425-02
SN03@JARI, 120425-03
E-leg@JARI, 120424-01
E-leg@JARI, 120424-02
E-leg@JARI, 120424-03
SN01@BASt, 120605-01
SN01@BASt, 120605-02
SN01@BASt, 120605-03
SN03@BASt, 120516-01
SN03@BASt, 120516-02
SN03@BASt, 120516-03
E-leg@BASt, 120516-01
E-leg@BASt, 120516-02
E-leg@BASt, 120516-03
SN01@Bertrandt, 120612-01
SN01@Bertrandt, 120612-02
SN01@Bertrandt, 120612-03
SN03@Bertrandt, 120606-01
SN03@Bertrandt, 120606-02
SN03@Bertrandt, 120606-03
E-leg@Bertrandt, 120606-01
E-leg@Bertrandt, 120611-02
E-leg@Bertrandt, 120611-03
BASt Updated Corridor - Upper
BASt Updated Corridor - Lower
10.0-8.0 mm (range 2.0 mm)
6.0-4.0 mm (range 2.0 mm)
21.0-17.0 mm (range 4.0 mm)
JARI BASt Bartrandt
JARI BASt Bartrandt
JARI BASt Bartrandt
Knee
GTR9-4-07
22
5. Discussion
• Update proposals for component level as well as assembly level certification corridor were accepted by TF-RUCC members in the 5th TF-RUCC meeting.
• However, Humanetics are concerned that the update proposal especially for inverse channel Tibia-4 could have a problem as corridor range was significantly reduced. BASt pointed out that this was due to the good repeatability and reproducibility and low range of Tibia-4 test results using master legs. As a precautionary measure Humanetics wanted to see certification results after car testing as they believed Tibia-4 had shown problems in the past (GTR-3-05). There is a chance that Flex-PLI can not meet the update proposals after car testing.
• Humanetics recommended that they would like to wait and see certification test results just after several car tests before TF-RUCC proposals are accepted by IG GTR9-PH2.
• All TF-RUCC members agreed that if a Flex-PLI response is changed after car testing (e.g. outside corridors), it could be considered as a durability issue. The IG GTR9-PH2 shall discuss that appropriately as the parent body of TF-RUCC.
GTR9-4-07
23
6. Conclusion
• TF-RUCC made update proposals for component level as well as assembly level certification corridors based on their activity until July 2012.
• The update proposals can be reviewed and discussed by IG GTR9-PH2 members hereafter.
• Just in case, if Flex-PLI response is changed after car testing (e.g. outside corridors), it shall be discussed appropriately in IG GTR9-PH2.
GTR9-4-07
24
7. Working Documents
• TF-RUCC working documents are available from following UN ECE web site.
https://www2.unece.org/wiki/pages/viewpage.action?pageId=4063359
GTR9-4-07
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