Activity Report - wiki.unece.org · Inverse type for Flex-PLI. •However, Humanetics had some difficultly producing a production Flex-PLI that could completely meet the inverse level

1

Activity ReportTask Force regarding Review and Update Certification Corridor

(TF-RUCC) under the IG GTR9-PH2

6th Sep. 2012TF-RUCC

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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


•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

)


No GapGapPlastic Plate

No NeopreneWith Neoprene

Corridor:GT Corridor:GTR Corridor:GTR Corridor:GTR




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)


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

]



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

]



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




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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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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.


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


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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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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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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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






E-leg@Bertrandt, 120606-01



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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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












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












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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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












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

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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.

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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.

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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

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